PFMEA severity, occurrence and detection poster

A process FMEA rates each way a process step could fail on three scales of 1 to 10: severity of the effect, occurrence of the cause given the prevention in place, and detection, how likely the current controls are to catch it. Since the AIAG and VDA FMEA Handbook of 2019, the three are read together as an action priority of high, medium or low rather than multiplied into an RPN, so a severe effect cannot hide behind a low product. This poster explains each scale and the rules for rating.

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The PNG is free to download now. The print-ready vector PDFs open after a short form, once.

Download PNG (300 dpi)2550 x 3300 px, prints at 8.5 x 11 in · 485 KB · no form

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The words on the poster

PFMEA: severity, occurrence, detection

Rate each failure on three scales, then act on the highest priority first.

Severity How bad is the effect? 10: safety or regulation. 1: no noticeable effect. Rate the effect, not the cause.
Occurrence How likely is the cause, with today's prevention? 10: very high. 1: prevented. Lower it with prevention.
Detection Will today's checks catch it before it ships? 1: error-proofed. 10: no check. Lower it with better checks.

Action priority, not RPN. S, O and D are read together as high, medium or low. Severity counts most: a high severity is never hidden by a low product.

Rules

Rate as a team, with operators.
Only a design or process change lowers severity.
Rate detection of the failure, not of the paperwork.
Re-rate after every action is in place.

After the AIAG and VDA FMEA Handbook (2019). Use your customer's tables if they set their own.

On the floor

How to use it

Putting the PFMEA severity, occurrence and detection poster to work

1
Hang it in the room where FMEA workshops are held.
2
Read the three cards aloud at the start of each workshop so everyone rates the same way.
3
Use your customer's rating tables if they set their own.
4
Pair it with the free PFMEA, DFMEA and control plan templates.

Where the poster goes and how to teach with it, in the order to try them.

Which size to print

24 x 36 in or A2: a main wall or team board, read from a few metres away.
18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
Letter or A4: a clipboard, binder or handout, on any office printer.

Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.