PFMEA RANKING TABLE Training

Material on FMEA

Suggested PFMEA Severity Evaluation Criteria

Effect Criteria: Ran Effect Criteria:

Severity of effect on product k Severity Of Effect On
(customer effect) Process
(Manufacturing
Assembly Effect)
Failure to Meet Potential failure mode effect safe vehicle 10 Failure to meet May endanger operator
safety and/or operation and/or involves noncompliance safety and/or (machine or assembly )
Regulatory with government regulation without warning. regulatory without warning
Requirement 9 requirements May endanger operator
Potential failure mode effect safe vehicle (machine or assembly) with
operation and/or involves noncompliance warning
with government regulation without warning
Loss or Loss of primary function (vehicle inoperable, 8 Major disruption 100% of product may have to
Degradation of does not affect safe vehicle operation) be scrapped. Line shutdown or
primary stop ship
Function Degradation of primary function (vehicle 7 Significant A portion of the production run
operable, but at reduced level of disruption may have to be scrapped.
performance) Deviation from primary
process including decreased
line speed or added manpower.
Loss or Degradation of primary function (vehicle 6 Moderate 100% of product may have to
Degradation of operable, but comfort convenience function disruption be reworked off line and
secondary inoperable). accepted.
Function Degradation of secondary function (vehicle 5 A portion of the production run
operable, but comfort/convenience) may have to be reworked off
line and accepted
Annoyance Appearance or Audible Noise, vehicle 4 100% of product may have to
operable, items does not conform and Moderate be reworked in station before it
noticed by most customer (>75%) disruption is processed.

Appearance or Audible Noise, vehicle 3 A portion of the production run

operable, items does not conform and may have to be reworked in-
noticed by most customer (50%) station before it is processed

Appearance or Audible Noise, vehicle 2 Minor disruption Slight in-convenience to

operable, items does not conform and process, operation, or operator.
noticed by most customer (<25%
No effect No discernible effect 1 No effect No discernible effect

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PFMEA RANKING TABLE Training
Material on FMEA

SUGGESTED PFMEA OCCURRENCE EVALUATION CRITERIA

Criteria: occurrence of
cause- PFMEA
Likelihood of failure Rank
(incidents per
items/vehicles)rank
≥100 per thousand
Very high 10
≥ 1 in 10

50 per thousand
9
1 in 20

20 per thousand
High 1 in 50 8

10 per thousand
7
1 in 100

2 per thousand
6
1 in 500

.5 per thousand
Moderate 5
1 in 2,000

.1 per thousand
4
1 in 10,000

.01 per thousand

3
1 in100,000
Low
≤.001 per thousand
2
1 in 1,000,000

Failure in eliminated through

Very low 1
preventive control

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PFMEA RANKING TABLE Training
Material on FMEA

Suggested Process FMEA Detection Evaluation Criteria

Opportunity for Likelihood of detection by process control Rank Likelihood

detection of
detection
No detection opportunity No current process control; cannot detect or is not analyzed 10 Almost
impossible
Not like to detect at any Failure mode and/or error(cause)is not easily detected (e.g 9 Very remote
stage random audit)
Problem detection post Failure mode detection post processing by operator through 8 Remote
processing visual/tactile/audible mean
Problem detection at Failure mode detection in-station by operator through 7 Very low
sources visual/tactile/audible mean or post processing through use of
attributes gauging (go/no-go, manual torque check/ clicker
wrench, etc).
Problem detection post Failure mode detection post processing by operator through 6 Low
processing use of variable gauging or in-station by operator through use
of attributes gauging(go/no-go, manual torque check/ clicker
wrench, etc).
Problem detection at Failure mode detection post processing by operator through 5 Moderate
sources use of variable gauging or by automated controls in-station
that will detect discrepant part and notify operator (light,
buzzer, etc). gauging performed on setup and first-piece
check (for set-up causes only).
Problem detection post Failure mode detection post processing by automated 4 Moderately
processing controls that will detect discrepant part and lock part to High
prevent further processing.
Problem detection at Failure mode detection post processing by automated 3 High
sources controls that will detect discrepant part and automatically
lock part in station to prevent further processing
Error detection and/or Error (cause) detection in-station by automated controls that 2 Very high
problem prevention will defect error and prevent discrepant part from being
made.
Detection not applicable, Error (cause) prevention as a result of fixture design, 1 Almost
error prevention machine design or part design. Discrepant parts cannot be Certain
made because items have been error-proofed by
process/product design

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