IntroductionWelcome to the FMEA WorksheetThis spreadsheet can be used to1.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 cellsFMEA - the actual sheet used to enter dataSeverity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categoriesExample - a partial exmample of an FMEA documentSheet Protection:Some sheets are protected. There is no password.Released for review:31-Jul-98A. Dembskirev 1

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DescriptionsDescription of FMEA WorksheetProtection:The spreadsheets are not protected or locked.SystemPotentialFMEA NumberSubsystemFailure Mode and Effects AnalysisPrepared ByComponent(Design FMEA)FMEA DateDesign LeadKey DateRevision DateCore TeamPageofAction ResultsItem / FunctionPotential Failure Mode(s)Potential Effect(s) of FailureSevPotential Cause(s)/ Mechanism(s) of FailureProbCurrent Design ControlsDetRPNRecommended Action(s)Responsibility & Target Completion DateActions TakenNew SevNew OccNew DetNew RPN00Coolant containment. Hose connection. Coolant fill. MCrack/break. Burst. Side wall flex. Bad seal. Poor hose reteLeak8Over pressure8Burst, validation pressure cycle.164Test included in prototype and production validation testing.J.P. Aguire 11/1/95 E. Eglin 8/1/9600000000000000000000000000000

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

FMEASystemDesign Verification ProcessPotentialFMEA NumberProject IIISubsystemFailure Mode and Effects AnalysisPrepared ByHouston MayerComponent(Design FMEA)FMEA Date10/22/99Design LeadHouston MayerKey DateRevision Date8/21/00Core TeamSee Project III R1 ReportPage1of6Action ResultsItem / FunctionPotential Failure Mode(s)Potential Effect(s) of FailureSevPotential Cause(s)/ Mechanism(s) of FailureProbCurrent Design ControlsDetRPNRecommended Action(s)Responsibility & Target Completion DateActions TakenNew SevNew OccNew DetNew RPNCustomer sends in a quote request for product.System, Software, Integration and Shipping requirements overlooked by customer.Customer needs not fully met by delivered system.7Human error1Design configuration tool.321Use configuration tool when available.Closed 10/21/990Requirement entered and verified by Inside Sales in config. tool.Data entry errorSystem compatability requirements not evaluated by config. tool.3Human error1Order verified by a configuration tool.39Continue order verification by configuration tool.Closed 10/21/990Sales identifies need for CII or SHCSpecific packing, labeling and shipping requirements may not be fully addressed.On time delivery and integraty of the product may be compramised if this issue is not addressed.7Requirements Overlooked.3Customer Inspection Instruction/ Special Handling Codes Process 033-001-02363Publish comprehensive procedure for the 1st Article Process.Jun-00Customer shipping requirements reviewed by quality assurance in 1st Article process.0Position of the DHR in ICD label packet not identified by GE.Requirment in Purchase Specification for mousepad, but not identified on Bill of Material.ICD Card content requirements not identified in Build Procedure.Loss of business with the customer.1Requirements Overlooked.5CII 033-001-00615Revisit contents of GE CII 033-001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.Sep-00OPEN 8/21/00QA and Pack and Ship Team reviews customer requirements during a 1st Article.Specific packing, labeling and shipping requirements may not be fully addressed.Customer's full expectations may not be realized.7Requirements overlooked.3Customer requirements physically verified by quality assurance during the 1st Article process.363Continue current pracices.Closed 10/25/990Inside sales submits Sales Order Authorization request to TECenter.Data entry errorOrder Processing Delay1Human Error1Customer requirements verified by a TECenter engineer.33Continue current practices.Closed 1/25/000TECenter Engineer reviews the design to determain if additional data is required.Requirements overlooked by EngineerCustomer's full expectations may not be realized.3Requirements Overlooked.6Customer requirements verified by a TECenter engineer.354Continue current practices.Closed 10/25/990Appropriate individuals are contacted to resolve issues.Appropriate individuals not available.Order Processing Delay1Process Failure1Individuals are contacted to resolve issues.11Continue current practices.Closed 1/25/000Design Review is completed.Requirements may not be completeCustomer's full expectations may not be realized.1Process Failure1Customer requirements verified by a TECenter engineer.11Continue current pracices.Closed 1/25/000Another engineer performs quality check of the design.Requirements overlooked by two EngineerCustomer's full expectations may not be realized.7Process Failure3Customer requirements verified by a TECenter engineer.363Continue current pracices.Closed 10/25/990Completed design verification is sent to appropriate organization.Design verification misroutedOrder Processing Delay1Process Failure1Verification is sent to appropriate organization.11Continue current pracices.Closed 1/25/000Requirements are defined and capability to meet/ accept requirements.Requirements may be missed or capibilty to meet overestamatedCustomer's full expectations may not be realized.1Process Failure1Requirements are defined and to meet requirements.11Continue current pracices.Closed 1/25/000Inside Sales quotes price and availabilityWrong price and availability provided to customerCustomer's full expectations may not be realized.3Process Failure1Price provided to customer13Continue current pracices.Closed 1/25/000Customer sends in purchase order.Order misroutedOrder Processing Delay1Process Failure1Reprocess Order11Continue current pracices.Closed 1/27/000Inside sales places order on system.Data Entry ErrorOrder Processing Delay3Human Error1Reprocess Order13Continue current pracices.Closed 1/27/000Order approved by Asset Management.Approval not timelyOrder Processing Delay1Process Failure1Expidite Process11Continue current pracices.Closed 1/27/000Order approved by credit.Approval not timelyOrder Processing Delay1Process Failure1Expidite Process11Continue current pracices.Closed 1/27/000Determaination made that product is available for build.All product required for the order may not be available at the start of the build.(1) Product delivery date requirements may not be met. (2) Workspace occupied for an order awaiting Product is not available for integration of other orders.5Needed components are not available at the time of need.3Assure product availability before the order commitment is given to customer.115Continue current practices.Closed 10/25/990Inside sales expedites with Asset to provide ship date.Shipdates may not be accurateCustomer's full expectations may not be realized.1Needed components are not available at the time of need.1Expidite Process11Continue current practices.Closed 1/27/000Order approved by Asset Mgmt. and e-mail sent to Integration.e-mail may be misroutedOrder Processing Delay1Process Failure1Expidite Process11Continue current practices.Closed 1/27/000Project Manager reviews order for special or internal instructions.Order processing requirements may be overlookedCustomer and processing needs not identified could prevent timely processing of the order.3Processing requirements overlooked.1Project Manager order review.13Continue current practices.Closed 10/25/990Build document bill of material matched with SCN.Documents do not matchOrder Processing Delay5Needed components are not available at the time of need.3Expidite ProcessIntegration Center Operations Manual 093-009-OPSMNL345Continue current practices.Closed 1/27/000Stock availability is checked and delivery dates are aquired for non stock items.stock availability and dates may be inaccurateCustomer's full expectations may not be realized.3Needed components are not available at the time of need.1Expidite Process13Continue current practices.Closed 1/27/000Order is forwarded to Production Engineer for review.Order may be misroutedOrder Processing Delay1Process Failure1Expidite Process11Continue current practices.Continue current practices.Determanation made for a 1st Article build.Need for 1st build may be overlookedCustomer's full expectations may not be realized.7Requirements Overlooked.3Individuals are contacted to resolve issues.5105Continue current practices.Continue current practices.Build document is reviewed and verified.Requirements may be overlookedCustomer's full expectations may not be realized.3Requirements Overlooked.3Individuals are contacted to resolve issues.327Continue current practices.Continue current practices.Project management notifies sales with status of order.Sales may not receive order statusOrder Processing Delay3Requirements Overlooked.1Individuals are contacted to resolve issues.13Continue current practices.Continue current practices.Asset management places order for non stock items.Items may not be orderedOrder Processing Delay3Needed components are not available at the time of need.1Expidite Process13Continue current practices.Closed 1/27/00Order is scheduled for production.Order may not be entered in scheduleOrder Processing Delay3Requirements Overlooked.1Individuals are contacted to resolve issues.13Continue current practices.Closed 1/27/00Whse Operator reviews parts to SOA & SCN.Parts may not match requirementOrder Processing Delay3Requirements Overlooked.3Individuals are contacted to resolve issues.19Continue current practices.Closed 1/27/00Whse. Operator Unpack,Iinspect & Kit order.All parts may not reach integrationOrder Processing Delay3All components are not available at the time of need.3Individuals are contacted to resolve issues.Integration Kitting and Packing 153-001-01327Continue current practices.Closed 1/27/00Techs. Check product against SOW and build instructions.Parts may not match requirementOrder Processing Delay5All components are not available at the time of need.3Individuals are contacted to resolve issues.115Continue current practices.Closed 1/27/00Integration Techs. inspect parts and chassis.Materials may not be compliantOrder Processing Delay7All components are not available at the time of need.3QA Inspection and Test Procedure 103-001-03363Continue current practices.Closed 1/27/00No NT Resource KitMissing Video BoardLoss of business with the customer.1Requirements Overlooked.1QA Inspection and Test Procedure 103-001-0355Update Build Procedures to clearly define product requirements specific to the model being integrated.Closed 8/21/00Techs. Integrate & Power-Up SystemSystem may be integrated incorrectlyOrder Processing Delay7Individuals are contacted to resolve issues.7QA Inspection and Test Procedure 103-001-033147Continue current practices.Closed 1/27/00Integration Techs. Test system.System and parts may not be compliantOrder Processing Delay10Needed components are not available at the time of need.10QA Inspection and Test Procedure 103-001-031100Continue current practices.Closed 1/27/00Quality techs. inspect product for build requirements.Specific build requirements may not be fully addressed.On time delivery and integraty of the product may be compramised if this issue is not addressed.5Requirements Overlooked.1Individuals are contacted to resolve issues.525Continue current practices.IO panel not installedLabel on CPU IncorrectNo feet or other components installedNo extension cablesMissing cablesIO panel gasket not installedWrong ICD cards providedDome calibrater includedLoss of business with the customer.1Human Error5Build Procedure for individual PathSpeed Model525Update Build Procedures to clearly define product requirements specific to the model being integrated.Closed 8/21/00Product serial numbers scanned into Genesis.Numbers may be incorrectOrder Processing Delay3Requirements Overlooked.3Individuals are contacted to resolve issues.19Continue current practices.Closed 1/27/00Change made after batch releaseControl of requirements may be lostOrder Processing Delay1Requirements Overlooked.1Individuals are contacted to resolve issues.11Continue current practices.Closed 1/27/00Order placed on hold when change is made.Shiping deadlines may not be metOrder Processing Delay3Requirements Overlooked.3Individuals are contacted to resolve issues.19Continue current practices.Closed 1/27/00Design Process reinitiatesControl of requirements may not be completeOrder Processing Delay3Process Failure1Individuals are contacted to resolve issues.13Continue current practices.Closed 1/27/00Whse. invoices and ships order per customer's shipping method.Wrong Shipping method may be usedOn time delivery and integraty of the product may be compramised if this issue is not addressed.7Process Failure1Individuals are contacted to resolve issues.17Continue current practices.Closed 1/27/00Quality techs. inspect shipment for CII/SHC requirements.Specific packing, labeling and shipping requirements may not be fully addressed.On time delivery and integraty of the product may be compramised if this issue is not addressed.10Requirements Overlooked.3Customer Inspection Instruction/ Special Handling Codes Process 033-001-02390Continue current pracices.Closed 1/25/00Label on outside of box did not match S/N on CPU.Loss of business with the customer.1Human Error3CII 033-001-00639Revisit contents of GE CII 033-001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.9/11/00Product ships to customer.Products misshippedOn time delivery and integraty of the product may be compramised if this issue is not addressed.7Needed components are not available at the time of need.3Individuals are contacted to resolve issues.7147Continue current practices.Closed 1/27/00Coordinator closes project & files quality records.Documents not filed correctlyDocuments may not be retrievable3Documents may not be retrievable1Individuals are contacted to resolve issues.13Continue current pracices.Closed 1/25/0000000

&L&8Houston MayerSix Sigma BlackbeltAugust 21, 2000&C&8 &R&P

SeverityEffectSEVERITY of EffectRankingHazardous without warningVery high severity ranking when a potential failure mode affects safe system operation without warning10Hazardous with warningVery high severity ranking when a potential failure mode affects safe system operation with warning9Very HighSystem inoperable with destructive failure without compromising safety8HighSystem inoperable with equipment damage7ModerateSystem inoperable with minor damage6LowSystem inoperable without damage5Very LowSystem operable with significant degradation of performance4MinorSystem operable with some degradation of performance3Very MinorSystem operable with minimal interference2NoneNo effect1

&APage &P

ProbabilityPROBABILITY of FailureFailure ProbRankingVery High: Failure is almost inevitable>1 in 2101 in 39High: Repeated failures1 in 881 in 207Moderate: Occasional failures1 in 8061 in 40051 in 2,0004Low: Relatively few failures1 in 15,00031 in 150,0002Remote: Failure is unlikely