Failure Mode And Effects Analysis Worksheet
A structured FMEA worksheet for industrial maintenance teams to systematically identify potential failure modes, evaluate risks via Severity, Occurrence, and Detection scores, and prioritize corrective actions.
This FMEA worksheet template enables reliability teams to systematically document each function of a system, identify potential failure modes, describe their effects and root causes, list current controls, and assign Severity (S), Occurrence (O), and Detection (D) ratings. The resulting Risk Priority Number (RPN = S × O × D) highlights the most critical failure modes. Use the pass/fail column to flag any RPN above your organisation's threshold (e.g., > 100 requires action). The corrective action log tracks follow-up tasks.
- Lockout/Tagout required when accessing guarded components for data collection.
- Up-to-date process and instrumentation diagrams for the system under analysis.
- Cross-functional team: operator, maintenance technician, and reliability engineer.
Inspection / FMEA Matrix
| Status (P/F) | Function / Process Step | Potential Failure Mode | Effect of Failure | Cause of Failure | Current Controls | S | O | D | RPN | Threshold |
|---|---|---|---|---|---|---|---|---|---|---|
| [ ] Pass [ ] Fail | Coolant pump supplies fluid to cutting head | Pump seizes due to cavitation | Overheating of cutting head, production stop | Low coolant level or clogged inlet filter | Level sensor alarm, weekly filter inspection | 7 | 5 | 4 | 140 | 100 |
| [ ] Pass [ ] Fail | Conveyor belt moves parts to packaging | Belt misalignment | Jamming, product damage, downtime | Worn tracking guides, debris buildup | Monthly alignment check, periodic cleaning | 6 | 4 | 3 | 72 | 100 |
| [ ] Pass [ ] Fail | Hydraulic press applies 5‑ton force | Pressure drop below 5000 psi | Insufficient forming, scrap parts | Piston seal wear, pump inefficiency | Daily pressure log, annual seal replacement | 8 | 3 | 5 | 120 | 100 |
Scoring: Severity (1‑10), Occurrence (1‑10), Detection (1‑10). RPN = S × O × D. Mark "Fail" if RPN exceeds the threshold (default 100).
Defect / Corrective Action Log
| Date / Time | Item # | Issue Identified | Corrective Action Taken | WO # |
|---|---|---|---|---|
| ___/___/_____ | 1 | Coolant pump RPN 140 exceeds threshold. Review filter cleaning frequency. | Increase filter inspection to weekly; install pressure gauge. | WO-0731 |
| ___/___/_____ | 2 | Hydraulic press RPN 120. Seal wear suspected. | Schedule piston seal replacement next shutdown. | WO-0732 |
By signing below, the FMEA team leader verifies that the analysis was conducted according to the procedure, all failure modes were reviewed, and corrective actions are assigned.