Introduction

Welcome to the FMEA Worksheet

This spreadsheet can be used to
1. 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 cells
FMEA - the actual sheet used to enter data
Severity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categories
Example - a partial exmample of an FMEA document
 Descriptions

Description of FMEA Worksheet

Protection:The spreadsheets are not protected or locked.

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results

Potential P

New RPN
New Occ
New Sev

New Det
S D R Responsibility &
Potential Failure Potential Effect(s) Cause(s)/ r Current Design Recommended
Item / Function e e P Target Completion Actions Taken
Mode(s) of Failure Mechanism(s) of o Controls Action(s)
v t N Date
Failure b

0 0
Coolant Crack/break. Leak 8 Over pressure 8 Burst, validation 1 64 Test included in J.P. Aguire 0
containment. Burst. Side wall pressure cycle. prototype and 11/1/95 E. Eglin
Hose connection. flex. Bad seal. production 8/1/96
Coolant fill. M Poor hose rete validation testing.

0 0
Write down each failure mode 0 Response Plans and Tracking 0
and potential consequence(s) 0 0
of that failure. 0 0
0
RiskPriority Number - The combined weighting of 0
Severity - On a scale of 1- Severity, Likelihood, and Detectability.
10, rate the Severity of each 0
RPN = Sev X Occ X Det 0
failure (10= most severe).
See Severity sheet. 0 0
0 0
Likelihood - Write down the Detectability 0- Examine the current 0
potential cause(s), and on a design, then, 0on a scale of 1-10, rate 0
scale of 1-10, rate the the Detectability
0
of each failure 0
Likelihood of each failure (10 = least detectable). See
0 0
(10= most likely). See Detectability sheet.
0 0
Likelihood sheet.
0 0

Page 2
System Design Verification Process Potential FMEA Number
Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team See Project III R1 Report Page 1 of 6

Action Results
P

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b

Customer sends System, Customer needs 7 Human error 1 Design 3 21 Use Closed 0
in a quote Software, not fully met by configuration configuration 10/21/99
request for Integration and delivered tool. tool when
product. Shipping system. available.
requirements
overlooked by
customer.

Requirement Data entry error System 3 Human error 1 Order verified by 3 9 Continue order Closed 0
entered and compatability a configuration verification by 10/21/99
verified by requirements tool. configuration
Inside Sales in not evaluated by tool.
config. tool. config. tool.

Sales identifies Specific On time delivery 7 Requirements 3 Customer 3 63 Publish Jun-00 Customer 0
need for CII or packing, and integraty of Overlooked. Inspection comprehensive shipping
SHC labeling and the product may Instruction/ procedure for requirements
shipping be compramised Special the 1st Article reviewed by
requirements if this issue is Handling Codes Process. quality
may not be fully not addressed. Process 033- assurance in 1st
addressed. 001-02 Article process.

Position of the Loss of business 1 Requirements 5 CII 033-001-006 1 5 Revisit contents Sep-00 OPEN 8/21/00
DHR in ICD with the Overlooked. of GE CII 033-
label packet not customer. 001-006 to
identified by GE. assure all
Requirment in requirements
Purchase are clearly
Specification for commumicated
mousepad, but to the
not identified on warehouse
Bill of Material. operators and
ICD Card quality
content technicians
requirements using these
not identified in documents.
Build Procedure.

3
QA and Pack Specific Customer's full 7 Requirements 3 Customer 3 63 Continue Closed 0
and Ship Team packing, expectations overlooked. requirements current 10/25/99
reviews labeling and may not be physically pracices.
customer shipping realized. verified by
requirements requirements quality
during a 1st may not be fully assurance
Article. addressed. during the 1st
Article process.

Inside sales Data entry error Order 1 Human Error 1 Customer 3 3 Continue Closed 1/25/00 0
submits Sales Processing requirements current
Order Delay verified by a practices.
Authorization TECenter
request to engineer.
TECenter.

TECenter Requirements Customer's full 3 Requirements 6 Customer 3 54 Continue Closed 0

Engineer overlooked by expectations Overlooked. requirements current 10/25/99
reviews the Engineer may not be verified by a practices.
design to realized. TECenter
determain if engineer.
additional data
is required.

Appropriate Appropriate Order 1 Process Failure 1 Individuals are 1 1 Continue Closed 1/25/00 0
individuals are individuals not Processing contacted to current
contacted to available. Delay resolve issues. practices.
resolve issues.

Design Review is Requirements Customer's full 1 Process Failure 1 Customer 1 1 Continue Closed 1/25/00 0
completed. may not be expectations requirements current
complete may not be verified by a pracices.
realized. TECenter
engineer.

Another Requirements Customer's full 7 Process Failure 3 Customer 3 63 Continue Closed 0

engineer overlooked by expectations requirements current 10/25/99
performs quality two Engineer may not be verified by a pracices.
check of the realized. TECenter
design. engineer.
Completed Design Order 1 Process Failure 1 Verification is 1 1 Continue Closed 1/25/00 0
design verification Processing sent to current
verification is misrouted Delay appropriate pracices.
sent to organization.
appropriate
organization.
Requirements Requirements Customer's full 1 Process Failure 1 Requirements 1 1 Continue Closed 1/25/00 0
are defined and may be missed expectations are defined and current
capability to or capibilty to may not be to meet pracices.
meet/ accept meet realized. requirements.
requirements. overestamated

4
Inside Sales Wrong price and Customer's full 3 Process Failure 1 Price provided to 1 3 Continue Closed 1/25/00 0
quotes price and availability expectations customer current
availability provided to may not be pracices.
customer realized.

Customer sends Order misrouted Order 1 Process Failure 1 Reprocess Order 1 1 Continue Closed 1/27/00 0
in purchase Processing current
order. Delay pracices.
Inside sales Data Entry Order 3 Human Error 1 Reprocess Order 1 3 Continue Closed 1/27/00 0
places order on Error Processing current
system. Delay pracices.

Order approved Approval not Order 1 Process Failure 1 Expidite Process 1 1 Continue Closed 1/27/00 0
by Asset timely Processing current
Management. Delay pracices.

Order approved Approval not Order 1 Process Failure 1 Expidite Process 1 1 Continue Closed 1/27/00 0
by credit. timely Processing current
Delay pracices.
Determaination All product (1) Product 5 Needed 3 Assure product 1 15 Continue Closed 0
made that required for the delivery date components are availability current 10/25/99
product is order may not requirements not available at before the order practices.
available for be available at may not be met. the time of need. commitment is
build. the start of the (2) Workspace given to
build. occupied for an customer.
order awaiting
Product is not
available for
integration of
other orders.

Inside sales Shipdates may Customer's full 1 Needed 1 Expidite Process 1 1 Continue Closed 1/27/00 0
expedites with not be accurate expectations components are current
Asset to provide may not be not available at practices.
ship date. realized. the time of need.

Order approved e-mail may be Order 1 Process Failure 1 Expidite Process 1 1 Continue Closed 1/27/00 0
by Asset Mgmt. misrouted Processing current
and e-mail sent Delay practices.
to Integration.

Project Manager Order Customer and 3 Processing 1 Project Manager 1 3 Continue Closed 0
reviews order for processing processing requirements order review. current 10/25/99
special or requirements needs not overlooked. practices.
internal may be identified could
instructions. overlooked prevent timely
processing of
the order.

5
Build document Documents do Order 5 Needed 3 Expidite Process 3 45 Continue Closed 1/27/00 0
bill of material not match Processing components are Integration current
matched with Delay not available at Center practices.
SCN. the time of need. Operations
Manual 093-
009-OPSMNL

Stock stock availability Customer's full 3 Needed 1 Expidite Process 1 3 Continue Closed 1/27/00 0
availability is and dates may expectations components are current
checked and be inaccurate may not be not available at practices.
delivery dates realized. the time of need.
are aquired for
non stock items.
Order is Order may be Order 1 Process Failure 1 Expidite Process 1 1 Continue Continue
forwarded to misrouted Processing current current
Production Delay practices. practices.
Engineer for
review.
Determanation Need for 1st Customer's full 7 Requirements 3 Individuals are 5 105 Continue Continue
made for a 1st build may be expectations Overlooked. contacted to current current
Article build. overlooked may not be resolve issues. practices. practices.
realized.
Build document Requirements Customer's full 3 Requirements 3 Individuals are 3 27 Continue Continue
is reviewed and may be expectations Overlooked. contacted to current current
verified. overlooked may not be resolve issues. practices. practices.
realized.
Project Sales may not Order 3 Requirements 1 Individuals are 1 3 Continue Continue
management receive order Processing Overlooked. contacted to current current
notifies sales status Delay resolve issues. practices. practices.
with status of
order.
Asset Items may not Order 3 Needed 1 Expidite Process 1 3 Continue Closed 1/27/00
management be ordered Processing components are current
places order for Delay not available at practices.
non stock items. the time of need.

Order is Order may not Order 3 Requirements 1 Individuals are 1 3 Continue Closed 1/27/00
scheduled for be entered in Processing Overlooked. contacted to current
production. schedule Delay resolve issues. practices.

Whse Operator Parts may not Order 3 Requirements 3 Individuals are 1 9 Continue Closed 1/27/00
reviews parts to match Processing Overlooked. contacted to current
SOA & SCN. requirement Delay resolve issues. practices.

Whse. Operator All parts may Order 3 All components 3 Individuals are 3 27 Continue Closed 1/27/00
Unpack,Iinspect not reach Processing are not available contacted to current
& Kit order. integration Delay at the time of resolve issues. practices.
need. Integration
Kitting and
Packing 153-
001-01

6
Techs. Check Parts may not Order 5 All components 3 Individuals are 1 15 Continue Closed 1/27/00
product against match Processing are not available contacted to current
SOW and build requirement Delay at the time of resolve issues. practices.
instructions. need.

Integration Materials may Order 7 All components 3 QA Inspection 3 63 Continue Closed 1/27/00
Techs. inspect not be compliant Processing are not available and Test current
parts and Delay at the time of Procedure 103- practices.
chassis. need. 001-03

No NT Resource Loss of business 1 Requirements 1 QA Inspection 5 5 Update Build Closed 8/21/00

Kit with the Overlooked. and Test Procedures to
Missing Video customer. Procedure 103- clearly define
Board 001-03 product
requirements
specific to the
model being
integrated.

Techs. Integrate System may be Order 7 Individuals are 7 QA Inspection 3 147 Continue Closed 1/27/00
& Power-Up integrated Processing contacted to and Test current
System incorrectly Delay resolve issues. Procedure 103- practices.
001-03

Integration System and Order 10 Needed 10 QA Inspection 1 100 Continue Closed 1/27/00
Techs. Test parts may not Processing components are and Test current
system. be compliant Delay not available at Procedure 103- practices.
the time of need. 001-03

Quality techs. Specific build On time delivery 5 Requirements 1 Individuals are 5 25 Continue
inspect product requirements and integraty of Overlooked. contacted to current
for build may not be fully the product may resolve issues. practices.
requirements. addressed. be compramised
if this issue is
not addressed.

7
 IO panel not Loss of business 1 Human Error 5 Build Procedure 5 25 Update Build Closed 8/21/00
installed with the for individual Procedures to
Label on CPU customer. PathSpeed clearly define
Incorrect Model product
No feet or other requirements
components specific to the
installed model being
No extension integrated.
cables
Missing cables
IO panel gasket
not installed
Wrong ICD
cards provided
Dome calibrater
included

Product serial Numbers may Order 3 Requirements 3 Individuals are 1 9 Continue Closed 1/27/00
numbers be incorrect Processing Overlooked. contacted to current
scanned into Delay resolve issues. practices.
Genesis.
Change made Control of Order 1 Requirements 1 Individuals are 1 1 Continue Closed 1/27/00
after batch requirements Processing Overlooked. contacted to current
release may be lost Delay resolve issues. practices.

Order placed on Shiping Order 3 Requirements 3 Individuals are 1 9 Continue Closed 1/27/00
hold when deadlines may Processing Overlooked. contacted to current
change is made. not be met Delay resolve issues. practices.

Design Process Control of Order 3 Process Failure 1 Individuals are 1 3 Continue Closed 1/27/00
reinitiates requirements Processing contacted to current
may not be Delay resolve issues. practices.
complete
Whse. invoices Wrong Shipping On time delivery 7 Process Failure 1 Individuals are 1 7 Continue Closed 1/27/00
and ships order method may be and integraty of contacted to current
per customer's used the product may resolve issues. practices.
shipping be compramised
method. if this issue is
not addressed.

Quality techs. Specific On time delivery 10 Requirements 3 Customer 3 90 Continue Closed 1/25/00
inspect packing, and integraty of Overlooked. Inspection current
shipment for labeling and the product may Instruction/ pracices.
CII/SHC shipping be compramised Special
requirements. requirements if this issue is Handling Codes
may not be fully not addressed. Process 033-
addressed. 001-02

8
 Label on outside Loss of business 1 Human Error 3 CII 033-001-006 3 9 Revisit contents 9/11/2000
of box did not with the of GE CII 033-
match S/N on customer. 001-006 to
CPU. assure all
requirements
are clearly
commumicated
to the
warehouse
operators and
quality
technicians
using these
documents.
Product ships to Products On time delivery 7 Needed 3 Individuals are 7 147 Continue Closed 1/27/00
customer. misshipped and integraty of components are contacted to current
the product may not available at resolve issues. practices.
be compramised the time of need.
if this issue is
not addressed.

Coordinator Documents not Documents may 3 Documents may 1 Individuals are 1 3 Continue Closed 1/25/00
closes project & filed correctly not be not be contacted to current
files quality retrievable retrievable resolve issues. pracices.
records.

9
 Severity

Effect SEVERITY of Effect Ranking

Hazardous without Very high severity ranking when a potential failure mode 10
warning affects safe system operation without warning
Hazardous with Very high severity ranking when a potential failure mode 9
warning affects safe system operation with warning
Very High System inoperable with destructive failure without 8
compromising safety
High System inoperable with equipment damage 7

Moderate System inoperable with minor damage 6

Low System inoperable without damage 5

Very Low System operable with significant degradation of performance 4

Minor System operable with some degradation of performance 3

Very Minor System operable with minimal interference 2

None No effect 1

Page 10
 Probability

PROBABILITY of Failure Failure Prob Ranking

Very High: Failure is almost inevitable >1 in 2 10
1 in 3 9
High: Repeated failures 1 in 8 8
1 in 20 7
Moderate: Occasional failures 1 in 80 6
1 in 400 5
1 in 2,000 4
Low: Relatively few failures 1 in 15,000 3
1 in 150,000 2
Remote: Failure is unlikely <1 in 1,500,000 1

Page 11
 Detectability

Detection Likelihood of DETECTION by Design Control Ranking

Absolute Design control cannot detect potential cause/mechanism and 10
Uncertainty subsequent failure mode
Very Remote Very remote chance the design control will detect potential 9
cause/mechanism and subsequent failure mode
Remote Remote chance the design control will detect potential 8
cause/mechanism and subsequent failure mode
Very Low Very low chance the design control will detect potential 7
cause/mechanism and subsequent failure mode
Low Low chance the design control will detect potential 6
cause/mechanism and subsequent failure mode
Moderate Moderate chance the design control will detect potential 5
cause/mechanism and subsequent failure mode
Moderately High Moderately High chance the design control will detect 4
potential cause/mechanism and subsequent failure mode
High High chance the design control will detect potential 3
cause/mechanism and subsequent failure mode
Very High Very high chance the design control will detect potential 2
cause/mechanism and subsequent failure mode
Almost Certain Design control will detect potential cause/mechanism and 1
subsequent failure mode

Page 12
 EXAMPLE

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b

Seals 0 0
Coolant 0 0
containment.
Hose
connection.
Coolant fill. M
Sensor mount. Compression set Leak 8 Gasket material 7 Pressure cycle 1 56 Use imported 0
Seal w/cold shock. material
Sensor mount. Loosen during Leak. Fall inside 8 Fitting not held 2 Added rib. 1 16 Implement J.P. Aguire 0
Seal sensor tank in place holding rib in 11/1/95
assembly/servic design. New
e fitting design.
Prototype
validation.
Sensor mount. Damaged Cannot install 5 Damaged during 2 1 10 0
Seal internal thread sensor installation or
transportation
Sensor mount. Damaged Cannot install 4 Damaged during 3 1 12 Damaged fitting 0
Seal external thread wire nut shipment to not used by
piracicaba Piracicaba
Coolant containment. Crack/break. Burst. Leak 8 Over pressure 8 Burst, validation 1 64 Test included in J.P. Aguire 11/1/95 0
Hose connection. Side wall flex. Bad pressure cycle. prototype and E. Eglin 8/1/96
Coolant fill. M seal. Poor hose rete production validation
testing.
Coolant containment. Crack/break. Burst. Failed mount 5 Vibration 9 Vibration w/road 3 135 Obtain GMB J.P. Aguire 0
Hose connection. Side wall flex. Bad tapes vibration road tape.
Coolant fill. M seal. Poor hose rete
Coolant containment. Crack/break. Burst. Hose leak 6 Overpressure. Poor 5 Burst, validation 2 60 Obtain GMB clamps J.P. Aguire 12/1/95 0
Hose connection. Side wall flex. Bad clamp pressure cycle and clamping
Coolant fill. M seal. Poor hose rete w/GMB clamps. specification.
Hold fluid, flow path, Stress crack Air conditioning does This is a test of the 0 Operator instruction 0
Heat transfer not work. Sudden ADD POTENTIAL
structure refrigerant loss. CAUSE/MECHANIS
M OF FAILURE
system functionality
Hold fluid, flow path, Stress crack Air conditioning does This is a test of the 0 This is a test of the 0
Heat transfer not work. Sudden ADD POTENTIAL ADD
structure refrigerant loss. CAUSE/MECHANIS RECOMMENDED
M OF FAILURE ACTION system
system functionality functionality
Hold fluid, flow path, Stress crack Leak. Loss of heat 8 Wicking. Material 7 Thermal cycle 1 56 Included in Product E. Eglin 8/1/96 0
Heat transfer transfer. strength Specification

Page 13
 EXAMPLE

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b

Hold fluid, flow path, Corrosion Air conditioning does this is a test while 0 0
Heat transfer not work. Sudden dan is here
structure refrigerant loss.
Hold fluid, flow path, Corrosion Leak. Loss of heat 8 Coolant quality. 7 SWAT, service 5 280 Brazilian coolant to J.P. Aguirre 11/1/95 Coolant ordered 0
Heat transfer transfer. Contamination. simulation. Coolant be evaluated. Zince
structure Environment - int/ext. evaluation. lined tubes may
need to be released.
Simulated service
test w/GMB coolant
Hold fluid, flow path, Puncture Leak. Loss of heat 8 External damage. 10 Leak test. Simulated 1 80 to be performed.
100% cores tested in E. Eglin 8/1/96 0
Heat transfer transfer. Coolant velocity. No service. production.
structure reinf sawcut. Simulated service
included in Product
Hold fluid, flow path, Seam fail Leak. Loss of heat 5 Environment - int/ext. 1 SWAT, service 1 5 Included in Product E. Eglin 8/1/96 0
Heat transfer transfer. simulation. Specification.
Hold fluid, flow path, Burst fail Leak. Loss of heat 8 Over pressure 2 Burst/leak pressure 5 80 GMB to study engine GMB 12/1/95 Study originated 0
Heat transfer transfer. contamination. cleanliness.
Hold fluid, flow path, Plugged Loss of heat transfer. 8 Contamination. 7 1 56 GMB coolant to be J.P. Aguirre 11/1/95 Coolant ordered 0
Heat transfer Leakage due to Coolant quality. evaluated. GMB to
structure increase flow velocity study engine
cleanliness.
Hold fluid, flow path, Ballooning Leak. Loss of heat 5 Over pressure 9 8 360 GMB to study engine GMB 12/1/95 0
Heat transfer transfer. contamination. cleanliness.
structure Clustomer profile to
be determined.
0 0
0 0
0 0

Page 14