FMEA Rating Tables
Severity (S) Rating
Severity is a rating corresponding to the seriousness of the effect of a potential failure mode. It evaluates the impact of a failure on the customer, manufacturing process, or end product. The rating ranges from 1 (no effect) to 10 (hazardous without warning), considering impacts to your plant operations, shipping facilities, and end users. This assessment helps identify critical failure modes that require immediate attention and preventive measures.
| S | Effect | Impact to Your Plant | Impact to Ship-to Plant (when known) | Impact to End User (when known) |
|---|---|---|---|---|
| 10 | High | Failure may result in health and/or safety risk for the manufacturing or assembly worker | Failure may result in health and/or safety risk for the manufacturing or assembly worker | Affects safe operation of the vehicle and/or other vehicles, the health of driver or passenger(s) or road users or pedestrians |
| 9 | High | Failure may result in in-plant regulatory noncompliance | Failure may result in in-plant regulatory noncompliance | Noncompliance with regulations |
| 8 | Moderately high | 100% of production run affected may have to be scrapped | Line shutdown greater than full production shift; stop shipment possible, field repair or replacement required (Assembly to End User) other than for regulatory noncompliance. | Loss of primary vehicle function necessary for normal driving during expected service life |
| 7 | Moderately high | Product may have to be sorted and a portion (less than 100%) scrapped; deviation from primary process, decreased line speed or added manpower | Line shutdown from 1 hour up to full production shift; stop shipment possible, field repair or replacement required (Assembly to End User) other than for regulatory noncompliance | Degradation of primary vehicle function necessary for normal driving during expected service life |
| 6 | Moderately low | 100% of production run may have to be reworked off line | Line shutdown up to one hour | Loss of secondary vehicle function |
| 5 | Moderately low | A portion of the production run may have to be reworked off line and accepted | Less than 100% of product affected; strong possibility for additional defective product; sort required; no line shutdown | Degradation of secondary vehicle function |
| 4 | Low | 100% of production run may have to be reworked in station before it is processed | Defective product triggers significant reaction plan; additional defective products not likely, sort not required | Very objectionable appearance, sound, vibration, harshness, or haptics |
| 3 | Low | A portion of the production run may have to be reworked in station before it is processed | Defective product triggers minor reaction plan; additional defective products not likely, sort not required | Moderately objectionable appearance, sound, vibration, harshness, or haptics |
| 2 | Low | Slight inconvenience to process, operation, or operator | Defective product triggers no reaction plan; additional defective products not likely, requires feedback to supplier | Slightly objectionable appearance, sound, vibration, harshness, or haptics |
| 1 | Very low | No discernible effect | No discernible effect or no effect | No discernible effect |
