FMEA - - Step 6: AIAG* Severity Guidelines

1 2009 The New Excellence Confidential and Proprietary FMEA -- Step 6: AIAG* Severity GuidelinesStep 6: AIAG* Severity GuidelinesEFFECTCRITERIA: Severity OF EFFECTRANKINGH azardous - without warningMay endanger machine or assembly operator. Very high Severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation. Failure will occur without - with warningMay endanger machine or assembly operator. Very high Severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation. Failure will occur with HighMajor disruption to production line. 100% of product may have to be scrapped. Vehicle/item inoperable, loss of primary function. Customer very disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Vehicle operable, but at a reduced level of performance.

2 Customer disruption to production line. A portion (less than 100%) of the product may have to be scrapped (no sorting). Vehicle/item operable, but some Comfort/Convenience item(s) inoperable. Customers experience disruption to production line. 100% of the product may have to be reworked. Vehicle/item operable, but some Comfort/Convenience item(s) operable at reduced level of performance. Customer experiences some LowMinor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by most disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average MinorMinor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit & Finish/Squeak & Rattle item does not conform.

3 Defect noticed by discriminating * Note: AIAG is the Automotive Industry Action Group, which currently compiles the FMEA standards for the North American Auto Industry. 2009 The New Excellence Confidential and Proprietary FMEA -- Step 8: AIAG* Occurrence GuidelinesStep 8: AIAG* Occurrence Guidelines * Note: AIAG is the Automotive Industry Action Group, which currently compiles the FMEA standards for the North American Auto of FailureRatesPpkRankingVery High:>1 in 2< almost inevitable1 in 3> : Generally associated with pro-1 in 8> similar to previous processes that have often failed1 in 20> : Generally associated with1 in 80> similar to previous pro-cesses which have experienced1 in 400> failures, but not in major proportions1 in 2,000> : Isolated failures associated with similar processes1 in 15,000> Low: Only isolated failures associated with almost identical processes1 in 150,000> : Failure is unlikely.

4 No failures ever associated with almost<1 in 1,500,000> processes 2009 The New Excellence Confidential and Proprietary FMEA -- Step 10: AIAG* Detection GuidelinesStep 10: AIAG* Detection Guidelines * Note: AIAG is the Automotive Industry Action Group, which currently compiles the FMEA standards for the North American Auto : Likelihood the Existence of a Defect will be Detected by Process Controls Before Next or Subsequent Process, or Before Part or Component Leaves the Manufacturing or Detection Assembly LocationRankingAlmostNo known control available to detect 10 Impossible cause/mechanism of failure or the failure modeVeryVery remote likelihood current control will detect9 Remotecause/mechanism of failure or the failure modeRemoteRemote likelihood current control will detect 8cause/mechanism of failure or the failure modeVeryVery low likelihood current control will detect 7 Lowcause/mechanism of failure or the failure modeLowLow likelihood current control will detect 6cause/mechanism of failure or the failure modeModerate Moderate likelihood current control will detect 5cause/mechanism of failure or the failure modeModerately Moderately high likelihood current control will 4 Highdetect cause/mechanism of failure or the failure modeHighHigh likelihood current control will detect3 cause/mechanism of failure or the failure

5 ModeVeryVery high likelihood current control will detect 2 Highcause/mechanism of failure or the failure modeAlmostCurrent control almost certain to detect 1 Certaincause/mechanism of failure or the failure mode. Reliable detection controls are known withsimilar processes