The failure mode occurrence enumeration defines a six-level scale (0-5) rating how frequently a failure mode is expected to occur.
Occurrence uses percentage-based probability ranges, from Never (<5%) to Always (>95%), with a dedicated Unanalyzed (0) level for tracking incomplete assessments.
Default. Failure mode occurrence has not yet been assessed.
1
1
Never
< 5%
Failure mode is highly improbable under expected conditions
2
2
Seldom
5% — 25%
Failure mode may occur in a small fraction of units or uses
3
3
Sometimes
25% — 75%
Failure mode occurs in a significant portion of units or uses
4
4
Often
75% — 95%
Failure mode is expected in most units or uses
5
5
Always
> 95%
Failure mode occurs in virtually every unit or use
Failure modes default to occurrence = 0 (Unanalyzed), explicitly marking items that have not been assessed. Since RPN = S x 0 x D = 0, unanalyzed items will have an RPN of zero and should be reviewed during FMEA completion checks.
Occurrence is one of three factors in the Risk Priority Number:
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Severity (S) Occurrence (O) Detection (D) 1-5 x 1-5 x 1-5 = RPN (1-125) How severe is How often does How likely is the the effect? the failure occur? failure detected?
Example: A failure mode with Severity=4 (High), Occurrence=3 (Sometimes), Detection=2 (Seldom detected) yields:
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RPN = 4 x 3 x 2 = 24
After implementing a design change that reduces occurrence to 1 (Never):
The solution includes a cascade mapping (subType_-__fmOccurrence) that can filter available occurrence values based on the design requirement subtype. This enables contextual FMEA scoring where the valid occurrence range depends on the engineering discipline:
Design Requirement SubType
Available Occurrence Values
Operation
Filtered set per configuration
Software
Filtered set per configuration
Design
Filtered set per configuration
Use
Filtered set per configuration
System
Filtered set per configuration
Process
Filtered set per configuration
The subtype-to-occurrence cascade is a many-to-many mapping — each subtype can map to multiple occurrence levels. This acts as a filter rather than a restriction, guiding assessors toward appropriate occurrence ratings for their discipline.