Review the Process – Map the process in question, step-by-step, capturing every value added activity.
Identify Failure Modes - For each process step, brainstorm all potential failure modes (things that could go wrong with that particular activity).
List the effects and causes - For each failure mode, list its effect on the output of that process step, and also the real root cause.
Give each item a severity score - Rank each failure mode as to how severe the failure mode could be (scoring 1 to 10).
Give each item an occurrence score - Rank each failure mode as to how often it will / does occur (scoring 1 to 10).
Give each item a detection score - Rank each failure mode as to how easy the failure mode can be detected by the next customer or next internal customer in the process. (Again, scoring 1 to 10).
Calculate RPN numbers - For each failure mode, give it a Risk priority number (RPN) by multiplying the severity score x occurrence score x detection score. This now allows you to focus on the highest scoring, higher risk problems first.
Develop an action plan – For each high scoring RPN, note who is doing what by when to close eliminate the failure modes.
Recalculate new RPNs – Once action has been taken, recalculate the new RPN numbers. Repeat the steps if further action is needed (if the RPN number is still too high)