The aim of this paper is to develop an effective risk prioritization method to improve the traditional FMEA
process. This paper has focused on the design FMEA to improve current design process and to ensure high quality
and reliability of the products. Based on the data presented, two failure modes were found to give identical RPN
values and there was a disagreement in ranking scale for three failure modes. The data were analyzed and
proposed a modified risk prioritization methodology to deal with subjective and qualitative nature of information
in design FMEA. The result obtained demonstrates the inherent potential of the modified prioritization of failure
modes, when the team has a disagreement in the ranking scale. The statistical analysis package like MINITAB
program was used for the data analysis and validation. The case studies presented in this paper resolves the
following limitations of traditional FMEA technique;
If two or more failure modes have the same RPN value, it is possible to prioritize the failure modes with
the help of Risk Priority Code (RPC).
RPN range helps to prioritize the failure modes, when the team has a disagreement in the ranking value
for severity, occurrence and detection indexes.