Free tool · Risk
FMEA
Write down how each step of a process can fail, what it costs, how often it happens and whether anyone would catch it. The sheet rates every failure mode, ranks them by action priority and RPN, and keeps the actions with their owners until the re-rating shows the risk is gone.
Rating scales
Each rating runs from 1 to 10. The same words appear in the rating lists of the sheet.
S · Severit y
How bad is the effect for the customer or the people when the failure happens?
- 1 · None No noticeable effect.
- 2 · Very minor A slight inconvenience that few notice.
- 3 · Minor A small inconvenience that most notice; no rework.
- 4 · Very low A little rework or a short delay inside the shift.
- 5 · Low Rework or a late order; the customer notices.
- 6 · Moderate A damaged or incomplete delivery; complaint and re-send.
- 7 · High The process stops or needs heavy rework; a customer may be lost.
- 8 · Very high The service fails for many customers at once.
- 9 · Hazardous, with warning Safety or regulatory breach that announces itself first.
- 10 · Hazardous, without warning Injury or regulatory breach with no warning at all.
O · Occurrence
How often does this cause lead to the failure, with the process as it runs today?
- 1 · Remote Practically ruled out; nobody has seen it.
- 2 · Very low A few times a year.
- 3 · Low About once a month.
- 4 · Moderately low A few times a month.
- 5 · Moderate About once a week.
- 6 · Moderately high Several times a week.
- 7 · High About once a shift.
- 8 · Very high Several times a shift.
- 9 · Very high, repeated Several times an hour.
- 10 · Almost ce
r tain Happens nearly every time the step runs.
D · De tection
How likely is it that today's controls catch the failure before it reaches the customer?
- 1 · Almost ce
r tain The step cannot pass the error; it is blocked at source. - 2 · Very high An automatic check at the step catches it every time.
- 3 · High An automatic check at a later step catches it.
- 4 · Moderately high A second person checks it at the step.
- 5 · Moderate The operator checks it by eye at the step.
- 6 · Low A visual check at a later step, or a sample check.
- 7 · Very low Found only by chance or in an audit.
- 8 · Remote Found only after the process, by the next department.
- 9 · Very remote Found only by the customer.
- 10 · Cannot d
e tect No control; it is never found, or found too late.
3 · Failure modes
| # | Process step | Function / requirement | Potential failure mode | Potential effect of failure | Severity (S) | Potential cause | Occurrence (O) | Current prevention control | Current detection control | Detection (D) | RPN | Action priority (AP) | Recommended action | Owner | Due | Status | S after action | O after action | D after action | RPN after action | Row tools |
|---|
No failure modes yet. Add the first row, fill the steps from a template, or .
The guide · Edition 3 · Page 38
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