FMEA Failure Mode Brainstorm Worksheet
Good scoring depends on a clean failure chain: function, failure mode, effect and cause. This worksheet lets the team brainstorm that chain quickly and edit it freely, before the pressure of rating begins.
| Process step or item | Function or requirement | Failure mode | Effect of failure | Effect level | Potential cause | Source of idea | Discuss first (1 = yes) | |
|---|---|---|---|---|---|---|---|---|
Do not score here. Use this table to get the failure chain right, then move each line into your PFMEA or DFMEA sheet for rating.
Seed your FMEA from ERP scrap data
Optional: we can pull scrap and NCR history by operation into a starter list for your team.
Optional. The tool and every export work without this. No spam.
How to use the worksheet
Work step by step through the process flow. For each step, write the function it must deliver, then ask how it could fail to deliver. For every failure mode, record the effect on the next operation, the plant, the customer or the end user, then list causes. Mark items for early discussion with 1. Export to Excel to paste into your FMEA form.
- One failure mode per row
- Write effects as what someone would notice
- List causes you can act on, not just operator error
- Note the source so the team can trace evidence
The failure chain
In the AIAG-VDA structure, a failure mode belongs to a function, has effects that propagate up to the customer, and has causes that sit lower in the process. Keeping that chain consistent matters more than the number of rows. A failure mode that is really a cause, such as worn tool, produces a confused sheet later.
Where ideas come from
Use real data before opinion: scrap reports, customer complaints, rework logs and the previous FMEA of a similar part. Ask operators what they fix daily. The source column keeps a record so the team can later check whether ratings match evidence. Pulling this data from your ERP, such as NCR or scrap transactions by operation, makes the first session more productive.
Common mistakes
Brainstorming only failures you have already seen leaves the new risks invisible. Writing vague modes such as bad quality cannot be scored. Mixing process and design failures in one table makes ownership unclear. Keep one worksheet per FMEA scope and review it with the process owner before scoring.
Frequently Asked Questions
Is this a replacement for the FMEA form?
No. It is a pre-work table for the failure chain. After agreeing the chain, enter each line into your FMEA form and add ratings, controls and actions.
How many failure modes per step?
As many as are credible, but most steps have two to six. If a step has dozens, split it into smaller steps or check whether you are listing causes as modes.
What is a good effect statement?
One that states what is noticed at the level affected, for example seal leaks at customer assembly. Avoid just writing defect or scrap, which hides the real consequence.
Can I use it for DFMEA?
Yes. Use the item column for the component or interface, the function column for the design requirement and keep the same chain of mode, effect and cause.
If scrap and NCR history are locked in your ERP, Netray can extract them by operation to seed this list. Ask for a quick review.
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