| 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 | Jordan Vale | 2027-06-15 | 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 | Jordan Vale | 2027-06-15 | 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 | Jordan Vale | 2027-06-15 | 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 | Jordan Vale | 2027-06-15 | 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 | Jordan Vale | 2027-06-15 | 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 | Jordan Vale | 2027-06-15 | Planned only |
| PF07 | P07 assemble/verify Entry baffle | Entry baffle | Second mouse opens occupied chamber | Escape or animal injury | 8 | Assembly/configuration error: One-way baffle back-driven from inside | Separate entry vestibule with anti-backdrive stop | 5 | Probe each chamber loaded with surrogates in 50 cycles | 7 | 280 | Fixture/configuration lock and independent check for Entry baffle | Jordan Vale | 2027-06-15 | Planned only |
| PF08 | P08 assemble/verify Occupancy sensor | Occupancy sensor | False empty status | User neglects occupied enclosure | 9 | Assembly/configuration error: Dust fouls optical beam | Use independent beam and weight checks; show uncertain as occupied | 5 | Injected beam blockage, drift and stuck-value cases | 8 | 360 | Fixture/configuration lock and independent check for Occupancy sensor | Jordan Vale | 2027-06-15 | Planned only |
| PF09 | P09 assemble/verify Wi-Fi alert queue | Wi-Fi alert queue | Alert never arrives | Delayed inspection harms captured animal | 9 | Assembly/configuration error: Router outage or mobile notification disabled | Offline local indicator; queued alerts and no-cloud-needed manual checks | 6 | Router loss/reconnect and phone permission fault injection | 8 | 432 | Fixture/configuration lock and independent check for Wi-Fi alert queue | Jordan Vale | 2027-06-15 | Planned only |
| PF10 | P10 assemble/verify BLE provisioning | BLE provisioning | Nearby stranger pairs to trap | Unauthorized control and household occupancy disclosure | 8 | Assembly/configuration error: Shared default credentials and insecure pairing | Authenticated pairing; expiring setup window; no shared password | 5 | Threat-model-led unauthorized pairing attempts on test build | 8 | 320 | Fixture/configuration lock and independent check for BLE provisioning | Jordan Vale | 2027-06-15 | Planned only |
| PF11 | P11 assemble/verify Firmware updater | Firmware updater | Corrupt update disables occupancy indication | Occupied trap appears inactive | 9 | Assembly/configuration error: Power loss during single-bank flashing | Signed dual-bank firmware with rollback and independent indicator | 4 | Interrupt update at 20 points; confirm last known good boot | 8 | 288 | Fixture/configuration lock and independent check for Firmware updater | Jordan Vale | 2027-06-15 | Planned only |
| PF12 | P12 assemble/verify Rechargeable pack | Rechargeable pack | Battery overheats during charging | Burn or fire | 10 | Assembly/configuration error: Unprotected cell, wet connector, charger fault | Protected replaceable pack; keyed certified-candidate charger; thermal cutoff | 4 | Specialist battery fault evaluation; no destructive tests by unqualified users | 8 | 320 | Fixture/configuration lock and independent check for Rechargeable pack | Jordan Vale | 2027-06-15 | Planned only |
| PF13 | P13 assemble/verify Electronics cassette | Electronics cassette | Wash water reaches PCB | Shock from faulty adapter or overheating | 9 | Assembly/configuration error: Electronics not removed before wash | Separate dry cassette with keyed seal and wash label | 5 | Assembly interlock test and controlled splash screen; no IP rating claimed | 7 | 315 | Fixture/configuration lock and independent check for Electronics cassette | Jordan Vale | 2027-06-15 | Planned only |
| PF14 | P14 assemble/verify Account and cloud | Account and cloud | Household presence patterns retained | Privacy loss after breach | 7 | Assembly/configuration error: Unbounded timestamp retention | Local-first alerts; minimal pseudonymous event data; documented deletion | 5 | Review data flows and test account deletion across backups | 8 | 280 | Fixture/configuration lock and independent check for Account and cloud | Jordan Vale | 2027-06-15 | Planned only |
| PF15 | P15 assemble/verify Radio module integration | Radio module integration | Host changes invalidate RF assumptions | Blocked market access or interference | 9 | Assembly/configuration error: Antenna/layout differs from module conditions | Freeze antenna/layout; RF lab review before launch | 5 | Host pre-scan and authorization-path review; results not performed | 8 | 360 | Fixture/configuration lock and independent check for Radio module integration | Jordan Vale | 2027-06-15 | Planned only |
| PF16 | P16 assemble/verify Crowded chamber | Crowded chamber | Animals compete or overheat | Injury to trapped animals | 9 | Assembly/configuration error: Capacity inferred from volume without welfare evidence | Independent compartments and ventilation; inhibit further entry if full | 5 | Surrogate occupancy/thermal analysis first; ethical live study only if approved | 8 | 360 | Fixture/configuration lock and independent check for Crowded chamber | Jordan Vale | 2027-06-15 | Planned only |
| PF17 | P17 assemble/verify Wall-side deployment carriage | Wall-side deployment carriage | Carriage crushes hand or pet | Crush/pinch injury | 9 | Assembly/configuration error: Uncommanded extension from base | Guard pinch points and torque-limit drive; positive travel stops | 5 | Test 20 surrogate obstruction positions with power isolated emergency stop | 8 | 360 | Fixture/configuration lock and independent check for Wall-side deployment carriage | Jordan Vale | 2027-06-15 | Planned only |
| PF18 | P18 assemble/verify Payload coupler | Payload coupler | Trap falls from drone | Impact injury and animal escape | 10 | Assembly/configuration error: Latch incompletely seated or sensor stuck | Captive redundant latch and diverse seated sensors | 5 | Static 5x proposed payload proof test plus single-fault latch injection | 8 | 400 | Fixture/configuration lock and independent check for Payload coupler | Jordan Vale | 2027-06-15 | Planned only |
| PF19 | P19 assemble/verify Propeller guards | Propeller guards | Person reaches rotor | Laceration | 10 | Assembly/configuration error: Accessible rotor at wall dock | Full guards; hardware arm inhibit; emergency motor stop | 5 | Articulated probe and arm-inhibit single-fault tests | 7 | 350 | Fixture/configuration lock and independent check for Propeller guards | Jordan Vale | 2027-06-15 | Planned only |
| PF20 | P20 assemble/verify Navigation estimator | Navigation estimator | GNSS error causes flyaway | Collision or loss of live payload | 10 | Assembly/configuration error: Multipath near building and stale map | Independent supervisor; no public flight in sample phase | 5 | Hardware-in-loop injected 20 m position jumps and stale fixes | 9 | 450 | Fixture/configuration lock and independent check for Navigation estimator | Jordan Vale | 2027-06-15 | Planned only |
| PF21 | P21 assemble/verify Mission battery | Mission battery | Energy exhausted on return | Crash and stranded animal | 10 | Assembly/configuration error: Payload/wind underestimated | Energy budget check before takeoff; abort to safe landing | 6 | Simulate doubled return energy and degraded pack capacity | 8 | 480 | Fixture/configuration lock and independent check for Mission battery | Jordan Vale | 2027-06-15 | Planned only |
| PF22 | P22 assemble/verify Command link | Command link | Bluetooth/phone loss leaves uncontrolled mission | Collision or unsafe release | 10 | Assembly/configuration error: Phone assumed to be safety controller | Independent flight controller and local abort plan | 5 | Disconnect phone, radio and cloud separately in simulation | 9 | 450 | Fixture/configuration lock and independent check for Command link | Jordan Vale | 2027-06-15 | Planned only |
| PF23 | P23 assemble/verify Field release door | Field release door | Door opens in flight | Falling animal and loss of containment | 10 | Assembly/configuration error: Software release request at wrong phase | Hardware ground/motor interlock plus software sequence checks | 4 | Inject release command in every mission phase; verify inhibited | 8 | 320 | Fixture/configuration lock and independent check for Field release door | Jordan Vale | 2027-06-15 | Planned only |
| PF24 | P24 assemble/verify Release destination | Release destination | Release occurs on unsuitable land | Animal harm, trespass or rule violation | 9 | Assembly/configuration error: User selects arbitrary field | Approved destination registry; human review before mission enable | 7 | Review jurisdiction and destination documents; no destination approved | 9 | 567 | Fixture/configuration lock and independent check for Release destination | Jordan Vale | 2027-06-15 | Planned only |
| PF25 | P25 assemble/verify Aircraft operation scope | Aircraft operation scope | Unattended route exceeds permitted operation | Injury exposure and regulatory violation | 10 | Assembly/configuration error: Autonomy marketed as unrestricted household convenience | Research-only simulation; human-supervised feasibility path with trained operator | 7 | FAA operational applicability review including line-of-sight and authorization questions | 9 | 630 | Fixture/configuration lock and independent check for Aircraft operation scope | Jordan Vale | 2027-06-15 | Planned only |
| PF26 | P26 assemble/verify Remote ID equipment | Remote ID equipment | Aircraft identity function absent or invalid | Operation not ready for intended regime | 9 | Assembly/configuration error: Carrier integration changes identity configuration | Qualified aircraft/Remote ID integration review; do not infer exemption | 5 | Bench configuration and record review; no registration asserted | 8 | 360 | Fixture/configuration lock and independent check for Remote ID equipment | Jordan Vale | 2027-06-15 | Planned only |
| PF27 | P27 assemble/verify Charging dock contacts | Charging dock contacts | Dock charges misaligned or damaged pack | Thermal runaway/fire near wall | 10 | Assembly/configuration error: Contact debris and failed temperature sensor | Enclosed contacts; current limiting and sensor disagreement shutdown | 5 | Specialist fault injection of short, misalignment and sensor open | 8 | 400 | Fixture/configuration lock and independent check for Charging dock contacts | Jordan Vale | 2027-06-15 | Planned only |
| PF28 | P28 assemble/verify Weather monitor | Weather monitor | Launch in rain or strong gust | Loss of control and wet animal | 10 | Assembly/configuration error: No environmental gate and stale weather input | Local weather interlock; fail closed on missing/stale reading | 6 | Hardware-in-loop gust and missing-sensor scenarios | 8 | 480 | Fixture/configuration lock and independent check for Weather monitor | Jordan Vale | 2027-06-15 | Planned only |
| PF29 | P29 assemble/verify Autonomy cybersecurity | Autonomy cybersecurity | Malicious command changes destination | Unsafe flight or household surveillance | 10 | Assembly/configuration error: Unsigned mission and permissive remote control | Secure boot; signed missions; least-privilege command channels | 5 | Replay, tamper and privilege escalation tests in isolated rig | 9 | 450 | Fixture/configuration lock and independent check for Autonomy cybersecurity | Jordan Vale | 2027-06-15 | Planned only |
| PF30 | P30 assemble/verify Return docking | Return docking | Drone misses wall dock and retries near person | Rotor collision or trapped animal delay | 10 | Assembly/configuration error: Visual marker occluded or dock moved | Independent dock fiducial check; keep-out zone and supervised abort | 6 | Simulate moved dock, marker occlusion and blocked return path | 8 | 480 | Fixture/configuration lock and independent check for Return docking | Jordan Vale | 2027-06-15 | 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.