FMEA - Step 6: AIAG* Severity Guidelines

CRITERIA: SEVERITY OF EFFECT RANKING 10 May endanger machine or assembly operator. Very high severity ranking when a Hazardous potential failure mode affects safe vehicle operation and/or involves noncompliance without warning with government regulation. Failure will occur without warning. 9 May endanger machine or assembly operator. Very high severity ranking when a Hazardous potential failure mode affects safe vehicle operation and/or involves noncompliance with warning with government regulation. Failure will occur with warning. 8 Major disruption to production line. 100% of product may have to be scrapped. Very High Vehicle/item inoperable, loss of primary function. Customer very dissatisfied. 7 Minor disruption to production line. Product may have to be sorted and a portion High (less than 100%) scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied. 6 Minor disruption to production line. A portion (less than 100%) of the product may Moderate have to be scrapped (no sorting). Vehicle/item operable, but some Comfort/Convenience item(s) inoperable. Customers experience discomfort. 5 Minor disruption to production line. 100% of the product may have to be reworked. Low Vehicle/item operable, but some Comfort/Convenience item(s) operable at reduced level of performance. Customer experiences some dissatisfaction. 4 Minor disruption to production line. The product may have to be sorted and a Very Low portion (less than 100%) reworked. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by most customers. 3 Minor disruption to production line. The product may have to be sorted and a Minor portion (less than 100%) reworked. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customers. 2 Minor disruption to production line. The product may have to be sorted and a Very Minor portion (less than 100%) reworked. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by discriminating customers. 1 Low No effect. EFFECT

* Note: AIAG is the Automotive Industry Action Group, which currently compiles the FMEA standards for the North American Auto Industry.
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FMEA - Step 8: AIAG* Occurrence Guidelines

Probability of Failure Very High: Failure almost inevitable High: Generally associated with processes similar to previous processes 1 in 20 that have often failed Moderate: Generally associated with 1 in 80 processes similar to previous pro1 in 400 cesses which have experienced occasional failures, but not in major 1 in 2,000 proportions Low: Isolated failures associated 1 in 15,000 with similar processes Very Low: Only isolated failures 1 in 150,000 associated with almost identical processes Remote: Failure is unlikely. No < 1 in 1,500,000 failures ever associated with almost identical processes Possible Failure Rates > 1 in 2 1 in 3 1 in 8 Ppk Ranking < 0.33 10 > 0.33 9 > 0.51 8 > 0.67 > 0.83 > 1.00 > 1.17 > 1.33 > 1.50 > 1.67 7 6 5 4 3 2 1

* Note: AIAG is the Automotive Industry Action Group, which currently compiles the FMEA standards for the North American Auto Industry.
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FMEA - Step 10: AIAG* Detection Guidelines

Detection Almost Impossible Very Remote Remote Very Low Low Moderate Moderately High High Very High Almost Certain Criteria: Likelihood the Existence of a Defect will be Detected by Process Controls Before Next or Subsequent Process, or Before Part or Component Leaves the Manufacturing or Assembly Location No known control available to detect cause/mechanism of failure or the failure mode Very remote likelihood current control will detect cause/mechanism of failure or the failure mode Remote likelihood current control will detect cause/mechanism of failure or the failure mode Very low likelihood current control will detect cause/mechanism of failure or the failure mode Low likelihood current control will detect cause/mechanism of failure or the failure mode Moderate likelihood current control will detect cause/mechanism of failure or the failure mode Moderately high likelihood current control will detect cause/mechanism of failure or the failure mode High likelihood current control will detect cause/mechanism of failure or the failure mode Very high likelihood current control will detect cause/mechanism of failure or the failure mode Current control almost certain to detect cause/mechanism of failure or the failure mode. Reliable detection controls are known with similar processes Ranking 10 9 8 7 6 5 4 3 2 1

* Note: AIAG is the Automotive Industry Action Group, which currently compiles the FMEA standards for the North American Auto Industry.
2009 The New Excellence Confidential and Proprietary

www.TheNewExcellence.com