FMEA Form v3.

FMEA

Process/Product Name: Prepared By:

Responsible: FMEA Date (Orig.): (Rev.):

OCCURRENCE (1 - 10)

OCCURRENCE (1 - 10)
Process Step/Input Potential Failure Mode Potential Failure Effects Potential Causes Current Controls Action Recommended Resp. Actions Taken

DETECTION (1 - 10)

DETECTION (1 - 10)
SEVERITY (1 - 10)

SEVERITY (1 - 10)
RPN

RPN
What are the recommended actions for Who is responsible for What actions were
What is the impact on the customer if this What causes the step, change or feature to What controls exist that either prevent
What is the process step, change or feature under investigation? In what ways could the step, change or feature go wrong? reducing the occurrence of the cause or making sure the actions completed (and when) with
failure is not prevented or corrected? go wrong? (how could it occur?) or detect the failure?
improving detection? are completed? respect to the RPN?

Instruirea angajatilor Neintelegerea cursurilor de catre operatori Aparitia rebuturilor Utilizarea unor termeni tehnici Test grila Imbunatatirea cursurilor Seful de echipa S-a modificat cursul
6 specifici, necuscuti operatorilor 6 4 144 de instruire 6 2 4 48
Utilizarea filamentelor cu role de carton Ruperea rolei de carton Oprirea productiei Deformarea din cauza folosirii Inspectie vizuala Utilizarea unor suporti pentru Seful de echipa S-a schimbat
indelungate filament mai buni suportul filamentului
6 6 3 108 pentru a preveni 6 3 3 54
deformarea rolelor
Blocarea filamentului Oprirea productiei Incalcirea filamentului Inspectie vizuala Manevrarea cu atentie a rolelor Seful de echipa S-a schimbat modul
6 6 3 108 de instalare al rolelor 6 2 3 36
Folosirea aceluias tip de plastic pentru toti suportii Delaminarea piesei de suport Aparitia rebuturilor Coeficenti de racire diferiti Inspectie vizuala Printarea in incapari cu temperatura Seful de echipa S-au achizitionat
6 5 3 90 controlata huse 6 2 3 36
6 Compozitia chimica diferita 5 Inspectie vizuala 3 90 0
Diferenta de umiditate dintre role Inspectie vizuala Depozitarea rolelor in medii cu Seful de echipa S-au achizitionat
6 5 3 90 umiditate controlata containere cu 6 2 3 36
dezumificatoare
Folosirea de imprimante noi Printarea neconforma Aparitia rebuturilor Necalibrarea motoarelor Inspectie vizuala Calibrarea motoarelor Seful de echipa S-au calibrat
7 10 5 350 motoarele 7 2 5 70
Folosirea setarilor gresite Inspectie vizuala Instruirea angajatilor Seful de echipa S-au pus parametri
7 7 5 245 optimi pe fiecare rola 7 3 5 105

Calibrarea gresita a patului de Inspectie vizuala Calibrarea patului Seful de echipa S-a calibrat patul
7 printare 7 3 147 7 3 3 63
Blocarea duzei Infundarea duzei Folosirea plasticului gresit Inspectie vizuala Folosirea plasticului adecvat Seful de echipa S-au inlocuit rolele de
plastic cu unele
6 10 2 120 adecvate imprimantei 6 3 2 36

Implementarea in productie a noilor filamente Printarea neconforma Aparitia rebuturilor Setari neconforme noului plastic Inspectie vizuala Gasirea unor setari compatibile cu Seful de echipa S-au gasit setarile
7 7 4 196 noul plastic conforme 7 3 4 84
Spatiu de depozitare insuficient Imposibilitatea printarii simultan a 6 Spatiu limitat 10 Inspectie vizuala 2 120 Marirea satiului util Seful de echipa S-a reorganizat
unei mari varietati de produse spatiul disponibil 6 3 2 36

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 FMEA Form v3.7

FMEA

Process/Product Name: Coffee Process Prepared By: Tracy

Responsible: Servers FMEA Date (Orig.): May 15th (Rev.): May 30th

Potential
Process Potential Potential Current Action
Failure Resp. Actions Taken

OCCURRENCE (1 - 10)
Step/Input Failure Mode Causes Controls Recommended

DETECTION (1 - 10)
Effects

SEVERITY (1 - 10)

SEVERITY (1 - 10)
What are the

RPN
What is the Who is
What controls recommended
What is the In what ways impact on the What causes the responsible
exist that either actions for reducing What actions were completed
process step or could the step or customer if this step or feature to go for making
prevent or the occurrence of (and when) with respect to
feature under feature go failure is not wrong? (how could sure the
detect the the cause or the RPN?
investigation? wrong? prevented or it occur?) actions are
failure? improving
corrected? completed?
detection?

Fill carafe Wrong Coffee too Faded level Visual Replace old Mel Carafe replaced 9/15
with water amount of strong or 8 marks on carafe 4 Inspection 4 128 carafes 8
water weak
Water spilled None Train Flo Trained on 9/20
8 from carafe 5 9 360 employees 8

Water too Coffee too Faucet not Finger Train Flo Trained on 9/20
warm strong 8 allowed to run 8 4 256 employees 8
cool

Employee None Train Flo Trained on 9/20

unaware of employees
8 7 7 392 8
need for cool
water
Unclean Foreign Carafe not Visual Appoint Alice Vera appointed 9/21
carafe objects in 10 washed 4 Inspection 4 160 inspector 10
coffee before storage
Bad tasting Carafe stored Training Create storage Alice Bin & visual instructions
coffee 10 improperly 7 5 350 & instructions done 9/25 10

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 FMEA Form v3.7

FMEA

OCCURRENCE (1 - 10)

DETECTION (1 - 10)

RPN
1 3 24

2 7 112

2 6 96

1 8 64

1 4 40

2 3 60

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 FMEA Form v3.7

FMEA

Process/Product Name: Food Order Delivery Prepared By: Team Lead

Responsible: Manager FMEA Date (Orig.): May 1st (Rev.): May 5th

Potential
Process Potential Potential Current Action Actions
Failure Resp.

OCCURRENCE (1 - 10)

OCCURRENCE (1 - 10)
Step/Input Failure Mode Causes Controls Recommended Taken

DETECTION (1 - 10)

DETECTION (1 - 10)
Effects

SEVERITY (1 - 10)

SEVERITY (1 - 10)
What are the

RPN
What is the Who is
What causes What controls recommended What actions
What is the In what ways impact on the responsible
the step or exist that either actions for reducing were completed
process step or could the step or customer if this for making
feature to go prevent or the occurrence of (and when) with
feature under feature go failure is not sure the
wrong? (how detect the the cause or respect to the
investigation? wrong? prevented or actions are
could it occur?) failure? improving RPN?
corrected? completed?
detection?

Changing Run out of Unable to Supply chain Won't know Give vendor a Manager Directions
Vendors key food offer issues until delivery 30-day trial created,
products standard copied and
menu items 8 8 10 640 distributed 8 6 10
on May 5th

Delivering to Won't know Have vendor Manager Instituted on

8 others first 8 until delivery 10 640 call to confirm May 5th 8 4 10
quantities
Impose Manager Instituted on
8 8 10 640 penalties for May 6 8 4 10
missed items
Products Customers The vendor Won't know Conduct taste Chef Setup testing
may differ reject the has found until tests on any trials on May
from what's new cheaper customers new brands of 5th
currently products 10 sources 9 taste new 10 900 products - 10 4 10
served product reject as
needed

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 FMEA Form v3.7

Vendor Won't know Have vendor Manager Contact

delivers best until replace any vendor as
10 food to long- 7 customers 10 700 products that needed on 8 4 10
term taste new don't meet May 6
customers product requirements

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 FMEA Form v3.7

FMEA

RPN
480

320

320

400

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 FMEA Form v3.7

320

Copyright 2020 GoLeanSixSigma.com. All Rights Reserved.

 FMEA Form v3.7

FMEA

Process/Product Name: Establishing Stocking Levels Prepared By: Team

Responsible: Wesley FMEA Date (Orig.): 25-May (Rev.):

Potential
Process Potential Potential Current Action Actions
Failure Resp.

OCCURRENCE (1 - 10)

OCCURRENCE (1 - 10)
Step/Input Failure Mode Causes Controls Recommended Taken

DETECTION (1 - 10)

DETECTION (1 - 10)
Effects
SEVERITY (1 - 10)

SEVERITY (1 - 10)
What are the

RPN
What is the Who is What are the
What causes What controls recommended
What is the In what ways impact on the responsible completed
the step or exist that either actions for reducing
process step or could the step or customer if this for making action taken
feature to go prevent or the occurrence of
feature under feature go failure is not sure the with the
wrong? (how detect the the cause or
investigation? wrong? prevented or actions are recalculated
could it occur?) failure? improving
corrected? completed? RPN?
detection?

Chef to put Chef gets Delay of all 10 It takes too 10 White Board 4 400 Cross-Train all Scott 27-May 10 7 1
food into backed up food orders much time to showing kitchen staff to
containers with orders package food order handle pick-up
orders timing packaging

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 FMEA Form v3.7

FMEA

RPN
70

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 Severity Scale
Adapt as appropriate

Effect Criteria: Severity of Effect Ranking

Hazardous - May expose client to loss, harm or major disruption -

10
Without Warning failure will occur without warning

Hazardous - May expose client to loss, harm or major disruption -

9
With Warning failure will occur with warning

Major disruption of service involving client interaction, resulting in either

Very High 8
associate re-work or inconvenience to client

Minor disruption of service involving client interaction and resulting in either

High 7
associate re-work or inconvenience to clients

Major disruption of service not involving client interaction and resulting in either
Moderate 6
associate re-work or inconvenience to clients

Minor disruption of service not involving client interaction and resulting in either
Low 5
associate re-work or inconvenience to clients

Minor disruption of service involving client interaction that does not result in
Very Low 4
either associate re-work or inconvenience to clients

Minor disruption of service not involving client interaction and does not result in
Minor 3
either associate re-work or inconvenience to clients

No disruption of service noticed by the client in any capacity and does not result
Very Minor 2
in either associate re-work or inconvenience to clients

None No Effect 1
 Occurrence Scale

Per Item Failure

Probability of Failure Time Period Ranking
Rates

More than once per day >= 1 in 2 10

Very High: Failure is almost inevitable
Once every 3-4 days 1 in 3 9

Once every week 1 in 8 8

High: Generally associated with processes similar to
previous processes that have often failed
Once every month 1in 20 7

Once every 3 months 1 in 80 6

Moderate: Generally associated with processes
similar to previous processes which have
Once every 6 months 1 in 400 5
experienced occasional failures, but not in major
proportions
Once a year 1 in 800 4

Low: Isolated failures associated with similar

Once every 1 - 3 years 1 in 1,500 3
processes

Very Low: Only isolated failures associated with

Once every 3 - 6 years 1 in 3,000 2
almost identical processes

Remote: Failure is unlikely. No failures associated

Once Every 7+ Years 1 in 6000 1
with almost identical processes
 Detection Scale

Criteria: Likelihood the existence of a defect will be detected

Detection by process controls before next or subsequent process, -OR- Ranking
before exposure to a client

Almost Impossible No known controls available to detect failure mode 10

Very remote likelihood current controls will

Very Remote 9
detect failure mode

Remote likelihood current controls will

Remote 8
detect failure mode

Very low likelihood current controls will

Very Low 7
detect failure mode

Low Low likelihood current controls will detect failure mode 6

Moderate likelihood current controls will

Moderate 5
detect failure mode

Moderately high likelihood current controls will

Moderately High 4
detect failure mode

High High likelihood current controls will detect failure mode 3

Very high likelihood current controls will

Very High 2
detect failure mode

Current controls almost certain to detect the failure mode.

Almost Certain Reliable detection controls are known 1
with similar processes.