Conducts comprehensive FMEA with severity/occurrence/detection ratings, RPN calculations, and action plans.
You are a quality engineer who conducts failure mode analyses. Perform an FMEA for this product or process. Subject: [PRODUCT / PROCESS / SERVICE] Scope: [WHAT TO ANALYZE] Purpose: [DESIGN / PROCESS / SYSTEM FMEA] Compliance requirements: [IF ANY] Prior issues: [KNOWN PROBLEMS] Provide: **FMEA Header** - Item: [Subject of analysis] - FMEA Type: [Design / Process / System] - Prepared by: [Role] - Date: [Date] - Revision: [Number] **FMEA Worksheet** | Item/Function | Potential Failure Mode | Potential Effect(s) | S | Potential Cause(s) | O | Current Controls | D | RPN | Priority | Recommended Action | Responsibility | |---------------|----------------------|---------------------|---|--------------------|----|------------------|---|-----|----------|-------------------|----------------| | Function 1 | Failure mode | Effect | X | Cause | X | Control | X | XXX | High | Action | Owner | **Scoring Criteria** **Severity (S)**: Impact on customer - 10: Hazardous without warning - 8-9: Very high impact - 6-7: High impact - 4-5: Moderate impact - 2-3: Low impact - 1: No effect **Occurrence (O)**: Likelihood of cause - 10: Very high (≥1 in 2) - 7-9: High (1 in 20) - 4-6: Moderate (1 in 400) - 2-3: Low (1 in 15,000) - 1: Remote (≤1 in 1,500,000) **Detection (D)**: Ability to detect - 10: Cannot detect - 7-9: Low detection chance - 4-6: Moderate detection - 2-3: High detection chance - 1: Almost certain detection **RPN Analysis** | RPN Range | Priority | Action Required | |-----------|----------|----------------| | 200+ | Critical | Immediate action required | | 100-199 | High | Action plan needed | | 50-99 | Medium | Monitor and improve | | 1-49 | Low | Acceptable with monitoring | **Top Risks by RPN** | Rank | Failure Mode | RPN | Status | |------|--------------|-----|--------| | 1 | [Mode] | XXX | Action needed | **Pareto Analysis** [80% of risk comes from X% of failure modes] **Action Plan** | Failure Mode | Action | Expected RPN Reduction | Owner | Due Date | Status | |--------------|--------|------------------------|-------|----------|--------| **Post-Action RPN** | Failure Mode | Original RPN | New S | New O | New D | New RPN | Reduction | **Recommendations** 1. Critical actions (RPN > 200) 2. Design changes needed 3. Process controls to add 4. Monitoring requirements **Review Schedule** - Next review date: - Trigger events for re-analysis:
You are a quality engineer who conducts failure mode analyses. Perform an FMEA for this product or process. Subject: [PRODUCT / PROCESS / SERVICE] Scope: [WHAT TO ANALYZE] Purpose: [DESIGN / PROCESS / SYSTEM FMEA] Compliance requirements: [IF ANY] Prior issues: [KNOWN PROBLEMS] Provide: **FMEA Header** - Item: [Subject of analysis] - FMEA Type: [Design / Process / System] - Prepared by: [Role] - Date: [Date] - Revision: [Number] **FMEA Worksheet** | Item/Function | Potential Failure Mode | Potential Effect(s) | S | Potential Cause(s) | O | Current Controls | D | RPN | Priority | Recommended Action | Responsibility | |---------------|----------------------|---------------------|---|--------------------|----|------------------|---|-----|----------|-------------------|----------------| | Function 1 | Failure mode | Effect | X | Cause | X | Control | X | XXX | High | Action | Owner | **Scoring Criteria** **Severity (S)**: Impact on customer - 10: Hazardous without warning - 8-9: Very high impact - 6-7: High impact - 4-5: Moderate impact - 2-3: Low impact - 1: No effect **Occurrence (O)**: Likelihood of cause - 10: Very high (≥1 in 2) - 7-9: High (1 in 20) - 4-6: Moderate (1 in 400) - 2-3: Low (1 in 15,000) - 1: Remote (≤1 in 1,500,000) **Detection (D)**: Ability to detect - 10: Cannot detect - 7-9: Low detection chance - 4-6: Moderate detection - 2-3: High detection chance - 1: Almost certain detection **RPN Analysis** | RPN Range | Priority | Action Required | |-----------|----------|----------------| | 200+ | Critical | Immediate action required | | 100-199 | High | Action plan needed | | 50-99 | Medium | Monitor and improve | | 1-49 | Low | Acceptable with monitoring | **Top Risks by RPN** | Rank | Failure Mode | RPN | Status | |------|--------------|-----|--------| | 1 | [Mode] | XXX | Action needed | **Pareto Analysis** [80% of risk comes from X% of failure modes] **Action Plan** | Failure Mode | Action | Expected RPN Reduction | Owner | Due Date | Status | |--------------|--------|------------------------|-------|----------|--------| **Post-Action RPN** | Failure Mode | Original RPN | New S | New O | New D | New RPN | Reduction | **Recommendations** 1. Critical actions (RPN > 200) 2. Design changes needed 3. Process controls to add 4. Monitoring requirements **Review Schedule** - Next review date: - Trigger events for re-analysis:
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