Xfmea Mfmea

REPORT SUMMARY
Date:
9/1/2015
Page
of
In addition to this summary, this report includes the following forms:

Rating Criteria and Classifications
J1739 (2009)
Actions
Xfmea Report Sample Machinery FMEA

This report was generated with ReliaSofts Xfmea software in Microsoft Word. Similar reports can also
be generated in Microsoft Excel. You can easily replace the Xfmea logo graphic with your own company
logo. Within Word and Excel, reports can be edited/annotated, if necessary, and generated in PDF
and/or HTML format for easy distribution.
This report includes:
A summary of the rating criteria (Severity Scale, Occurrence Scale, Detection Scale) and classifications
that were used in the analysis.
The Machinery FMEA (MFMEA) spreadsheet report in the SAE J1739 reporting format.
A summary list of the recommended actions identified during the analysis.
The report is based on the sample analysis provided in the SAE J1739 guidelines, on page 45.
Date Created: 9/1/2015
Creator ReliaSoft Corporation
Non-proprietary and non-confidential information.
Generated by ReliaSoft's Xfmea Software http://www.ReliaSoft.com
RATING CRITERIA AND CLASSIFICATIONS
Severity Rating Scale

# Description
1
None
Criteria 1
No discernible effect.
Fit and finish/Squeak and rattle item does not conform.
Defect noticed by discriminating customers (less than
25%).
Very Minor
Minor
Very Low
Low
Moderate
High
Very High
Hazardous with warning
10
Hazardous without warning
Detection Rating Scale

# Description
1
Almost Certain
Very High
High
Moderately High
Moderate
Low
Very Low
Remote
Very Remote

Defect noticed by 50% of customers.
Defect noticed by most customers (greater than 75%).
Vehicle/Item operable but Comfort/Convenience item(s)
inoperable. Customer somewhat dissatisfied.
Vehicle/Item operable but Comfort/Convenience item(s)
inoperable. Customer dissatisfied.
Vehicle/Item operable but at a reduced level of
performance. Customer very dissatisfied.
Vehicle/Item inoperable (loss of primary function).
Very high severity ranking when a potential failure mode
affects safe vehicle operation and/or involves
noncompliance with government regulation with
warning.
Very high severity ranking when a potential failure mode
affects safe vehicle operation and/or involves
noncompliance with government regulation without
warning.
Occurrence Rating Scale

# Description
1
Remote: Failure is unlikely
9/1/2015
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Criteria
<= 0.01 per thousand vehicles/items
Low: Relatively few failures
0.1 per thousand vehicles/items
Low: Relatively few failures
0.5 per thousand vehicles/items
Moderate: Occasional failures
1 per thousand vehicles/items
High: Frequent failures
High: Frequent failures
Very High: Persistent failures
10
Very High: Persistent failures
=> 100 per thousand vehicles/items
Classification Options
Criteria 1
Abbreviation
Design Control will almost certainly detect a potential
C
cause/mechanism and subsequent failure mode.
Very High chance the Design Control will detect a
potential cause/mechanism and subsequent failure
KI
mode.
High chance the Design Control will detect a potential
KLd
Moderately High chance the Design Control will detect a
KLg
mode.
Moderate chance the Design Control will detect a
S
mode.
Low chance the Design Control will detect a potential
KPC
Very Low chance the Design Control will detect a
KCC
mode.
Remote chance the Design Control will detect a potential
Very Remote chance the Design Control will detect a
mode.
Date:
Description
Critical
Key Intermediate
Key Leading
Key Lagging
Significant
Key Product Characteristic
Key Control Characteristic
RATING CRITERIA AND CLASSIFICATIONS
10
Absolute Uncertainty
Date:
9/1/2015
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of
Design Control will not and/or cannot detect a potential

cause/mechanism and subsequent failure mode; or there
is no Design Control.
FAILURE MODE AND EFFECTS ANALYSIS

Vacuum Pump
Model Year(s)/Program(s)
Design Responsibility
Core Team
Support Team
MF112
5/2/2015
John Doe
2/2/2015
120 Investigate longer

life cables, hoses
and jumpers.
(Reduces
occurrence)
Responsibility & Planned

Completion Date
Jim
Manufacturing,
Mike Cable,
Supplier
Actions Taken &

Actual
Completion Date
3/30/2015 Selected cables and

hoses with longer
life than originally
specified. 3/30/2015
Investigate use of Joe Dressiing,

abrasion resistant
Supplier
protective covering
for cables and
hoses. (Reduces
occurrence)
3/12/2015 Abrasion resistant

sleeves to be used
at points that are
subject to high wear
and tear.
- 3/12/2015
Split cabling for

Joe Dressing,
water hoses/cables Supplier
to minimize length
of replacement.
(Reduces
downtime/effects
severity)
3/12/2015 Completed.
- 3/12/2015
Utilize infrared
thermography to
predict robot
dressing failure.
(Improves
detection)
3/13/2015 Infrared
Thermography
incorporated into
predictive
maintenance plans.
- 3/13/2015
Joe Dressing,
Assembly Plant
123
RPNr
Recommended
Action(s)
DETr
6 Robot dressing
practices.
Recommended
jumper and cable
lengths.
Preventive
maintenance.
Water Savers
Machinery
Controls stop the
process.
Current Design
Controls
(Detection)
OCCr
Flexing, rubbing of
cables, jumpers and
hoses with each other
during welding.
Current Design
Controls
(Prevention)
SEVr
Potential
Cause(s)/Mechanisms
of Failure
RPNi
Moderate
downtime in
replacing the
dressing.
Downtime varies
from 10-30
minutes for
replacement.
Key Date
Prepared By
FMEA Date (Orig.)
DETi
Partial or
complete loss of
air, water, and
power supply to
the weld gun.
Potential
Effect(s) of
Failure
FMEA Number
Action Results
OCCi
Vacuum Pump
Provides vacuum
to evacuate brake
system. Achieve X
millimeters in Y
seconds as the
furthest wheel
from the vacuum
source.
Potential
Failure Mode
SEVi
Name /
Function
1.1 - Vacuum Pump

201X/AllStar
Firebrakes (supplier)
Mike Brake, John Doe, Jim Dominion (Supplier)
Classification
Item
48
ACTIONS
Date:
9/1/2015
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of
Planned
Actual
Review
Last
Potential Potential
Potential
Actio Action Recommended
Actions
Planned
Actual Review
Last
Responsibility Completion Completion
Reviewer
Com- Updated
Name Function Failure Effect(s) of Cause(s)/Mechanisms RPNi RPNr
n ID
#
Action(s)
Taken
Cost
Cost Date
Updated
Date
Date
ments
By
Mode
Failure
of Failure
5
1.1.1.1. Investigate
Jim
3/30/2015 3/30/2015 Selected
0
0
ReliaSoft 7/29/2015 Vacuum Provides Partial or Moderate
Flexing, rubbing of
120 48
1
longer life
Manufacturing,
cables and
Corporation 10:53 AM Pump vacuum to complete downtime in cables, jumpers and
cables, hoses
Mike Cable,
evacuate loss of
replacing the hoses with each other
hoses with
brake
longer life
during welding.
and jumpers.
Supplier
air, water, dressing.
system.
(Reduces
than originally
and
Downtime
Achieve X power
varies from
occurrence)
specified.
millimeters supply to 10-30
in Y
the weld minutes for
seconds
gun.
replacement.
as the
furthest
wheel
from the
vacuum
source.
6
1.1.1.1. Investigate use Joe Dressiing,
3/12/2015 3/12/2015 Abrasion
0
0
Flexing, rubbing of
120 48
2
of abrasion
Supplier
resistant
sleeves to be
resistant
evacuate loss of
during welding.
protective
used at points
brake
Downtime
system.
covering for
that are
and
varies from
cables and
Achieve X power
subject to
hoses. (Reduces
high wear and
occurrence)
tear.
in Y
replacement.
seconds
gun.
as the
furthest
wheel
from the
vacuum
source.
7
1.1.1.1. Split cabling for Joe Dressing,
3/12/2015 3/12/2015 Completed.
0
0
Flexing, rubbing of
120 48
3
water
Supplier
hoses/cables to
evacuate loss of
brake
during welding.
minimize length
system.
of replacement.
and
Downtime
(Reduces
Achieve X power
varies from
downtime/effects
severity)
in Y
seconds
gun.
replacement.
as the
furthest
wheel
from the
vacuum
source.
ACTIONS
1.1.1.1. Utilize infrared Joe Dressing,

4
thermography to Assembly Plant
predict robot
123
dressing failure.
(Improves
detection)
3/13/2015
3/13/2015 Infrared
Thermography
incorporated
into predictive
maintenance
plans.
Date:
9/1/2015
Page
of

Flexing, rubbing of
evacuate loss of
during welding.
brake
Downtime
system.
and
varies from
Achieve X power
in Y
replacement.
seconds
gun.
as the
furthest
wheel
from the
vacuum
source.
120
48

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REPORT SUMMARY

In addition to this summary, this report includes the following forms:

Xfmea Report Sample Machinery FMEA

Date Created: 9/1/2015

Creator ReliaSoft Corporation

Non-proprietary and non-confidential information.

Generated by ReliaSoft's Xfmea Software http://www.ReliaSoft.com

RATING CRITERIA AND CLASSIFICATIONS

Severity Rating Scale

Hazardous with warning

Hazardous without warning

Detection Rating Scale

Date Created: 9/1/2015

Fit and finish/Squeak and rattle item does not conform.

Occurrence Rating Scale

Low: Relatively few failures

0.1 per thousand vehicles/items

Low: Relatively few failures

0.5 per thousand vehicles/items

Moderate: Occasional failures

1 per thousand vehicles/items

Moderate: Occasional failures

2 per thousand vehicles/items

Moderate: Occasional failures

5 per thousand vehicles/items

High: Frequent failures

10 per thousand vehicles/items

High: Frequent failures

20 per thousand vehicles/items

Very High: Persistent failures

50 per thousand vehicles/items

Very High: Persistent failures

=> 100 per thousand vehicles/items

Creator ReliaSoft Corporation

Non-proprietary and non-confidential information.

Generated by ReliaSoft's Xfmea Software http://www.ReliaSoft.com

RATING CRITERIA AND CLASSIFICATIONS

Date Created: 9/1/2015

Design Control will not and/or cannot detect a potential

Creator ReliaSoft Corporation

Non-proprietary and non-confidential information.

Generated by ReliaSoft's Xfmea Software http://www.ReliaSoft.com

FAILURE MODE AND EFFECTS ANALYSIS

120 Investigate longer

Responsibility & Planned

Actions Taken &

3/30/2015 Selected cables and

Investigate use of Joe Dressiing,

3/12/2015 Abrasion resistant

Split cabling for

Non-proprietary and non-confidential information.

Generated by ReliaSoft's Xfmea Software http://www.ReliaSoft.com

Creator ReliaSoft Corporation

Date Created: 9/1/2015

1.1 - Vacuum Pump

Date Created: 9/1/2015

Creator ReliaSoft Corporation

Non-proprietary and non-confidential information.

Generated by ReliaSoft's Xfmea Software http://www.ReliaSoft.com

1.1.1.1. Utilize infrared Joe Dressing,

Date Created: 9/1/2015

Creator ReliaSoft Corporation

ReliaSoft 7/29/2015 Vacuum Provides Partial or Moderate