Enter your FMEA rows
Sample FMEA entries
| Function | Failure mode | Effect | Cause | S | O | D | RPN |
|---|---|---|---|---|---|---|---|
| Maintain seal integrity | Seal gap present | Leakage, returns | Heat drift | 8 | 5 | 6 | 240 |
| Detect label position | Label misalignment | Rework, scrap | Sensor contamination | 6 | 4 | 4 | 96 |
| Control fill volume | Underfill | Regulatory risk | Nozzle wear | 9 | 3 | 7 | 189 |
How scores are calculated
- RPN = Severity (S) × Occurrence (O) × Detection (D). Range: 1–1000.
- Weighted RPN = (S×wS) × (O×wO) × (D×wD), rounded to a whole number.
- Risk band is assigned using your thresholds for the selected score.
- Criticality Index (shown in CSV) = S × O, useful for quick screening.
Always apply your organization’s scoring tables for S, O, and D to keep evaluations consistent across teams.
Steps for practical use
- Describe each function and failure mode with clear language.
- Assign S, O, and D using agreed definitions and evidence.
- Set thresholds and, if needed, adjust weights for local priorities.
- Click Calculate to sort and identify top priorities.
- Assign actions, owners, and target dates for high-scoring items.
- Re-run after improvements to confirm risk reduction.
Common questions
1) What does FMEA help me achieve?
It helps you anticipate failures, quantify relative risk, and prioritize actions. By scoring severity, occurrence, and detection consistently, teams focus on the few issues most likely to cause harmful outcomes.
2) What is a good RPN value?
There isn’t one universal cutoff. Use your process history, compliance needs, and customer impact to set thresholds. This calculator lets you define Low, Medium, High, and Critical bands to match local standards.
3) Why include a weighted option?
Some teams want severity to dominate decisions, while others emphasize detection. Multipliers can reflect those priorities. Keep weights stable across analyses, and document why you changed them for audits and comparability.
4) How do I score Detection correctly?
Detection measures how likely current controls will catch the issue before it escapes. Lower is better. Base the rating on control capability, frequency, automation, and real performance data, not only confidence.
5) Should I always fix the highest RPN first?
Not always. Very high severity can warrant immediate action even if RPN is modest. Consider safety, regulations, and customer harm alongside the score. Use engineering judgment to validate the priority list.
6) What if I have many failure modes?
Add rows and focus on the top cluster of High and Critical items. Group similar modes, confirm causes, then assign targeted actions. Recalculate after each improvement cycle to track progress.
7) Can I share results with my team?
Yes. Use the CSV for spreadsheets and dashboards, and the PDF for a quick summary. Exports are based on your latest calculation, so run the calculator again after making changes.
8) Does this replace formal standards?
No. It supports structured scoring and reporting, but it doesn’t provide industry-specific rating tables. Use your company’s procedures and validation methods when assigning S, O, and D values.