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POTENTIALFAILUREMODEANDEFFECTSANALYSIS(FMEA)ReferenceManualFourthEditionFirstEdition,February1993•SecondEdition,February1995•ThirdEdition,July2001,FourthEdition,June2008Copyright©1993,©1995,©2001,©2008ChryslerLLC,FordMotorCompany,GeneralMotorsCorporationISBN:978-1-60534-136-1PropertyofFordMotorCompany-InternalUseOnlyFOREWORD4thEditionTheFMEA4thEditionisareferencemanualtobeusedbysupplierstoChryslerLLC,FordMotorCompany,andGeneralMotorsCorporationasaguidetoassisttheminthedevelopmentofbothDesignandProcessFMEAs.Themanualdoesnotdefinerequirements;itisintendedtoclarifyquestionsconcerningthetechnicaldevelopmentofFMEAs.ThismanualisalignedwithSAEJ1739.SummaryofChangesinthe4theditionFMEAReferenceManualTheDFMEAandPFMEAmethodsdescribedinthe4theditionFMEAReferenceManualincludethoseassociatedwithdesignatthesystem,subsystem,interface,andcomponentlevelandtheprocessatmanufacturingandassemblyoperations.GeneralChanges•Theformattingusedinthe4theditionisintendedtoprovideeasierreading.oAnindexisincluded.oIconsareusedtoindicatekeyparagraphsandvisualcuesareused.•AdditionalexamplesandverbiagehavebeenprovidedtoimprovetheutilityofthemanualandtoprovideaclosertieintotheFMEAprocessasitdevelops.•Reinforcementoftheneedformanagementsupport,interest,andreviewoftheFMEAprocessandresults.•DefineandstrengthentheunderstandingofthelinkagebetweenDFMEAandPFMEAaswellasdefiningthelinkagestoothertools.•ImprovementstotheSeverity,Occurrence,Detectionrankingtablessothattheyaremoremeaningfultorealworldanalysisandusage.•Alternativemethodsareintroducedthatarecurrentlybeingappliedinindustry.oAdditionalappendiceswhichhaveexampleformsandspecialcaseapplicationofFMEA.oThefocusonthe“standardform”hasbeenreplacedwithseveraloptionsthatrepresentthecurrentapplicationofFMEAinindustry.•ThesuggestionthatRPNnotbeusedastheprimarymeansforassessingrisk.Theneedforimprovementhasbeenrevisedincludinganadditionalmethod,andtheuseofthresholdsonRPNisclarifiedasapracticethatisnotrecommended.ChapterIprovidesgeneralFMEAguidelines,theneedformanagementsupportandhavingadefinedprocessfordevelopingandmaintainingFMEAs,andtheneedforcontinuousimprovement.ChapterIIdescribesthegeneralapplicationoftheFMEAmethodology,whichiscommonbetweenDFMEAandPFMEAprocesses.Thisincludestheplanning,strategy,actionplans,andtheneedformanagementsupportandresponsibilityinFMEAs.ChapterIIIfocusesonDFMEA(DesignFailureModeEffectsandAnalysis),establishingthescopeoftheanalysis,useofblockdiagrams,varioustypesofDFMEAs,formationoftheteams,basicprocedureforanalysis,actionplans,andfollow-up,alternativestoRPN,andconnectiontoPFMEAsandvalidationplans.iPropertyofFordMotorCompany-InternalUseOnlyChapterIVfocusesonPFMEA(ProcessFailureModeEffectsandAnalysis),establishingthescopeoftheanalysis,useofflowdiagrams,formationofteams,basicprocedureforanalysis,actionplans,theconnectiontoDFMEAsandthedevelopmentofcontrolplans.TheAppendiceshaveseveralexamplesofformsforDMFEAandPFMEAandaddressesdifferentapplicationsandproceduresforaddressingdesignandprocessrisk.TheSupplierQualityRequirementsTaskForcewouldliketothankthefollowingindividuals,andtheircompanies,whohavecontributedtheirtimeandeffortstothedevelopmentofthiseditionoftheFMEAReferenceManual:MichaelDown,GeneralMotorsCorporationLawrenceBrozowski,GeneralMotorsCorporationHishamYounis,FordMotorCompanyDavidBenedict,ChryslerLLCJohnFeghali,ChryslerLLCMichaelSchubert,DelphiRhondaBrender,DelphiGregoryGruska,OmnexGlenVallance,ControlPlanningInitiativesMilenaKrasich,BoseWilliamHaughey,ReliaTrainThismanualisacopyrightofChryslerLLC,FordMotorCompanyandGeneralMotorsCorporation,withallrightsreserved.AdditionalcopiesmaybeobtainedfromAIAG@