FMEA / RPN Calculator
Free Failure Mode and Effects Analysis tool — calculate RPN, rank risks, and prioritize corrective actions
FMEA / RPN Calculator
Rating Scale (1-10)
Complete Guide to FMEA
What is FMEA?
Failure Mode and Effects Analysis (FMEA) is a systematic methodology for identifying potential failure modes, their causes, and effects. It uses the Risk Priority Number (RPN) to prioritize which failures need corrective action first.
RPN = Severity × Occurrence × DetectionRating Scales
- Severity (S): 1 = No effect → 5 = Moderate → 10 = Hazardous without warning
- Occurrence (O): 1 = Nearly impossible → 5 = Moderate → 10 = Very high (>1 in 2)
- Detection (D): 1 = Almost certain detection → 5 = Moderate → 10 = No detection possible
RPN ranges from 1 (lowest risk) to 1000 (highest risk)
RPN Action Thresholds
| RPN Range | Risk Level | Required Action |
|---|---|---|
| 200 - 1000 | Critical | Immediate corrective action required |
| 120 - 199 | High | Corrective action should be prioritized |
| 80 - 119 | Medium | Plan corrective action |
| 1 - 79 | Low | Monitor — action may not be required |
FAQ
What are the types of FMEA?
Design FMEA (DFMEA) focuses on product design failures. Process FMEA (PFMEA) focuses on manufacturing process failures. System FMEA analyzes complete systems. IATF 16949 requires both DFMEA and PFMEA for automotive suppliers.
Is RPN still the best way to prioritize risk?
The AIAG-VDA FMEA handbook (2019) moved away from RPN to an Action Priority (AP) table that considers severity first. However, RPN remains widely used and is still a valid risk ranking tool for most industries.