FMEA Form

Failure mode
Effect of failure
Cause of failure
Cause prevention
Severity ranking
Occurrence ranking

Detection ranking

Risk Priority
Number (RPN)
 Definition
The manner in which a part or system fails to meet the design intent
The experience the owner encounters as a result of a failure mode
An indication of a design weakness
The in place and scheduled design verifications and quality assurance inspections
A subjective evaluation of the consequence of a failure mode on the end user
A subjective estimate of the likelihood that if a defective part is installed it will cause the failure mode with its partic

A subjective estimate of the probability that a cause of a potential failure will be detected and corrected before reac
end user
The product of severity, occurrence, and detection rankings
Failure modes and effects analysis (FMEA)

Project: Date:

FMEA Team: Prepared by:

SEV = How severe is effect on the customer?

OCC = How frequent is the cause likely to occur?
DET = How probable is detection of cause?
RPN = Risk priority number in order to rank concerns; calculated as SEV x OCC x DET
N N N N
e e e e
S O D R w w w w
Actions Responsibility (target
Process step Potential failure mode Potential failure effects E Potential causes C Current process controls E P Actions taken
recommended date)
V C T N S O D R
E C E P
V C T N
What are the actions
for reducing the
occurrence of the Who is responsible for What were the actions
What are the existing controls that
What is the impact on the What causes the step to go cause or for improving the recommended implemented? Include
What is the In what ways can the step either prevent the failure mode
customer if the failure mode is 10 wrong? (i.e., How could the 10 10 1000 its detection? You action? What date completion month/year 10 10 10 1000
step? go wrong? from occurring or detect it should it
not prevented or corrected? failure mode occur?) should provide actions should it be completed (then recalculate resulting
occur?
on all high RPNs and by? RPN).
on severity ratings of 9
or 10.

0 0

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 Severity

Effect SEVERITY of Effect Ranking

Hazardous without Very high severity ranking when a potential failure mode 10
warning affects safe system operation without warning
Hazardous with Very high severity ranking when a potential failure mode 9
warning affects safe system operation with warning
Very High System inoperable with destructive failure without 8
compromising safety
High System inoperable with equipment damage 7

Moderate System inoperable with minor damage 6

Low System inoperable without damage 5

Very Low System operable with significant degradation of performance 4

Minor System operable with some degradation of performance 3

Very Minor System operable with minimal interference 2

None No effect 1

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 Severity

Effect SEVERITY of Effect Ranking

Very high (the failure will affect safe product operation)
Hazardous without/With
warning 10,9
High (there will be a high degree of customer
dissatisfaction because of the failure)
High (there will be a high degree of customer
dissatisfaction because of the failure)
Very High/High 8,7
System inoperable with equipment damage

Moderate (the failure will generate some customer

OR dissatisfaction)
4,5,6
System inoperable without damage
Moderate/Low/Very Low 3,2
System operable with significant degradation of
performance 2
Minor Minor (customer may not even become aware of the
failure)
2,1
Very Minor
1
None
1

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 Probability

PROBABILITY of Failure Failure Prob Ranking

Very High: Failure is almost inevitable >1 in 2 10
1 in 3 9
High: Repeated failures 1 in 8 8
1 in 20 7
Moderate: Occasional failures 1 in 80 6
1 in 400 5
1 in 2,000 4
Low: Relatively few failures 1 in 15,000 3
1 in 150,000 2
Remote: Failure is unlikely <1 in 1,500,000 1

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 Detectability

Detection Likelihood of DETECTION by Design Control Ranking

Absolute Design control cannot detect potential cause/mechanism and 10
Uncertainty subsequent failure mode
Very Remote Very remote chance the design control will detect potential 9
cause/mechanism and subsequent failure mode
Remote Remote chance the design control will detect potential 8
cause/mechanism and subsequent failure mode
Very Low Very low chance the design control will detect potential 7
cause/mechanism and subsequent failure mode
Low Low chance the design control will detect potential 6
cause/mechanism and subsequent failure mode
Moderate Moderate chance the design control will detect potential 5
cause/mechanism and subsequent failure mode
Moderately High Moderately High chance the design control will detect 4
potential cause/mechanism and subsequent failure mode
High High chance the design control will detect potential 3
cause/mechanism and subsequent failure mode
Very High Very high chance the design control will detect potential 2
cause/mechanism and subsequent failure mode
Almost Certain Design control will detect potential cause/mechanism and 1
subsequent failure mode

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