DELPHI Supplier Quality FMEA SEVERITY RANKINGS

Note #1: Any Failure Mode affecting the Vehicle Assembly Plant MUST be ranked an 8 or higher.
Note #2: Any Failure Mode affecting a Delphi Plant MUST be ranked 5 or higher.
Select from the categories below, using the highest applicable ranking.
Ranking
10

Effect
Hazardouswithout warning

Hazardous-with
warning

Very High

High

4
3
2
1

Moderate

Low

Very Low
Minor
Very Minor
None

End Customer
Potential failure mode affects
safe vehicle operation and/or
involves noncompliance with
government regulation without
warning.
Potential failure mode affects
safe vehicle operation and/or
involves noncompliance with
government regulation with
warning.
Vehicle/item inoperable (loss
of primary function); failure
mode may cause customer
walk home, field return, or
durability issue.
Vehicle/item operable but at a
reduced level of performance.
Customer very dissatisfied.
Failure mode may cause
vehicle repairs at Dealer.
Includes Noise issues
(squeak/rattle).
Vehicle/item operable but
comfort/convenience item(s))
inoperable/not performing to
customer expectation (e.g..
Noise)
Vehicle/item operable but
comfort/convenience item(s)
operable at a reduced level of
performance.
Fit and finish item does not
conform. Defect noticed by
most customers.
Fit and finish item does not
conform. Defect noticed by
average customers.
Fit and finish item does not
conform. Defect noticed by
discriminating customers.
No effect.

Vehicle Assembly Plant

Potential failure mode may
cause unsafe condition for
plant personnel without
warning.

Delphi Plant
Potential failure mode may
cause unsafe condition for
plant personnel without
warning.

Supplier Plant
Potential failure mode may
cause unsafe condition for
plant personnel without
warning.

Potential failure mode may

cause unsafe condition for
plant personnel with warning.

Potential failure mode may

cause unsafe condition for
plant personnel with warning.

Potential failure mode may

cause unsafe condition for
plant personnel with warning.

Potential failure mode may

cause a spill/major disruption,
repair, assembly difficulty,
rework, or sorting at the
Vehicle Assembly Plant

Potential failure mode may

cause a spill/major disruption
at a Delphi Plant.

See Note #1

Potential failure mode may

cause repair, assembly
difficulty, rework, sorting at a
Delphi plant.

See Note #1

Potential failure mode may

cause special handling of
components at Delphi-S.

See Note #1

Potential failure mode may

cause inconvenience to Delphi
prior to assembly.
See Note #2

See Note #1
See Note #2
See Note #1
See Note #2
See Note #1
See Note #1

See Note #2

DELPHI Supplier Quality FMEA OCCURRENCE EVALUATION RANKINGS

Sample calculation to determine Ppk value from a likely failure rate of 5 per thousand pieces (see FMEA third Appendix I).
Probability

Likely Failure Rates

Ppk

Ranking

< 0.55

10

> 0.55

20 per thousand pieces

> 0.78

10 per thousand pieces

> 0.86

5 per thousand pieces

> 0.94

2 per thousand pieces

>1.00

1 per thousand pieces

>1.10

0.5 per thousand pieces

>1.20

> 1.30

> 1.67

Very High: Persistent Failures

100 per thousand pieces
50 per thousand pieces
High: Frequent Failures

Moderate: Occasional Failures

Low: Relatively Few Failures

0.1 per thousand pieces
Remote: Failure is unlikely

< 0.001 per thousand pieces *

Note: Identical to Manual except for Ranking of 1. Manual allows for .01 per thousand (10 PPM)

DELPHI Supplier Quality FMEA Detection Rankings

Ranking

Effect

PFMEA

10

Absolute Uncertainty

Cannot detect or is not checked.

Very Remote

Control is achieved with indirect or random checks only.

Remote

Control is achieved with visual inspection only.

Very Low

Control is achieved with double visual inspection only.

Low

Control is achieved with charting methods, such as SPC

(Statistical Process Control) OR gauging performed on setup
and first-piece check. *

Moderate

Control is based on variable or attribute gauging performed

100% of the parts after parts have left the station.

Moderately High

Error detection in subsequent operation. *

High

Error detection in-station, or error detection in subsequent

operations by multiple layers of acceptance: supply, select,
install, verify. Cannot accept discrepant part.

Very High

Error detection in-station (automatic gauging with automatic

stop feature). Cannot pass discrepant part.

Almost Certain

Discrepant parts cannot be made because item has been

error-proofed by process/product design.

* Note: Identical to Manual except for Rankings of 6 and 4. Words OR gauging performed on setup and first piece check
moved from a detection of 4 to a detection of 6