Brake System Risk Analysis
Risk Matrix
Risk Summary
Risk Level Distribution
Top Risk Items
RPN Threshold
100Risk Priority Number (RPN) Calculation
| ID | Function | Failure Mode | Severity | Occurrence | Detection | RPN | Risk Level | Actions | |
|---|---|---|---|---|---|---|---|---|---|
|
F1
|
Convert driver input
|
Pedal resistance too high
|
6 | 4 | 3 | 72 | High |
|
|
Risk AssessmentCurrent Controls Pedal force testing, lubrication Risk Evaluation High risk due to moderate occurrence and severity with relatively good detection capability Recommended Actions Redesign pedal pivot with lower friction material, adjust return spring tension Mitigation Plan
Material Change
In Progress
Replace current pivot material with PTFE-based composite
Due: July 25, 2025
Owner: Robert Chen
Spring Adjustment
Completed
Reduce return spring tension by 15%
Completed: June 28, 2025
Owner: Sarah Johnson
|
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|
F1.1
|
Amplify force
|
Insufficient mechanical advantage
|
7 | 3 | 2 | 42 | Medium |
|
|
Risk AssessmentCurrent Controls Pedal ratio verification, durability testing Risk Evaluation Medium risk due to high severity but low occurrence and good detection capability Recommended Actions Optimize pedal ratio to provide 5:1 mechanical advantage, implement wear-resistant pivot materials Mitigation Plan
Pedal Ratio Optimization
Planned
Redesign pedal geometry to achieve consistent 5:1 ratio
Due: August 15, 2025
Owner: Michael Thompson
|
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|
F1.2
|
Generate pressure
|
Internal leakage in master cylinder
|
9 | 3 | 4 | 108 | High |
|
|
Risk AssessmentCurrent Controls Pressure testing, seal material selection Risk Evaluation High risk due to critical severity despite low occurrence rate Recommended Actions Improve seal material durability, implement enhanced cylinder bore surface finish requirements Mitigation Plan
Enhanced Seal Material
In Progress
Implement high-durability EPDM compound seals
Due: July 30, 2025
Owner: Jennifer Wu
Surface Finish Improvement
Planned
Enhance cylinder bore surface finish from 16 Ra to 8 Ra
Due: August 20, 2025
Owner: David Park
|
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|
F2
|
Distribute hydraulic pressure
|
External fluid leakage
|
10 | 2 | 5 | 100 | Critical |
|
|
Risk AssessmentCurrent Controls Pressure testing, corrosion protection, secure mounting Risk Evaluation Critical risk due to maximum severity rating despite low occurrence probability Recommended Actions Implement double-flare connections, use corrosion-resistant materials, add protective coatings Mitigation Plan
Connection Upgrade
In Progress
Implement double-flare connections throughout system
Due: July 15, 2025
Owner: Thomas Garcia
Corrosion Protection
Completed
Apply zinc-nickel coating to all hydraulic line components
Completed: June 20, 2025
Owner: Lisa Anderson
Protective Shielding
Planned
Add protective shields in high-risk areas
Due: August 10, 2025
Owner: Kevin Rodriguez
|
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|
F3
|
Maintain fluid reservoir
|
Fluid contamination
|
7 | 4 | 6 | 168 | Critical |
|
|
Risk AssessmentCurrent Controls Fluid quality testing, cap seal design Risk Evaluation Critical risk due to combination of high severity, moderate occurrence and low detection capability Recommended Actions Improve reservoir cap seal design, add contamination indicator, enhance service instructions Mitigation Plan
Improved Cap Design
In Progress
Redesign cap with triple-seal technology
Due: July 20, 2025
Owner: Emily Nguyen
Contamination Indicator
Planned
Add visual fluid quality indicator in reservoir
Due: September 5, 2025
Owner: Ryan Mitchell
Service Documentation
Completed
Update service manual with enhanced fluid handling procedures
Completed: June 15, 2025
Owner: Amanda Taylor
|
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|
F4
|
Provide fail-safe operation
|
Failure detection system malfunction
|
8 | 2 | 3 | 48 | Low |
|
|
Risk AssessmentCurrent Controls System self-test, redundant sensors Risk Evaluation Low risk due to good detection capability and low occurrence despite high severity Recommended Actions Implement dual sensor system, add system self-test at vehicle startup, improve electrical connection design Mitigation Plan
Dual Sensor Implementation
Planned
Install redundant sensors with separate circuits
Due: August 30, 2025
Owner: Christopher Lee
Startup Self-Test
In Progress
Implement comprehensive system self-test at vehicle startup
Due: July 18, 2025
Owner: Stephanie Wilson
|
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