IntroductionWelcome to the FMEA WorksheetThis spreadsheet can be
used to1.Identify potential failure modes and their impact on
product reliability.2.Rank the potential defects to establish
priority - The highest RPN value items deserve the most
attention.3.Capture owners, action plans, and status on high RPN
items.Note, FMEA's are living documents and this may be updated
periodically.Organization of Spreadsheet:Descriptions - explains
the spreadsheet cellsFMEA - the actual sheet used to enter
dataSeverity/Likelihood/Detectability - guidelines for the 1-10
rankins in these categoriesExample - a partial exmample of an FMEA
documentSheet Protection:Some sheets are protected. There is no
password.Released for review:31-Jul-98A. Dembskirev 1
&A
DescriptionsDescription of FMEA WorksheetProtection:The
spreadsheets are not protected or locked.SystemPotentialFMEA
NumberSubsystemFailure Mode and Effects AnalysisPrepared
ByComponent(Design FMEA)FMEA DateDesign LeadKey DateRevision
DateCore TeamPageofAction ResultsItem / FunctionPotential Failure
Mode(s)Potential Effect(s) of FailureSevPotential Cause(s)/
Mechanism(s) of FailureProbCurrent Design ControlsDetRPNRecommended
Action(s)Responsibility & Target Completion DateActions
TakenNew SevNew OccNew DetNew RPN00Coolant containment. Hose
connection. Coolant fill. MCrack/break. Burst. Side wall flex. Bad
seal. Poor hose reteLeak8Over pressure8Burst, validation pressure
cycle.164Test included in prototype and production validation
testing.J.P. Aguire 11/1/95 E. Eglin
8/1/9600000000000000000000000000000
&APage &PResponse Plans and TrackingRisk Priority Number
- The combined weighting of Severity, Likelihood, and
Detectability.RPN = Sev X Occ X DetLikelihood - Write down the
potential cause(s), and on a scale of 1-10, rate the Likelihood of
each failure (10= most likely). See Likelihood sheet.Severity - On
a scale of 1-10, rate the Severity of each failure (10= most
severe). See Severity sheet.Detectability - Examine the current
design, then, on a scale of 1-10, rate the Detectability of each
failure(10 = least detectable). See Detectability sheet.Write down
each failure mode and potential consequence(s) of that failure.
FMEASystemDesign Verification ProcessPotentialFMEA NumberProject
IIISubsystemFailure Mode and Effects AnalysisPrepared ByHouston
MayerComponent(Design FMEA)FMEA Date10/22/99Design LeadHouston
MayerKey DateRevision Date8/21/00Core TeamSee Project III R1
ReportPage1of6Action ResultsItem / FunctionPotential Failure
Mode(s)Potential Effect(s) of FailureSevPotential Cause(s)/
Mechanism(s) of FailureProbCurrent Design ControlsDetRPNRecommended
Action(s)Responsibility & Target Completion DateActions
TakenNew SevNew OccNew DetNew RPNCustomer sends in a quote request
for product.System, Software, Integration and Shipping requirements
overlooked by customer.Customer needs not fully met by delivered
system.7Human error1Design configuration tool.321Use configuration
tool when available.Closed 10/21/990Requirement entered and
verified by Inside Sales in config. tool.Data entry errorSystem
compatability requirements not evaluated by config. tool.3Human
error1Order verified by a configuration tool.39Continue order
verification by configuration tool.Closed 10/21/990Sales identifies
need for CII or SHCSpecific packing, labeling and shipping
requirements may not be fully addressed.On time delivery and
integraty of the product may be compramised if this issue is not
addressed.7Requirements Overlooked.3Customer Inspection
Instruction/ Special Handling Codes Process 033-001-02363Publish
comprehensive procedure for the 1st Article Process.Jun-00Customer
shipping requirements reviewed by quality assurance in 1st Article
process.0Position of the DHR in ICD label packet not identified by
GE.Requirment in Purchase Specification for mousepad, but not
identified on Bill of Material.ICD Card content requirements not
identified in Build Procedure.Loss of business with the
customer.1Requirements Overlooked.5CII 033-001-00615Revisit
contents of GE CII 033-001-006 to assure all requirements are
clearly commumicated to the warehouse operators and quality
technicians using these documents.Sep-00OPEN 8/21/00QA and Pack and
Ship Team reviews customer requirements during a 1st
Article.Specific packing, labeling and shipping requirements may
not be fully addressed.Customer's full expectations may not be
realized.7Requirements overlooked.3Customer requirements physically
verified by quality assurance during the 1st Article
process.363Continue current pracices.Closed 10/25/990Inside sales
submits Sales Order Authorization request to TECenter.Data entry
errorOrder Processing Delay1Human Error1Customer requirements
verified by a TECenter engineer.33Continue current practices.Closed
1/25/000TECenter Engineer reviews the design to determain if
additional data is required.Requirements overlooked by
EngineerCustomer's full expectations may not be
realized.3Requirements Overlooked.6Customer requirements verified
by a TECenter engineer.354Continue current practices.Closed
10/25/990Appropriate individuals are contacted to resolve
issues.Appropriate individuals not available.Order Processing
Delay1Process Failure1Individuals are contacted to resolve
issues.11Continue current practices.Closed 1/25/000Design Review is
completed.Requirements may not be completeCustomer's full
expectations may not be realized.1Process Failure1Customer
requirements verified by a TECenter engineer.11Continue current
pracices.Closed 1/25/000Another engineer performs quality check of
the design.Requirements overlooked by two EngineerCustomer's full
expectations may not be realized.7Process Failure3Customer
requirements verified by a TECenter engineer.363Continue current
pracices.Closed 10/25/990Completed design verification is sent to
appropriate organization.Design verification misroutedOrder
Processing Delay1Process Failure1Verification is sent to
appropriate organization.11Continue current pracices.Closed
1/25/000Requirements are defined and capability to meet/ accept
requirements.Requirements may be missed or capibilty to meet
overestamatedCustomer's full expectations may not be
realized.1Process Failure1Requirements are defined and to meet
requirements.11Continue current pracices.Closed 1/25/000Inside
Sales quotes price and availabilityWrong price and availability
provided to customerCustomer's full expectations may not be
realized.3Process Failure1Price provided to customer13Continue
current pracices.Closed 1/25/000Customer sends in purchase
order.Order misroutedOrder Processing Delay1Process
Failure1Reprocess Order11Continue current pracices.Closed
1/27/000Inside sales places order on system.Data Entry ErrorOrder
Processing Delay3Human Error1Reprocess Order13Continue current
pracices.Closed 1/27/000Order approved by Asset Management.Approval
not timelyOrder Processing Delay1Process Failure1Expidite
Process11Continue current pracices.Closed 1/27/000Order approved by
credit.Approval not timelyOrder Processing Delay1Process
Failure1Expidite Process11Continue current pracices.Closed
1/27/000Determaination made that product is available for build.All
product required for the order may not be available at the start of
the build.(1) Product delivery date requirements may not be met.
(2) Workspace occupied for an order awaiting Product is not
available for integration of other orders.5Needed components are
not available at the time of need.3Assure product availability
before the order commitment is given to customer.115Continue
current practices.Closed 10/25/990Inside sales expedites with Asset
to provide ship date.Shipdates may not be accurateCustomer's full
expectations may not be realized.1Needed components are not
available at the time of need.1Expidite Process11Continue current
practices.Closed 1/27/000Order approved by Asset Mgmt. and e-mail
sent to Integration.e-mail may be misroutedOrder Processing
Delay1Process Failure1Expidite Process11Continue current
practices.Closed 1/27/000Project Manager reviews order for special
or internal instructions.Order processing requirements may be
overlookedCustomer and processing needs not identified could
prevent timely processing of the order.3Processing requirements
overlooked.1Project Manager order review.13Continue current
practices.Closed 10/25/990Build document bill of material matched
with SCN.Documents do not matchOrder Processing Delay5Needed
components are not available at the time of need.3Expidite
ProcessIntegration Center Operations Manual
093-009-OPSMNL345Continue current practices.Closed 1/27/000Stock
availability is checked and delivery dates are aquired for non
stock items.stock availability and dates may be
inaccurateCustomer's full expectations may not be realized.3Needed
components are not available at the time of need.1Expidite
Process13Continue current practices.Closed 1/27/000Order is
forwarded to Production Engineer for review.Order may be
misroutedOrder Processing Delay1Process Failure1Expidite
Process11Continue current practices.Continue current
practices.Determanation made for a 1st Article build.Need for 1st
build may be overlookedCustomer's full expectations may not be
realized.7Requirements Overlooked.3Individuals are contacted to
resolve issues.5105Continue current practices.Continue current
practices.Build document is reviewed and verified.Requirements may
be overlookedCustomer's full expectations may not be
realized.3Requirements Overlooked.3Individuals are contacted to
resolve issues.327Continue current practices.Continue current
practices.Project management notifies sales with status of
order.Sales may not receive order statusOrder Processing
Delay3Requirements Overlooked.1Individuals are contacted to resolve
issues.13Continue current practices.Continue current
practices.Asset management places order for non stock items.Items
may not be orderedOrder Processing Delay3Needed components are not
available at the time of need.1Expidite Process13Continue current
practices.Closed 1/27/00Order is scheduled for production.Order may
not be entered in scheduleOrder Processing Delay3Requirements
Overlooked.1Individuals are contacted to resolve issues.13Continue
current practices.Closed 1/27/00Whse Operator reviews parts to SOA
& SCN.Parts may not match requirementOrder Processing
Delay3Requirements Overlooked.3Individuals are contacted to resolve
issues.19Continue current practices.Closed 1/27/00Whse. Operator
Unpack,Iinspect & Kit order.All parts may not reach
integrationOrder Processing Delay3All components are not available
at the time of need.3Individuals are contacted to resolve
issues.Integration Kitting and Packing 153-001-01327Continue
current practices.Closed 1/27/00Techs. Check product against SOW
and build instructions.Parts may not match requirementOrder
Processing Delay5All components are not available at the time of
need.3Individuals are contacted to resolve issues.115Continue
current practices.Closed 1/27/00Integration Techs. inspect parts
and chassis.Materials may not be compliantOrder Processing
Delay7All components are not available at the time of need.3QA
Inspection and Test Procedure 103-001-03363Continue current
practices.Closed 1/27/00No NT Resource KitMissing Video BoardLoss
of business with the customer.1Requirements Overlooked.1QA
Inspection and Test Procedure 103-001-0355Update Build Procedures
to clearly define product requirements specific to the model being
integrated.Closed 8/21/00Techs. Integrate & Power-Up
SystemSystem may be integrated incorrectlyOrder Processing
Delay7Individuals are contacted to resolve issues.7QA Inspection
and Test Procedure 103-001-033147Continue current practices.Closed
1/27/00Integration Techs. Test system.System and parts may not be
compliantOrder Processing Delay10Needed components are not
available at the time of need.10QA Inspection and Test Procedure
103-001-031100Continue current practices.Closed 1/27/00Quality
techs. inspect product for build requirements.Specific build
requirements may not be fully addressed.On time delivery and
integraty of the product may be compramised if this issue is not
addressed.5Requirements Overlooked.1Individuals are contacted to
resolve issues.525Continue current practices.IO panel not
installedLabel on CPU IncorrectNo feet or other components
installedNo extension cablesMissing cablesIO panel gasket not
installedWrong ICD cards providedDome calibrater includedLoss of
business with the customer.1Human Error5Build Procedure for
individual PathSpeed Model525Update Build Procedures to clearly
define product requirements specific to the model being
integrated.Closed 8/21/00Product serial numbers scanned into
Genesis.Numbers may be incorrectOrder Processing Delay3Requirements
Overlooked.3Individuals are contacted to resolve issues.19Continue
current practices.Closed 1/27/00Change made after batch
releaseControl of requirements may be lostOrder Processing
Delay1Requirements Overlooked.1Individuals are contacted to resolve
issues.11Continue current practices.Closed 1/27/00Order placed on
hold when change is made.Shiping deadlines may not be metOrder
Processing Delay3Requirements Overlooked.3Individuals are contacted
to resolve issues.19Continue current practices.Closed 1/27/00Design
Process reinitiatesControl of requirements may not be completeOrder
Processing Delay3Process Failure1Individuals are contacted to
resolve issues.13Continue current practices.Closed 1/27/00Whse.
invoices and ships order per customer's shipping method.Wrong
Shipping method may be usedOn time delivery and integraty of the
product may be compramised if this issue is not addressed.7Process
Failure1Individuals are contacted to resolve issues.17Continue
current practices.Closed 1/27/00Quality techs. inspect shipment for
CII/SHC requirements.Specific packing, labeling and shipping
requirements may not be fully addressed.On time delivery and
integraty of the product may be compramised if this issue is not
addressed.10Requirements Overlooked.3Customer Inspection
Instruction/ Special Handling Codes Process 033-001-02390Continue
current pracices.Closed 1/25/00Label on outside of box did not
match S/N on CPU.Loss of business with the customer.1Human
Error3CII 033-001-00639Revisit contents of GE CII 033-001-006 to
assure all requirements are clearly commumicated to the warehouse
operators and quality technicians using these
documents.9/11/00Product ships to customer.Products misshippedOn
time delivery and integraty of the product may be compramised if
this issue is not addressed.7Needed components are not available at
the time of need.3Individuals are contacted to resolve
issues.7147Continue current practices.Closed 1/27/00Coordinator
closes project & files quality records.Documents not filed
correctlyDocuments may not be retrievable3Documents may not be
retrievable1Individuals are contacted to resolve issues.13Continue
current pracices.Closed 1/25/0000000
&L&8Houston MayerSix Sigma BlackbeltAugust 21,
2000&C&8 &R&P
SeverityEffectSEVERITY of EffectRankingHazardous without
warningVery high severity ranking when a potential failure mode
affects safe system operation without warning10Hazardous with
warningVery high severity ranking when a potential failure mode
affects safe system operation with warning9Very HighSystem
inoperable with destructive failure without compromising
safety8HighSystem inoperable with equipment damage7ModerateSystem
inoperable with minor damage6LowSystem inoperable without
damage5Very LowSystem operable with significant degradation of
performance4MinorSystem operable with some degradation of
performance3Very MinorSystem operable with minimal
interference2NoneNo effect1
&APage &P
ProbabilityPROBABILITY of FailureFailure ProbRankingVery High:
Failure is almost inevitable>1 in 2101 in 39High: Repeated
failures1 in 881 in 207Moderate: Occasional failures1 in 8061 in
40051 in 2,0004Low: Relatively few failures1 in 15,00031 in
150,0002Remote: Failure is unlikely