Example of Design FMEA Worksheet

Action Results
O
Potential Design

New RPN
New Occ
New Sev

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

0 0
Radiator endplate External Leaks Water loss 8 Insufficient O- 4 Incorrect seal Calculations and 6 192 Statistical Des Engr & BB Seal 8 3 4 96
static O-rings: leading to engine Ring seal and sealing design review. tolerance analysis, Compression
Contains water over temp compression. surfaces accelerated life Statistical
flow leading to engine geometry and/or test and field test. Analysis and
derate and/or tolerances Accel cycling
shutdown leading specified. Test.
to locomotive
Identify each feature shutdown
(item) and its function. Response Plans and Tracking. Beginning with
Identify the most critical RPN's and severities (CTQ's), define
current design 0 recommended actions, responsibilities and target 0
Identify each failure mode. dates. As a result of the completed actions taken,
controls. 0 0
re-rate severity, occurrence and detection based on
0 0
any changes to the end effect, likelihood of
Identify each potential 0 occurrrence, and the likelihood of the actions taken + 0
consequence(s) (local, next and Identify the potential design 0 design controls to detect the failure mechanism. 0
end) of that failure. cause(s) of the failure 0 0
mechanism(s).
0 0
Severity - On a scale of 1-10, rate 0 0
Risk Priority Number - The combined weighting of Severity,
the Severity of the end effect. See 0
Occurrence, and Detection. RPN = Sev X Occ X Det 0
Occurrence - On a scale of 1-10, rate
Severity sheet for full definition. 0 0
the likelihood of Occurrence of the
0 0
failure mechanism and subsequent Detection - On a scale of 1-10, rate the Detection. (The likelihood that
failure mode. See Occurrence sheet for 0 0
Identify the potential failure the current design controls will detect the design cause and failure
mechanism(s). full definition. 0
mechanism). See Detection sheet for full definition. 0
0 0
System FMEA Number
Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Revision Date
Core Team

Action Results

New RPN
New Occ
New Sev

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

0 0
0 0
0 0
0 0

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Effect Severity of Effect Ranking
Hazardous without Potential failure mode affects safe system operation 10
warning and/or involves noncompliance with government safety
regulation without warning. Severity
Hazardous with Potential failure mode affects safe system operation 9 Severity is an assessment of the
warning and/or involves noncompliance with government safety seriousness of the effects (next, local and
end) as felt by the customer.
regulation with warning.
Very High System/item inoperable with loss of primary function, but 8 (The 2nd severity ranking may be less than
safe. (Such as a locomotive mission failure) the first as a result of completing all
recommended actions.)

High System/item operable but at reduced performance level. 7

Customer dissatisfied.
Moderate System/item operable, but comfort/convenience item 6
inoperable.
Low System/item operable, but comfort/convenience item 5
compromised.
Very Low Defect noticed by most customers. 4
Minor Defect noticed by average customer. 3
Very Minor Defect noticed by discriminating customer. 2
None No effect 1
 Equiv. Failures per
Occurrence: Failure Rates* unit per year
Probability of Failure (within 1 year of service) (Similar to F/LY) Ranking

Very High: Failure is almost inevitable > 1 in 2 0.5 10

1 in 3 0.333 9
High: Repeated failures 1 in 8 0.125 8
1 in 20 0.05 7
Moderate: Occasional failures 1 in 80 0.0125 6
1 in 400 0.0025 5
1 in 2,000 0.0005 4
Low: Relatively few failures 1 in 15,000 6.66666666667E-05 3
1 in 150,000 6.66666666667E-06 2
Remote: Failure is unlikely < 1 in 1,500,000 6.66666666667E-07 1

Occurrence is the likelihood that the failure mechanism and

subsequent failure mode will occur (based on historical data
on similar designs, past experience or best engineering

Occurrence knowledge).

(The 2nd occurrence ranking may be less than the first

as a result of completing all recommended actions.)
 Likelihood of
Detection Likelihood of Detection by Design Control Detection
Ranking
Absolute Design control will not or cannot detect potential design cause < 1% 10
Uncertainty and subsequent failure mechanism, or there is no design
control.
Very Remote Very remote chance the design control will detect potential 1% - 5% 9
design cause and subsequent mechanism mode. Detection
Remote Remote chance the design control will detect potential design 5% - 15% 8
cause and subsequent failure mechanism. Detection is the likelihood that the
design control will detect the
Very Low Very low chance the design control will detect potential design 15% - 30% 7 failure/design cause, and
cause and subsequent failure mechanism. subsequent failure mechanism.

Low Low chance the design control will detect potential design 30% - 50% 6 The 2nd Detection ranking may be
cause and subsequent failure mechanism. less than the first as it considers both
the design control AND the
Moderate Moderate chance the design control will detect potential design 50% - 75% 5 completed recommended action's
cause and subsequent failure mechanism. likelihood of detecting the
failure/design cause and subsequent
Moderately Moderately high chance the design control will detect potential 75% - 85% 4 failure mechanism.
High design cause and subsequent failure mechanism.
High High chance the design control will detect potential design 85% - 93% 3
cause and subsequent failure mechanism.
Very High Very high chance the design control will detect potential design 93% - 99% 2
cause and subsequent failure mechanism.

Almost Design control will detect potential design cause and >99 % 1
Certain subsequent failure mechanism.