Download - pfmea_rankings.xls
PFMEA Severity Rankings
PFMEA Occurrence Rankings
ProbabilityLikely Failure RatesPpkRankingVery High: Persistent Failures100 per thousand pieces50 per thousand pieces< 0.55> 0.55109High: Frequent Failures20 per thousand pieces10 per thousand pieces> 0.78> 0.8687Moderate: Occasional Failures5 per thousand pieces
2 per thousand pieces
1 per thousand pieces> 0.94
>1.00
>1.106
5
4Low: Relatively Few Failures0.5 per thousand pieces
0.1 per thousand pieces>1.20
> 1.303
2Remote: Failure is unlikely< 0.001 per thousand pieces *> 1.671Note: Identical to Manual except for Ranking of 1. Manual allows for .01 per thousand (10 PPM)DELPHI Supplier Quality FMEA OCCURRENCE EVALUATION RANKINGSSample calculation to determine Ppk value from a likely failure rate of 5 per thousand pieces (see FMEA third Appendix I).
PFMEA Detection Rankings
RankingEffectPFMEA10Absolute UncertaintyCannot detect or is not checked.9Very RemoteControl is achieved with indirect or random checks only.8RemoteControl is achieved with visual inspection only.7Very LowControl is achieved with double visual inspection only.6LowControl is achieved with charting methods, such as SPC (Statistical Process Control) OR gauging performed on setup and first-piece check. *5ModerateControl is based on variable or attribute gauging performed 100% of the parts after parts have left the station.4Moderately HighError detection in subsequent operation. *3HighError detection in-station, or error detection in subsequent operations by multiple layers of acceptance: supply, select, install, verify. Cannot accept discrepant part.2Very HighError detection in-station (automatic gauging with automatic stop feature). Cannot pass discrepant part.1Almost CertainDiscrepant parts cannot be made because item has been error-proofed by process/product design.* Note: Identical to Manual except for Rankings of 6 and 4. Words OR gauging performed on setup and first piece check moved from a detection of 4 to a detection of 6DELPHI Supplier Quality FMEA Detection Rankings
MBD001AC6F1.docDELPHI Supplier Quality FMEA SEVERITY RANKINGS
Note #1: Any Failure Mode affecting the Vehicle Assembly Plant MUST be ranked an 8 or higher.
Note #2: Any Failure Mode affecting a Delphi Plant MUST be ranked 5 or higher.
Select from the categories below, using the highest applicable ranking.
Ranking
Effect
End Customer
Vehicle Assembly Plant
Delphi Plant
Supplier Plant
10
Hazardous-without warning
Potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning.
Potential failure mode may cause unsafe condition for plant personnel without warning.
Potential failure mode may cause unsafe condition for plant personnel without warning.
Potential failure mode may cause unsafe condition for plant personnel without warning.
9
Hazardous-with warning
Potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning.
Potential failure mode may cause unsafe condition for plant personnel with warning.
Potential failure mode may cause unsafe condition for plant personnel with warning.
Potential failure mode may cause unsafe condition for plant personnel with warning.
8
Very High
Vehicle/item inoperable (loss of primary function); failure mode may cause customer walk home, field return, or durability issue.
Potential failure mode may cause a spill/major disruption, repair, assembly difficulty, rework, or sorting at the Vehicle Assembly Plant
Potential failure mode may cause a spill/major disruption at a Delphi Plant.
7
High
Vehicle/item operable but at a reduced level of performance. Customer very dissatisfied. Failure mode may cause vehicle repairs at Dealer. Includes Noise issues (squeak/rattle).
See Note #1
Potential failure mode may cause repair, assembly difficulty, rework, sorting at a Delphi plant.
6
Moderate
Vehicle/item operable but comfort/convenience item(s)) inoperable/not performing to customer expectation (e.g.. Noise)
See Note #1
Potential failure mode may cause special handling of components at Delphi-S.
5
Low
Vehicle/item operable but comfort/convenience item(s) operable at a reduced level of performance.
See Note #1
Potential failure mode may cause inconvenience to Delphi prior to assembly.
4
Very Low
Fit and finish item does not conform. Defect noticed by most customers.
See Note #1
See Note #2
3
Minor
Fit and finish item does not conform. Defect noticed by average customers.
See Note #1
See Note #2
2
Very Minor
Fit and finish item does not conform. Defect noticed by discriminating customers.
See Note #1
See Note #2
1
None
No effect.
See Note #1
See Note #2
LPHI-S FMEA DETTION RANKking
Effect
PFMEA
10
Absolute Uncertainty
Cannot detect or is not checked.
9
Very Remote
Control is achieved with indirect or random checks only.
DELPHI-S FMEA RANKINGS
k.bourassa
Revised: 11/12/01