SHEET 1 - SEVERITY

Chart can be used for Things to Consider When Ranking:

DFMEA or PFMEA Design Centric Information Process Centric Information 1. Determine who is the customer.
2. Consider the effect on end user
Severity of Effect on Process (left side of matrix) and the Mfg.
Effect on End User Severity of Effect Rank # Effect on Mfg (Mfg/Assy Effect) process (right side of matrix).

Potential failure mode affects safe vehicle May endanger operator (machine or
operation and/or involves noncompliance with 10
government regulation without warning Failure to meet assembly) without warning.
Failure to Meet Safety Safety and/or
and/or Regulatory Regulatory
Potential failure mode affects safe vehicle Requirements
operation and/or involves noncompliance with May endanger operator (machine or
9 assembly) with warning. Legend
government regulation with warning

Loss of primary function (vehicle inoperable, Major 100% of product may have to be scrapped. Red Items are related are Safety
does not affect safe vehicle operation). 8 Disruption Line shutdown or stop ship. Related to end user or process
personnel
Loss or Degradation of
Primary Function A portion of the production run may have
Degradation of primary function (vehicle Significant to be scrapped. Deviation from primary Orange Items are Major or
operable, but at reduced level of performance). 7 Disruption process including decreased line speed or Significant Functional or Production
added manpower. Disruptions

Loss of secondary function (vehicle operable, 100% of production run may have to be Bright Yellow is Moderate impact to
but comfort/ convenience functions 6 reworked off line and accepted. end user or production process
inoperable).
Problem Detection At Moderate
Source Disruption
Degradation of secondary function (vehicle A portion of the production run may have Yellow is minor to moderate impact
operable, but comfort/convenience functions at 5 to be reworked off line and accepted. to end user or production process
reduced level of performance).

Appearance or Audible Noise, vehicle operable, 100% of production run may have to be Green is no detectable effect to end
but comfort/ convenience functions at reduced 4 reworked in station before it is processed. user or production
level of performance (>75%).
Moderate
Disruption
Appearance or Audible Noise, vehicle operable, A portion of the production run may have
Annoyance item does not conform and noticed by many 3 to be reworked in-station before it is
customers (50%). processed.

Appearance or Audible Noise, vehicle operable, Minor Slight inconvenience to process, operation,
item does not conform and noticed by 2 Disruption or operator.
discriminating customers (< 25%).

No Effect No discernable effect 1 No Effect No discernable effect.

 SHEET 2 - Occurrence
Chart can be used
for DFMEA or Design Centric Occurrence Definition Process or Design Occurrence Gage
PFMEA

Likelihood of DFMEA Criteria: Occurrence of Failure or Cause of PFMEA Criteria: Occurrence of Failure or Cause of
Failure Failure Failure Rank Legend

Very High New technology/ new design with no history. ≥ 500 per thousand Ppk ≥ 0.00 Sigma (Z) 0.00 10
≥ 5 in 10 Depending on Severity
rating, Occurrences from
4-10 may indicate
characteristics become
Failure is inevitable with new design, new significant or critical.
application, or change in duty cycle/operating ≥ 200 per thousand Ppk ≥ 0.25 Sigma (Z) 0.84 9
conditions. ≥ 1 in 5

High Failure is likely with new design, new application or ≥ 100 per thousand
change in duty cycle /operating conditions. ≥ 1 in 10 Ppk ≥ 0.40 Sigma (Z) 1.28 8
Ppk and Sigma are not an
exact match to "per
thousand" calculation,
Failure is uncertain with new design, new ≥ 50 per thousand hence > or < symbol
application, or change in duty cycle/operating ≥ 1 in 20 Ppk ≥ 0.50 Sigma (Z) 1.64 7
conditions.

Frequent failures associated with similar designs or ≥ 20 per thousand Sigma (Z) 2.05
in design simulation and testing. ≥ 1 in 50 Ppk ≥ 0.78 6

Problem Occasional failures associated with similar designs or 10 per thousand

Detection At in design simulation and testing. 1 in 100 Ppk ≥ 1.00 Sigma (Z) 2.33 5
Source
Isolated failures associated with similar design or in 2 per thousand
design simulation and testing. 1 in 500 Ppk ≥ 1.10 Sigma (Z) 2.87 4

Only isolated failures associated with almost .5 per thousand Ppk ≥ 1.30 Sigma (Z) 3.29 3
identical design or in design simulation and testing. 1 in 2,000
Low
No observed failures associated with almost .1 per thousand Ppk ≥ 1.47 Sigma (Z) 3.72 2
identical design or in design simulation and testing. 1 in 10,000

.01 per thousand

Very Low Failure is eliminated through preventive control. 1 in 1,000,000 Ppk ≥ 1.57 Sigma (Z) 4.75 1

Ppk is not an exact match to "per thousand"

calculation, hence > or < symbol
 SHEET 3 - Class
Initiated DFMEA PFMEA Occ. Face of
Class Definition
By: Sev. Sev. Rank Drwg?
A critical characteristic is one that, if not
in conformance with design
CC
Design requirements, could increase the 10 10 ANY Yes
(Critical)
probability of occurrence of one of the
failure modes.
Significant characteristics are key
characteristics highlighted by Program
IPTs or Research and Design Engineering
Design SC (Significant) to communicate a special need for 9 9 ANY Yes
emphasis on properly performing
manufacturing operations affecting the
characteristic.
An attribute or feature whose variation has a
significant effect on product fit, form, function,
KC
Design performance, service life or producibility, that 5-8 5-8 6-10 TBD
Key
requires specific actions for the purpose of
controlling variation.
Characteristic identified on PFMEA that
OS has an increased probability of impacting
MFG 9-10 9-10 ANY No
(Operator Safety) the safety of operator performing mfg.
operation

Problem Variable in the process that is found to be key

Detectio to manufacturing another special characteristic,
KPV
performing downstream operations or 5-8 5-8 6-10 No
n At (Key Process Variable)
assembly or key to the function of the process
Source (Does not have to be drawing characteristic.
 SHEET 4 - Detection

Interpretation
1. Error Proof

3. Subjective
Chart can be used for DFMEA or

2. Variable
PFMEA

Gage
Likelihood of
Opportunity for Detection 1 2 3 Criteria: Likelihood of Detection by Process Control Rank
Detection
No detection opportunity Almost Impossible X No current process control; Cannot detect or is not analyzed. 10 Legend
Not likely to detect at any Failure Mode and/or Error (Cause) is not easily detected (e.g. random No attribute or
Very Remote X 9
stage audits). variable gage
Problem Detection Post Failure Mode detection post-processing by operator through
Remote X 8
Processing visual/tactile/audible means
Detection in-station by operator; visual/tactile/audible means or post-
Problem Detection At Source Very Low X processing with attribute gauging (go/no-go, manual torque, 7
check/clicker wrench etc.)

Detection post-processing by operator, variable gauging or in-station by

Problem Detection Post
Low X X operator with attribute gauging (go/no-go, manual torque, check/clicker 6
Processing
wrench etc.)

Detection in-station by operator; variable gauging or by automated

Problem Detection At Source Moderate X controls in-station that will detect discrepancy in part and notify 5
operator (light, buzzer, etc.)

Problem Detection Post Failure Mode detection post-processing by automated controls that will
Moderately High X 4
Processing detect discrepancy in part and lock part to prevent further processing.

Failure Mode detection in-station by automated controls that will detect

Problem Detection At Source High X discrepancy in part and automatically lock part in station to prevent 3
further processing.
Error Detection and/or Error (Cause) detection in-station by automated controls that will detect
Very High X 2
Problem Prevention error and prevent discrepancy from being made.
Error (Cause) prevention by fixture, machine, or part design. Discrepancy
Detection not applicable;
Almost Certain X cannot be made because item has been error-proofed by 1
error Prevention
process/product design.