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VDA

FMEA

Process: QA

Product: TESTING

Core team: ND and ND

Operation / Part:
Function / Characteristic:
Failure Effect S Failure Mode Failure Cause
ND NOT STUDY 2 AD AND PD ANGRY ANGER

Page 1
VDA

Factors 1 to 5

1, 2, 3, 4, 5, 6, 8, 9, 10, 12, 15,16, 18, 20, 24, 25, 27, 30, 32, 35, 36, 40, 45, 48, 50, 60, 64, 75, 80, 10

Factors 1 to 10

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 16, 18, 20, 21, 24, 25, 27, 28, 30, 32, 35, 36, 40, 42, 45, 48, 49

Page 2
VDA

FMEA Page:1

Responsibility: AD Number:DH/)1/0712

Prepared by: PD Created: SPD

Key Date: 7/12/2019 Modified: AD

Preventive O Detection D RPN Responsible / deadline


TALK 2 2 3 12 2 hours study daily by nd

Page 3
VDA

36, 40, 45, 48, 50, 60, 64, 75, 80, 100, 125

28, 30, 32, 35, 36, 40, 42, 45, 48, 49, 50, 54, 56, 60, 63, 64, 70, 72, 75, 80, 81, 84, 90, 96, 98, 100, 105, 108, 112

Page 4
VDA

98, 100, 105, 108, 112, 120, 125, 126, 128, 135, 140, 144, 147, 150, 160, 162, 168, 175, 180, 189, 192, 196, 200

Page 5
VDA

1 2 3 4 5
1 1 4 9 16 25
2 2 8 18 32 50
3 3 12 27 48 75
4 4 16 36 64 100
5 5 20 45 80 125
1 2 3 4 5

2 3 4 5 1
1 2 6 12 20 5
2 4 12 24 40 10
3 6 18 36 60 15
4 8 24 48 80 20
5 10 30 60 100 25
1 2 3 4 5

175, 180, 189, 192, 196, 200, 210, 216, 224, 225, 240, 243, 245, 250, 252, 256, 270, 280, 288, 294, 300, 315, 32
3 4 5 1 2
1 3 8 15 4 10
2 6 16 30 8 20
3 9 24 45 12 30
4 12 32 60 16 40
5 15 40 75 20 50
1 2 3 4 5

4 5 1 2 3
1 4 10 3 8 15
2 8 20 6 16 30
3 12 30 9 24 45
4 16 40 12 32 60
5 20 50 15 40 75
1 2 3 4 5

5 1 2 3 4
1 5 2 6 12 20
2 10 4 12 24 40

Page 6
VDA
3 15 6 18 36 60
4 20 8 24 48 80
5 25 10 30 60 100
1 2 3 4 5

1 2 3 4 5
1 1 4 9 16 25
2 2 8 18 32 50
3 3 12 27 48 75
4 4 16 36 64 100
5 5 20 45 80 125
6 6 24 54 96 150
7 7 28 63 112 175
8 8 32 72 128 200
9 9 36 81 144 225
10 10 40 90 160 250
1 2 3 4 5

2 3 4 5 6
1 2 6 12 20 30
2 4 12 24 40 60
3 6 18 36 60 90
4 8 24 48 80 120
5 10 30 60 100 150
6 12 36 72 120 180
7 14 42 84 140 210
8 16 48 96 160 240
9 18 54 108 180 270
10 20 60 120 200 300
1 2 3 4 5

3 4 5 6 7
1 3 8 15 24 35
2 6 16 30 48 70
3 9 24 45 72 105
4 12 32 60 96 140
5 15 40 75 120 175
6 18 48 90 144 210
7 21 56 105 168 245
8 24 64 120 192 280
9 27 72 135 216 315
10 30 80 150 240 350
1 2 3 4 5

4 5 6 7 8
1 4 10 18 28 40
2 8 20 36 56 80
3 12 30 54 84 120
4 16 40 72 112 160
5 20 50 90 140 200
6 24 60 108 168 240
7 28 70 126 196 280
8 32 80 144 224 320

Page 7
VDA
9 36 90 162 252 360
10 40 100 180 280 400
1 2 3 4 5

5 6 7 8 9
1 5 12 21 32 45
2 10 24 42 64 90
3 15 36 63 96 135
4 20 48 84 128 180
5 25 60 105 160 225
6 30 72 126 192 270
7 35 84 147 224 315
8 40 96 168 256 360
9 45 108 189 288 405
10 50 120 210 320 450
1 2 3 4 5

6 7 8 9 10
1 6 14 24 36 50
2 12 28 48 72 100
3 18 42 72 108 150
4 24 56 96 144 200
5 30 70 120 180 250
6 36 84 144 216 300
7 42 98 168 252 350
8 48 112 192 288 400
9 54 126 216 324 450
10 60 140 240 360 500
1 2 3 4 5

7 8 9 10 1
1 7 16 27 40 5
2 14 32 54 80 10
3 21 48 81 120 15
4 28 64 108 160 20
5 35 80 135 200 25
6 42 96 162 240 30
7 49 112 189 280 35
8 56 128 216 320 40
9 63 144 243 360 45
10 70 160 270 400 50
1 2 3 4 5

8 9 10 1 2
1 8 18 30 4 10
2 16 36 60 8 20
3 24 54 90 12 30
4 32 72 120 16 40
5 40 90 150 20 50
6 48 108 180 24 60
7 56 126 210 28 70
8 64 144 240 32 80
9 72 162 270 36 90

Page 8
VDA
10 80 180 300 40 100
1 2 3 4 5

9 10 1 2 3
1 9 20 3 8 15
2 18 40 6 16 30
3 27 60 9 24 45
4 36 80 12 32 60
5 45 100 15 40 75
6 54 120 18 48 90
7 63 140 21 56 105
8 72 160 24 64 120
9 81 180 27 72 135
10 90 200 30 80 150
1 2 3 4 5

10 1 2 3 4
1 10 2 6 12 20
2 20 4 12 24 40
3 30 6 18 36 60
4 40 8 24 48 80
5 50 10 30 60 100
6 60 12 36 72 120
7 70 14 42 84 140
8 80 16 48 96 160
9 90 18 54 108 180
10 100 20 60 120 200
1 2 3 4 5

Page 9
VDA

1 2 3 4 5
1 1 4 9 16 25
2 2 8 18 32 50
3 3 12 27 48 75
4 4 16 36 64 100
5 5 20 45 80 125
1 2 3 4 5

2 3 4 5 1
2 2 6 12 20 5
3 4 12 24 40 10
4 6 18 36 60 15
5 8 24 48 80 20
1 10 30 60 100 25
1 2 3 4 5

0, 280, 288, 294, 300, 315, 320, 324, 336, 343, 350, 360, 378, 384, 392, 400, 405, 420, 432, 441, 448, 450, 480,
3 4 5 1 2
3 3 8 15 4 10
4 6 16 30 8 20
5 9 24 45 12 30
1 12 32 60 16 40
2 15 40 75 20 50
1 2 3 4 5

4 5 1 2 3
4 4 10 3 8 15
5 8 20 6 16 30
1 12 30 9 24 45
2 16 40 12 32 60
3 20 50 15 40 75
1 2 3 4 5

5 1 2 3 4
5 5 2 6 12 20
1 10 4 12 24 40

Page 10
VDA
2 15 6 18 36 60
3 20 8 24 48 80
4 25 10 30 60 100
1 2 3 4 5

6 7 8 9 10 1
36 49 64 81 100 1 1
72 98 128 162 200 2 2
108 147 192 243 300 3 3
144 196 256 324 400 4 4
180 245 320 405 500 5 5
216 294 384 486 600 6 6
252 343 448 567 700 7 7
288 392 512 648 800 8 8
324 441 576 729 900 9 9
360 490 640 810 1000 10 10
6 7 8 9 10 1

7 8 9 10 1 2
42 56 72 90 10 2 2
84 112 144 180 20 3 4
126 168 216 270 30 4 6
168 224 288 360 40 5 8
210 280 360 450 50 6 10
252 336 432 540 60 7 12
294 392 504 630 70 8 14
336 448 576 720 80 9 16
378 504 648 810 90 10 18
420 560 720 900 100 1 20
6 7 8 9 10 1

8 9 10 1 2 3
48 63 80 9 20 3 3
96 126 160 18 40 4 6
144 189 240 27 60 5 9
192 252 320 36 80 6 12
240 315 400 45 100 7 15
288 378 480 54 120 8 18
336 441 560 63 140 9 21
384 504 640 72 160 10 24
432 567 720 81 180 1 27
480 630 800 90 200 2 30
6 7 8 9 10 1

9 10 1 2 3 4
54 70 8 18 30 4 4
108 140 16 36 60 5 8
162 210 24 54 90 6 12
216 280 32 72 120 7 16
270 350 40 90 150 8 20
324 420 48 108 180 9 24
378 490 56 126 210 10 28
432 560 64 144 240 1 32

Page 11
VDA
486 630 72 162 270 2 36
540 700 80 180 300 3 40
6 7 8 9 10 1

10 1 2 3 4 5
60 7 16 27 40 5 5
120 14 32 54 80 6 10
180 21 48 81 120 7 15
240 28 64 108 160 8 20
300 35 80 135 200 9 25
360 42 96 162 240 10 30
420 49 112 189 280 1 35
480 56 128 216 320 2 40
540 63 144 243 360 3 45
600 70 160 270 400 4 50
6 7 8 9 10 1

1 2 3 4 5 6
6 14 24 36 50 6 6
12 28 48 72 100 7 12
18 42 72 108 150 8 18
24 56 96 144 200 9 24
30 70 120 180 250 10 30
36 84 144 216 300 1 36
42 98 168 252 350 2 42
48 112 192 288 400 3 48
54 126 216 324 450 4 54
60 140 240 360 500 5 60
6 7 8 9 10 1

2 3 4 5 6 7
12 21 32 45 60 7 7
24 42 64 90 120 8 14
36 63 96 135 180 9 21
48 84 128 180 240 10 28
60 105 160 225 300 1 35
72 126 192 270 360 2 42
84 147 224 315 420 3 49
96 168 256 360 480 4 56
108 189 288 405 540 5 63
120 210 320 450 600 6 70
6 7 8 9 10 1

3 4 5 6 7 8
18 28 40 54 70 8 8
36 56 80 108 140 9 16
54 84 120 162 210 10 24
72 112 160 216 280 1 32
90 140 200 270 350 2 40
108 168 240 324 420 3 48
126 196 280 378 490 4 56
144 224 320 432 560 5 64
162 252 360 486 630 6 72

Page 12
VDA
180 280 400 540 700 7 80
6 7 8 9 10 1

4 5 6 7 8 9
24 35 48 63 80 9 9
48 70 96 126 160 10 18
72 105 144 189 240 1 27
96 140 192 252 320 2 36
120 175 240 315 400 3 45
144 210 288 378 480 4 54
168 245 336 441 560 5 63
192 280 384 504 640 6 72
216 315 432 567 720 7 81
240 350 480 630 800 8 90
6 7 8 9 10 1

5 6 7 8 9 10
30 42 56 72 90 10 10
60 84 112 144 180 1 20
90 126 168 216 270 2 30
120 168 224 288 360 3 40
150 210 280 360 450 4 50
180 252 336 432 540 5 60
210 294 392 504 630 6 70
240 336 448 576 720 7 80
270 378 504 648 810 8 90
300 420 560 720 900 9 100
6 7 8 9 10 1

Page 13
VDA

1 2 3 4 5
1 1 4 9 16 25
2 2 8 18 32 50
3 3 12 27 48 75
4 4 16 36 64 100
5 5 20 45 80 125
1 2 3 4 5

2 3 4 5 1
2 4 9 16 25 1
3 8 18 32 50 2
4 12 27 48 75 3
5 16 36 64 100 4
1 20 45 80 125 5
2 3 4 5 1

20, 432, 441, 448, 450, 480, 486, 490, 500, 504, 512, 540, 560, 567, 576, 600, 630, 640, 648, 700, 720, 729, 800
3 4 5 1 2
3 9 16 25 1 4
4 18 32 50 2 8
5 27 48 75 3 12
1 36 64 100 4 16
2 45 80 125 5 20
3 4 5 1 2

4 5 1 2 3
4 16 25 1 4 9
5 32 50 2 8 18
1 48 75 3 12 27
2 64 100 4 16 36
3 80 125 5 20 45
4 5 1 2 3

5 1 2 3 4
5 25 1 4 9 16
1 50 2 8 18 32

Page 14
VDA
2 75 3 12 27 48
3 100 4 16 36 64
4 125 5 20 45 80
5 1 2 3 4

2 3 4 5 6 7 8 9
4 9 16 25 36 49 64 81
8 18 32 50 72 98 128 162
12 27 48 75 108 147 192 243
16 36 64 100 144 196 256 324
20 45 80 125 180 245 320 405
24 54 96 150 216 294 384 486
28 63 112 175 252 343 448 567
32 72 128 200 288 392 512 648
36 81 144 225 324 441 576 729
40 90 160 250 360 490 640 810
2 3 4 5 6 7 8 9

3 4 5 6 7 8 9 10
6 12 20 30 42 56 72 90
12 24 40 60 84 112 144 180
18 36 60 90 126 168 216 270
24 48 80 120 168 224 288 360
30 60 100 150 210 280 360 450
36 72 120 180 252 336 432 540
42 84 140 210 294 392 504 630
48 96 160 240 336 448 576 720
54 108 180 270 378 504 648 810
60 120 200 300 420 560 720 900
2 3 4 5 6 7 8 9

4 5 6 7 8 9 10 1
8 15 24 35 48 63 80 9
16 30 48 70 96 126 160 18
24 45 72 105 144 189 240 27
32 60 96 140 192 252 320 36
40 75 120 175 240 315 400 45
48 90 144 210 288 378 480 54
56 105 168 245 336 441 560 63
64 120 192 280 384 504 640 72
72 135 216 315 432 567 720 81
80 150 240 350 480 630 800 90
2 3 4 5 6 7 8 9

5 6 7 8 9 10 1 2
10 18 28 40 54 70 8 18
20 36 56 80 108 140 16 36
30 54 84 120 162 210 24 54
40 72 112 160 216 280 32 72
50 90 140 200 270 350 40 90
60 108 168 240 324 420 48 108
70 126 196 280 378 490 56 126
80 144 224 320 432 560 64 144

Page 15
VDA
90 162 252 360 486 630 72 162
100 180 280 400 540 700 80 180
2 3 4 5 6 7 8 9

6 7 8 9 10 1 2 3
12 21 32 45 60 7 16 27
24 42 64 90 120 14 32 54
36 63 96 135 180 21 48 81
48 84 128 180 240 28 64 108
60 105 160 225 300 35 80 135
72 126 192 270 360 42 96 162
84 147 224 315 420 49 112 189
96 168 256 360 480 56 128 216
108 189 288 405 540 63 144 243
120 210 320 450 600 70 160 270
2 3 4 5 6 7 8 9

7 8 9 10 1 2 3 4
14 24 36 50 6 14 24 36
28 48 72 100 12 28 48 72
42 72 108 150 18 42 72 108
56 96 144 200 24 56 96 144
70 120 180 250 30 70 120 180
84 144 216 300 36 84 144 216
98 168 252 350 42 98 168 252
112 192 288 400 48 112 192 288
126 216 324 450 54 126 216 324
140 240 360 500 60 140 240 360
2 3 4 5 6 7 8 9

8 9 10 1 2 3 4 5
16 27 40 5 12 21 32 45
32 54 80 10 24 42 64 90
48 81 120 15 36 63 96 135
64 108 160 20 48 84 128 180
80 135 200 25 60 105 160 225
96 162 240 30 72 126 192 270
112 189 280 35 84 147 224 315
128 216 320 40 96 168 256 360
144 243 360 45 108 189 288 405
160 270 400 50 120 210 320 450
2 3 4 5 6 7 8 9

9 10 1 2 3 4 5 6
18 30 4 10 18 28 40 54
36 60 8 20 36 56 80 108
54 90 12 30 54 84 120 162
72 120 16 40 72 112 160 216
90 150 20 50 90 140 200 270
108 180 24 60 108 168 240 324
126 210 28 70 126 196 280 378
144 240 32 80 144 224 320 432
162 270 36 90 162 252 360 486

Page 16
VDA
180 300 40 100 180 280 400 540
2 3 4 5 6 7 8 9

10 1 2 3 4 5 6 7
20 3 8 15 24 35 48 63
40 6 16 30 48 70 96 126
60 9 24 45 72 105 144 189
80 12 32 60 96 140 192 252
100 15 40 75 120 175 240 315
120 18 48 90 144 210 288 378
140 21 56 105 168 245 336 441
160 24 64 120 192 280 384 504
180 27 72 135 216 315 432 567
200 30 80 150 240 350 480 630
2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8
2 6 12 20 30 42 56 72
4 12 24 40 60 84 112 144
6 18 36 60 90 126 168 216
8 24 48 80 120 168 224 288
10 30 60 100 150 210 280 360
12 36 72 120 180 252 336 432
14 42 84 140 210 294 392 504
16 48 96 160 240 336 448 576
18 54 108 180 270 378 504 648
20 60 120 200 300 420 560 720
2 3 4 5 6 7 8 9

Page 17
VDA

640, 648, 700, 720, 729, 800, 810, 900, 1000

Page 18
VDA

10 1 2 3 4 5
100 1 1 4 9 16 25
200 2 2 8 18 32 50
300 3 3 12 27 48 75
400 4 4 16 36 64 100
500 5 5 20 45 80 125
600 6 6 24 54 96 150
700 7 7 28 63 112 175
800 8 8 32 72 128 200
900 9 9 36 81 144 225
1000 10 10 40 90 160 250
10 1 2 3 4 5

1 2 3 4 5 6
10 2 4 9 16 25 36
20 3 8 18 32 50 72
30 4 12 27 48 75 108
40 5 16 36 64 100 144
50 6 20 45 80 125 180
60 7 24 54 96 150 216
70 8 28 63 112 175 252
80 9 32 72 128 200 288
90 10 36 81 144 225 324
100 1 40 90 160 250 360
10 2 3 4 5 6

2 3 4 5 6 7
20 3 9 16 25 36 49
40 4 18 32 50 72 98
60 5 27 48 75 108 147
80 6 36 64 100 144 196
100 7 45 80 125 180 245
120 8 54 96 150 216 294
140 9 63 112 175 252 343
160 10 72 128 200 288 392
180 1 81 144 225 324 441
200 2 90 160 250 360 490
10 3 4 5 6 7

3 4 5 6 7 8
30 4 16 25 36 49 64
60 5 32 50 72 98 128
90 6 48 75 108 147 192
120 7 64 100 144 196 256
150 8 80 125 180 245 320
180 9 96 150 216 294 384
210 10 112 175 252 343 448
240 1 128 200 288 392 512

Page 19
VDA
270 2 144 225 324 441 576
300 3 160 250 360 490 640
10 4 5 6 7 8

4 5 6 7 8 9
40 5 25 36 49 64 81
80 6 50 72 98 128 162
120 7 75 108 147 192 243
160 8 100 144 196 256 324
200 9 125 180 245 320 405
240 10 150 216 294 384 486
280 1 175 252 343 448 567
320 2 200 288 392 512 648
360 3 225 324 441 576 729
400 4 250 360 490 640 810
10 5 6 7 8 9

5 6 7 8 9 10
50 6 36 49 64 81 100
100 7 72 98 128 162 200
150 8 108 147 192 243 300
200 9 144 196 256 324 400
250 10 180 245 320 405 500
300 1 216 294 384 486 600
350 2 252 343 448 567 700
400 3 288 392 512 648 800
450 4 324 441 576 729 900
500 5 360 490 640 810 1000
10 6 7 8 9 10

6 7 8 9 10 1
60 7 49 64 81 100 1
120 8 98 128 162 200 2
180 9 147 192 243 300 3
240 10 196 256 324 400 4
300 1 245 320 405 500 5
360 2 294 384 486 600 6
420 3 343 448 567 700 7
480 4 392 512 648 800 8
540 5 441 576 729 900 9
600 6 490 640 810 1000 10
10 7 8 9 10 1

7 8 9 10 1 2
70 8 64 81 100 1 4
140 9 128 162 200 2 8
210 10 192 243 300 3 12
280 1 256 324 400 4 16
350 2 320 405 500 5 20
420 3 384 486 600 6 24
490 4 448 567 700 7 28
560 5 512 648 800 8 32
630 6 576 729 900 9 36

Page 20
VDA
700 7 640 810 1000 10 40
10 8 9 10 1 2

8 9 10 1 2 3
80 9 81 100 1 4 9
160 10 162 200 2 8 18
240 1 243 300 3 12 27
320 2 324 400 4 16 36
400 3 405 500 5 20 45
480 4 486 600 6 24 54
560 5 567 700 7 28 63
640 6 648 800 8 32 72
720 7 729 900 9 36 81
800 8 810 1000 10 40 90
10 9 10 1 2 3

9 10 1 2 3 4
90 10 100 1 4 9 16
180 1 200 2 8 18 32
270 2 300 3 12 27 48
360 3 400 4 16 36 64
450 4 500 5 20 45 80
540 5 600 6 24 54 96
630 6 700 7 28 63 112
720 7 800 8 32 72 128
810 8 900 9 36 81 144
900 9 1000 10 40 90 160
10 10 1 2 3 4

Page 21
VDA

6 7 8 9 10
36 49 64 81 100
72 98 128 162 200
108 147 192 243 300
144 196 256 324 400
180 245 320 405 500
216 294 384 486 600
252 343 448 567 700
288 392 512 648 800
324 441 576 729 900
360 490 640 810 1000
6 7 8 9 10

7 8 9 10 1
49 64 81 100 1
98 128 162 200 2
147 192 243 300 3
196 256 324 400 4
245 320 405 500 5
294 384 486 600 6
343 448 567 700 7
392 512 648 800 8
441 576 729 900 9
490 640 810 1000 10
7 8 9 10 1

8 9 10 1 2
64 81 100 1 4
128 162 200 2 8
192 243 300 3 12
256 324 400 4 16
320 405 500 5 20
384 486 600 6 24
448 567 700 7 28
512 648 800 8 32
576 729 900 9 36
640 810 1000 10 40
8 9 10 1 2

9 10 1 2 3
81 100 1 4 9
162 200 2 8 18
243 300 3 12 27
324 400 4 16 36
405 500 5 20 45
486 600 6 24 54
567 700 7 28 63
648 800 8 32 72

Page 22
VDA
729 900 9 36 81
810 1000 10 40 90
9 10 1 2 3

10 1 2 3 4
100 1 4 9 16
200 2 8 18 32
300 3 12 27 48
400 4 16 36 64
500 5 20 45 80
600 6 24 54 96
700 7 28 63 112
800 8 32 72 128
900 9 36 81 144
1000 10 40 90 160
10 1 2 3 4

1 2 3 4 5
1 4 9 16 25
2 8 18 32 50
3 12 27 48 75
4 16 36 64 100
5 20 45 80 125
6 24 54 96 150
7 28 63 112 175
8 32 72 128 200
9 36 81 144 225
10 40 90 160 250
1 2 3 4 5

2 3 4 5 6
4 9 16 25 36
8 18 32 50 72
12 27 48 75 108
16 36 64 100 144
20 45 80 125 180
24 54 96 150 216
28 63 112 175 252
32 72 128 200 288
36 81 144 225 324
40 90 160 250 360
2 3 4 5 6

3 4 5 6 7
9 16 25 36 49
18 32 50 72 98
27 48 75 108 147
36 64 100 144 196
45 80 125 180 245
54 96 150 216 294
63 112 175 252 343
72 128 200 288 392
81 144 225 324 441

Page 23
VDA
90 160 250 360 490
3 4 5 6 7

4 5 6 7 8
16 25 36 49 64
32 50 72 98 128
48 75 108 147 192
64 100 144 196 256
80 125 180 245 320
96 150 216 294 384
112 175 252 343 448
128 200 288 392 512
144 225 324 441 576
160 250 360 490 640
4 5 6 7 8

5 6 7 8 9
25 36 49 64 81
50 72 98 128 162
75 108 147 192 243
100 144 196 256 324
125 180 245 320 405
150 216 294 384 486
175 252 343 448 567
200 288 392 512 648
225 324 441 576 729
250 360 490 640 810
5 6 7 8 9

Page 24
Ratings description
S
1 not perceptible
2 small
3 small
4 medium
5 medium
significance
6 medium
7 significant
8 significant
9 very significant
10 very significant
1 very probable
2 probable
3 medium
4 medium
5 medium
detection
6 small
7 small
8 small
9 very small
10 improbable
1 improbable
2 very small
3 very small
4 small
5 small
occurrence
6 small
7 medium
8 medium
9 high
10 high
DESIGN
1 None
2 Very Minor
3 Minor
4 Very Low
5 Low
significance
6 Moderate
7 High
8 Very High
9 Hazardous-with warni
10 Hazardous-without wa
1 Almost Certain
2 Very High
3 High
4 Moderately High
5 Moderate
detection
6 Low

Page 25
detection Ratings description
7 Very Low
8 Remote
9 Very Remote
10 Absolute Uncertainty
1 Remote
2 Low
3 Low
4 Moderate
5 Moderate
occurrence
6 Moderate
7 High
8 High
9 Very High
10 Very High
PR
1 None
2 Very Minor
3 Minor
4 Very Low
5 Low
significance
6 Moderate
7 High
8 Very High
9 Hazardous-with warni
10 Hazardous-without wa
1 Almost Certain
2 Very High
3 High
4 Moderately High
5 Moderate
detection
6 Low
7 Very Low
8 Remote
9 Very Remote
10 Almost impossible
1 Remote
2 Very Low
3 Low
4 Moderate
5 Moderate
occurrence
6 Moderate
7 High
8 High
9 Very High
10 Very High

Page 26
Ratings description
SYSTEM
not perceptible It is improbable that this failure will result in a perceptible change in the perform
small This failure is not significant. The customer will not be inconvenienced by a the malfunctio
small This failure is not significant. The customer will not be inconvenienced by a the malfunctio
medium This failure is significant enough to inconvenience or angry the customer. He or she wil
medium This failure is significant enough to inconvenience or angry the customer. He or she wil
medium This failure is significant enough to inconvenience or angry the customer. He or she wil
significant Significant failure that causes a total malfunction of the system. The customer will not
significant Significant failure that causes a total malfunction of the system. The customer will not
very significant Significant failure that causes total inoperabilty of the system and possible malfu
very significant Significant failure that causes total inoperabilty of the system and possible malfu
very probable It is improbable that the failure will not be recognized during testing. Chance of d
probable It is improbable that the failure will not be recognized during testing. Chance of discov
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
very small Chance of discovery >= 90%
improbable Chance of discovery < 90%
improbable It is improbable for this failure to occur. Chance of failure <= 1/100000
very small This design is only slightly different from earlier proven designs. Chance of failure <=
very small This design is only slightly different from earlier proven designs. Chance of failure <=
small This design is only slightly different from earlier proven designs which failed in some case
small This design is only slightly different from earlier proven designs which failed in some case
small This design is only slightly different from earlier proven designs which failed in some case
medium This design is only slightly different from earlier proven designs which caused problem
medium This design is only slightly different from earlier proven designs which caused problem
high This design is almost certain to cause problems. Chance of failure <= 1/10
high This design is almost certain to cause problems. Chance of failure <= 1/2
DESIGN / MACHINE
No Effect
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by discriminating customer.
Minor Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customer.
Very Low Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by most customers.
Low Vehicle/item operable, but Comfort/Convenience item(s) operable at reduced level of perform
Moderate Vehicle/item operable, but Comfort/Convenience item(s) inoperable. Customer experie
High Vehicle/item operable, but at reduced level of performance. Customer dissatisfied.
Very High Vehicle/item inoperable, with loss of primary function.
Hazardous-with warning Very high severity ranking when a potential failure mode affects safe ve
Hazardous-without warning Very high severity ranking when a potential failure mode affects safe
Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subs
Very High Very high chance the Design Control will detect a potential cause/mechanism and subs
High High chance the Design Control will detect a potential cause/mechanism and subsequent fa
Moderately High Moderately high chance the Design Control will detect a potential cause/mechan
Moderate Moderate chance the Design Control will detect a potential cause/mechanism and subs
Low Low chance the Design Control will detect a potential cause/mechanism and subsequent fail

Page 27
Ratings description
Very Low Very low chance the Design Control will detect a potential cause/mechanism and subse
Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequ
Very Remote Very remote chance the Design Control will detect a potential cause/mechanism an
Absolute Uncertainty Design Control will not and/or can not detect a potential cause/mechanism
Remote Failure is unlikely Possible Failure Rate <=1 in 1,500,000
Low Relatively few failures Possible Failure Rate 1 in 150,000
Low Relatively few failures Possible Failure Rate 1 in 15,000
Moderate Occasional failures Possible Failure Rate 1 in 2,000
Moderate Occasional failures Possible Failure Rate 1 in 400
Moderate Occasional failures Possible Failure Rate 1 in 80
High Repeated failures Possible Failure Rate 1 in 20
High Repeated failures Possible Failure Rate 1 in 8
Very High Failure is almost inevitable Possible Failure Rate 1 in 3
Very High Failure is almost inevitable Possible Failure Rate >=1 in 2
PROCESS
None No Effect.
Very Minor Minor disruption to production line. A portion (less than 100%) of the product may hav
Minor Minor disruption to production line. A portion (less than 100%) of the product may have to
Very Low Minor disruption to production line. The product may have to be sorted and a portion (le
Low Minor disruption to production line. 100% of product may have to be reworked. Fit & Finish/S
Moderate Minor disruption to production line. A portion (less than 100%) of the product may have
High Minor disruption to production line. Product may have to be sorted and a portion (less than
Very High Major disruption to production line. 100% of product may have to be scrapped. Vehicl
Hazardous-with warning May endanger machine of assembly operator. Very high severity ranking
Hazardous-without warning May endanger machine of assembly operator. Very high severity rank
Almost Certain Design control(s) almost certain to detect the failure mode. Reliable detectio
Very High Very high likelihood current control(s) will detect failure mode.
High High likelihood current control(s) will detect failure mode.
Moderately High Moderately high likelihood current control(s) will detect failure mode.
Moderate Moderate likelihood current control(s) will detect failure mode.
Low Low likelihood current control(s) will detect failure mode.
Very Low Very low likelihood current control(s) will detect failure mode.
Remote Remote likelihood current control(s) will detect failure mode.
Very Remote Very remote likelihood current control(s) will detect failure mode.
Almost impossible No known control(s) available to detect failure mode.
Remote Failure is unlikely. No failures ever associated with almost identical processes.
Very Low Only isolated failures associated with almost identical processes. Possible Failure Rate
Low Isolated failures associated with similar processes. Possible Failure Rate 1 in 15,000 Cpk >=
Moderate Generally associated with processes similar to previous processes which have experien
Moderate Generally associated with processes similar to previous processes which have experien
Moderate Generally associated with processes similar to previous processes which have experien
High Generally associated with processes similar to previous processes that have often failed. Po
High Generally associated with processes similar to previous processes that have often failed. Po
Very High Failure is almost inevitable. Possible Failure Rate 1 in 3 Cpk >= 0.33
Very High Failure is almost inevitable. Possible Failure Rate >= 1 in 2 Cpk < 0.33

Page 28
Ratings description

ice this failure.

e system are not impaired.


e system are not impaired.

overnment regulation with warning.


h government regulation without warning.

Page 29
Ratings description

Notes_Spanish
ueak & Rattle item does not conform. Defect noticed by average customers.
Ninguno Sin efecto
Muy menor Puede estropear levemente la linea de producción
Menor Puede estropear levemente la linea de producción
Muy bajo Puede estropear levemente la linea de producción
Bajo Puede estropear levemente la linea de producción
Moderado Puede estropear levemente la linea de producción
Alto Puede estropear levemente la linea de producción
Muy alto Puede estropear la linea de producción
Aleatoriamente con aviso Puede dañar la máquina o la operación de ensamblaje
Aleatoriamente sin aviso Puede dañar la máquina o la operación de ensamblaje

Casi siempre Los controles actuales detectarán el fallo casi siempre


Muy Alta Muy normalmente los controles actuales detectarán el fallo
Alta Normalmente los controles actuales detectarán el fallo
Moderada alta Los controles actuales detectarán el fallo muy a menudo
Moderada Los controles actuales detectarán el fallo a menudo
Baja Difilcilmente los controles actuales detectarán el fallo
Muy baja Muy dificilmente los controles actuales detectarán el fallo
Remota Remotamente los controles detectarán el fallo
Muy remota Muy remotamente los controles actuales detectarán el fallo
Casi imposible No se conocen controles para detectar el fallo
Remota (1 en 1,500,000) El fallo es casi imposible Cpk>=1.67
Muy baja (1 en 150,000) Asociados a idéticos procesos Cpk=1.5
Baja (1 en 15,000) Asociados a procesos similares Cpk>=1.33
Moderada (1 en 2000) Asociados a procesos anteriores en baja proporción Cpk>=1.17
Moderada (1 en 400) Asociados a procesos anteriores en baja proporción Cpk>=1.00
Moderada (1 en 80) Asociados a procesos anteriores en baja proporción Cpk>=0.88

Page 30
Ratings description
Alta (1 de 20) Asociados a procesos anteriores Cpk>=0.67
Alta (1 de 8) Asociados a procesos anteriores Cpk>=0.51
Muy alta (1 de 3) El fallo es casi inevitable Cpk=0.33
Muy alta (>=1 de 2) El fallo es casi inevitable Cpk<0.33

Page 31
Ratings description

ensamblaje
ensamblaje

orción Cpk>=1.17
ción Cpk>=1.00
ón Cpk>=0.88

Page 32
FMEA

Process

Type/Model/Fabrication/Load: Item Code: Responsible:


Beer making (based on Indian Pale Ale)
Revision State: Company:

FMEA/Process Step: Item Code: Responsible:


Sterilisation
Revision State: Company:

Effects S C Failure Mode Causes Preventive Action O


Process Element: OPERATION UNDER ANALYSIS - e.g. welding
Function: WHAT YOU INTEND TO ACHIEVE AT THIS STATION - e.g. weld as per drawing

Failure Cause - Coded Welders


Outcome of insufficient 4
the Failure acetylene gas Way to prevent the
Mode e.g cause!
8
Reduced
structural
Integrity Failure Mode -
Poor weld Failure Cause -
Total Preventative
penetration Wire feed
Maintenance
blocked

Fails crash
10
test Failure Cause -
No gas shield

Outcome of
the Failure
Mode e.g
8
Reduced
structural
Integrity Failure Mode - Failure Cause -
Company welding
Excess weld Wire feed too
procedures
penetration slow

Fails crash
10
test
Number: 1.1

Page:  

Created: 13/03/2013

Created: 13/03/2013

Modified: 13/03/2013

Detection D RPN R/D


Action
r drawing
Gas checked
before shift
2 80
First off
inspecion

Something that
you would do to
discover the
failure cause