Failure Mode and Effects Analysis
Based on AIAG V4
SOD : Table
Process FMEA Severity Rating (AIAG – V04)
Rank Effect Severity of Effect on Product
10 Failure to meet Safety Affect safe vehicle operation and/or involves noncompliance with government regulation without warning.
and/or Regulatory
9 requirements Affect safe vehicle operation and/or involves noncompliance with government regulation with warning.
8 Loss of primary function (vehicle inoperable, does not affect safe vehicle operation).
Loss or degradation of
Primary function
7 Degradation of primary function (vehicle operable but at reduced level of performance).
6 Loss of secondary function (vehicle operabel, but comfort / convenience functions in operabel).
Loss or degradation of
Secondary function
5 Degradation of secondary function (vehicle operabel, but comfort / convenience functions at reduced level of performance).
4 Appearance or Audible Noise, vehicle operable, items does not conform and noticed by most customers (>75%)
3 Annoyance Appearance or Audible Noise, vehicle operable, items does not conform and noticed by many customers (50%)
2 Appearance or Audible Noise, vehicle operable, items does not conform and noticed by discriminating customers (<25%)
1 No effect No discernible effect.
Process FMEA Occurrence Rating (AIAG – V04)
Occurrence of Cause
Rank Likehood of Failure
(Incident per items/vehicles)
> 100 per thousand
10 Very High
> 1 in 10
50 per thousand
9
1 in 20
20 per thousand
8 High
1 in 50
10 per thousand
7
1 in 100
2 per thousand
6
1 in 500
0.5 per thousand
5 Moderate
1 in 2000
0.1 per thousand
4
1 in 10000
0.01 per thousand
3
1 in 100000
Low
< 0.001 per thousand
2
1 in 100000
1 Very Low Failure is eliminated through preventive control
Process FMEA Detection Rating (AIAG – V04)
Rank Likehood of Failure Likelihood of Detection by process control
No detection opportunity
10 No current process control; Cannot detect or is not analyzed.
(Almost impossible)
Not likely to detect at any stage
9 Failure mode and/or error (Cause) is not easily detected (e.g. random audits)
(Very remote)
Problem detection post processing
8 Failure mode detection post - processing by operator through visual/ audible means.
(Remote)
Problem detection at source Failure mode detection in-station by operator through visual / audible means or post processing through use of
7
(Very low) attribute gauging.
Problem detection post processing Failure mode detection post-processing by operator through use of variable gauging or in-station by operator
6
(Low) through use of attribute gauging.
Problem detection at source Error detection in-station by operator thorugh use of variable gauging or by automated controls in-station that
5
(Moderate) will detect discrepant part and notify operator (light, buzzer etc)
Problem detection post processing Failure mode detection post-processing by automated controls that will detect discrepant part and lock part to
4
(Moderately high) prevent further processing.
Problem detection at source Failure mode detection in-station by automated controls that will detect discrepant part and lock part to
3
(High) prevent further processing.
Error detection and/or problem prevention Error detection in-station by automated controls that will detect error and prevent discrepant part from being
2
(Very high) made.
Detection not applicable; Error prevention Error prevention as a result of fixture design, machine design or part design. Discrepant parts can not be
1
(Almost certain) process/product design.
