| ID | Process step | Function | Failure mode | Effect | Severity | Cause | Prevention | Occurrence | Detection control | Detection rating | RPN | Action | Owner | Target date | Status |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| PF01 | P01 assemble/verify Capture door | Capture door | Door rebounds after entry | Mouse escapes; repeated handling increases bite exposure | 7 | Assembly/configuration error: Hinge rebound and latch misalignment | Add positive over-center latch and keyed hinge pin | 5 | Cycle rig then 5 N outward retention pull | 6 | 210 | Fixture/configuration lock and independent check for Capture door | Sam Reed | 2026-12-15 | Planned only |
| PF02 | P02 assemble/verify Ventilation ribs | Ventilation ribs | Air paths blocked by nesting material | Confined mouse distress or death | 9 | Assembly/configuration error: Vents all located on floor near bait | Raise vents on opposing walls; add no-bedding instructions | 4 | Occlude either vent bank with paper surrogate; inspect remaining airflow path | 7 | 252 | Fixture/configuration lock and independent check for Ventilation ribs | Sam Reed | 2026-12-15 | Planned only |
| PF03 | P03 assemble/verify Release slider | Release slider | Finger enters closing-door path | Pinch or bite during release | 8 | Assembly/configuration error: Grip next to opening and no positive open detent | Extend external slider and add hold-open detent | 4 | Video-record unloaded representative-user task | 6 | 192 | Fixture/configuration lock and independent check for Release slider | Sam Reed | 2026-12-15 | Planned only |
| PF04 | P04 assemble/verify Washable shell | Washable shell | Soiled corners retain contamination | User exposure to rodent waste | 8 | Assembly/configuration error: Blind corners and poor disassembly | Round internal corners; detach door cassette; hygiene instructions | 5 | Fluorescent soil inspection after hand wash; biological efficacy not claimed | 6 | 240 | Fixture/configuration lock and independent check for Washable shell | Sam Reed | 2026-12-15 | Planned only |
| PF05 | P05 assemble/verify Bait pocket | Bait pocket | Bait holder detaches | Small-part ingestion by child or pet | 9 | Assembly/configuration error: Uncaptured insert fits through entrance | Integrate pocket into shell; no loose insert | 3 | Force gauge pull and foreseeable misuse inspection | 6 | 162 | Fixture/configuration lock and independent check for Bait pocket | Sam Reed | 2026-12-15 | Planned only |
| PF06 | P06 assemble/verify Occupancy inspection | Occupancy inspection | User leaves occupied trap unchecked | Animal dehydration and distress | 9 | Assembly/configuration error: Trap hidden and no inspection habit | Transparent inspection window; explicit do-not-leave-unattended warning | 6 | 10-user visibility/teach-back study; no live animals before ethical review | 8 | 432 | Fixture/configuration lock and independent check for Occupancy inspection | Sam Reed | 2026-12-15 | Planned only |
Sample — fictitious company. All numbers and people are invented scenario assumptions. This is draft concept paperwork; no physical testing, customer evidence, certification, filing or sign-off has occurred.