Severity Rankings for PFMEA -- A = Appearance F = Function

Delphi Operating Definitions AIAG Guideline Delphi Guideline AIAG Guideline

Impact on Process or Operation (Manufacturing / Assembly Effect) Impact on Product (Customer Effect)

Hazardous- without- warning:

(F) May involve safety, and/or noncompliance

with regulatory issues.

Hazardous -with- warning:

(F) May involve safety, and/or noncompliance

with regulatory issues.

Extreme/Very High: System function lost

(F) Can’t use the system, but no safety or

noncompliance with regulatory issues.

Customer walk home.

Serious disruption to downstream operation, or major

operational impact, e.g. extensive rework, major scrap,

significantly increased in inventory.

Significant/High: Customer Dissatisfaction

Defect caught in customer plant, Dealer repair/rework,

Product returned, major disruption spill occurs.

(A&F) The failure causes high degree of

customer dissatisfaction on the part user.

6Major disruption to production line. Defect caught at

Final Assembly / Test. Major rework required or scrap.

A portion (less than 100%) of the product may have to

be scrapped with no sorting, or vehicle / item repaired

in the repair department with a repair time less than a

half-hour.

Moderate: (F) Partial system function is lost,

but still can use it without safety concern.

Moderate: Vehicle/item operable, but comfort/convenience item(s)

inoperable. Customer experiences discomfort.

Moderately Significant: Customer

Dissatisfaction

(A&F) the user will notice a negative impact

as failure occurs; i.e. difficult to apply,

difficult to use, discomfort, etc.

4

Failure may cause inconvenience to subsequent

operations, minor rework required. Defect passed to

next process.

The product may have to be sorted, with no scrap, and

a portion (less than 100%) reworked.

Very Low: (F) Parts of the system operable

at reduced performance, and/or gradual

performance degradation.

Very Low: Fit & finish; squeak & rattle item does not conform.

Defect noticed by most customers.

Minor: Nuisance, noticeable

(F) Nuisance but likely negligible.

2Failure detected at local operation, may cause slight

inconvenience to operation, minor rework.

A portion (less than 100%) of the product may have to

be reworked, with no scrap, on-line but in-station.

Minor: (A) The user will probably notice only

a minor negative impact on the product.

Minor: Fit & finish; squeak & rattle item does not conform. Defect

noticed by discriminating customer.

Imperceptible: Not noticeable

(F) The consequence will not have any

perceptible impact on the performance of the

product

(A) The user will not notice the consequence.

1 No effect detected.Slight inconvenience to operation or operator, or no

effect.None: No effect.

5

Minor disruption to production. Defect caught at Final

Assembly Line. Light rework or scrap. May cause

minor damages to tooling.

100% of product may have to be reworked, or vehicle /

item repaired off-line but does not go to repair

department.

Low: Vehicle/item operable, but comfort/convenience item(s)

operable at reduced level of performance. Customer experiences

some dissatisfaction.

3

Failure detected at subsequent operation. May cause

slight inconvenience to subsequent operation, minor

rework required.

A portion (less than 100%) of the product may have to

be reworked, with no scrap, on-line but out-of-station.

Minor: Fit & finish; squeak & rattle item does not conform. Defect

noticed by average customer.

8

Equipment/machines down for a significant period of

time. Major financial impact. Internal production down

which may lead to delay or short shipment.

100% of product may have to be scrapped, or vehicle /

item repaired in the repair department with a repair

time greater than one hour.

Very High: Vehicle/item inoperable, with loss of primary function.

7

Product may have to be sorted and a portion (less

than 100%) scrapped, or vehicle / item repaired in the

repair department with a repair time between a half-

hour and a hour.

High: Vehicle/item operable, but at reduced level of performance.

Customer dissatisfied.

Rank

10

Potential for injury or harm to operating personnel.

Non-compliance with governmental regulations (spill of

hazardous material, etc).

May endanger operator (machine or assembly) without

warning.

Hazardous-without-warning: Very high severity ranking when a

potential failure mode affects safe vehicle operation and/or involves

noncompliance with government regulation without warning.

9Missed shipment shutting down customer’s production

line. Equipment/machines severely damaged.

May endanger operator (machine or assembly) with

warning.

Hazardous-with-warning: Very high severity ranking when a

potential failure mode affects safe vehicle operation and/or involves

noncompliance with government regulation with warning.

Occurrence Rankings for PFMEA

AIAG

Ppk Rate

10 < 0.55 100

9 0.55 50

8 0.78 20

7 0.86 10

6 0.94 5

5 1.00 2

4 1.20 0.5

3 1.30 0.1

2 1.50 0.010

1 Remote: Situation unlikely 1.67 0.0010 Remote: Failure is unlikely.

Detection Rankings for PFMEA

A B C

Almost ImpossibleAbsolute certainty of non-

detection.X 10

Very Remote Controls will probably not detect. X 9

RemoteControls have poor chance of

detection.X 8

Very LowControls have poor chance of

detection.X 7

Low Controls may detect. X X 6

Moderate Controls may detect. X 5

Moderately HighControls have a good chance to

detect.X X 4

HighControls have a good chance to

detect.X X 3

Very High Controls almost certain to detect. X X 2

Very High Controls certain to detect. X 1Discrepant parts cannot be made because item has been error-proofed by

process / product design.

Control is achieved with indirect or random checks only.

Control is achieved with visual inspection only.

Control is achieved with double visual inspection only.

Control is achieved with charting methods, such as SPC (Statistical Process

Control).

Control is based on variable gauging after parts have left the station, or Go / No

Go gauging performed on 100% of the parts after parts have left the station.

Error detection in subsequent operation, OR gauging performed on setup and

first-piece check (for set-up causes only).

Error detection in-station, or error detection in subsequent operations by

multiple layers of acceptance: supply, select, install, verify. Cannot accept

discrepant part.

Error detection in-station (automatic gauging with automatic stop feature).

Cannot pass discrepant part.

100.000 PPM

50.000 PPM

Inspection TypesAIAG Guidelines

Cannot detect or is not checked.

RankDetection Criteria

5000 PPM

2000 PPM

1 PPM

Low: Relatively few failures100 PPM

10 PPMLow: Situation relatively rare

Moderate: Occasional failures

500 PPM

Moderate: Situation occasionally

occurs

20.000 PPM

10.000 PPMHigh: Frequent failuresHigh: Situation frequently occurs

Very High: Persistent failures

Rank Delphi Operating Definitions AIAG Failure Rate

(IPTV/items)

Extreme: Almost inevitable

AIAG GuidelineDelphi

Failure Rate