Does a score of 72 mean 72% risk?

No. The product is a relative priority number from ordinal ratings. It has no probability or percentage interpretation.

Can this replace a scale-up trial?

No. It organizes review of a documented failure mode. Mixer performance, heat transfer, material behavior, and product quality still require appropriate engineering and trial evidence.

What if our worksheet uses another rating scale?

Use the method required by that worksheet. This calculator accepts only the traditional three ratings from 1 to 10, with higher detection values meaning harder detection.

Does a low score clear a severe failure?

No. Review severity separately under your procedure. Different rating combinations can produce the same product score, concealing very different consequences.

Paint, Resin & Polymer Compounding calculator

Batch Scale-Up FMEA Priority Calculator

Prioritize one documented scale-up failure mode with traditional FMEA scoring. Copy severity, occurrence, and detection-difficulty ratings from your approved worksheet and enter its review trigger.

What this calculator does

Calculate the traditional review priority for one documented scale-up failure mode using your approved FMEA ratings.

Formula used

Risk priority number = severity × occurrence × detection difficulty
Displayed ratings = entered worksheet ratings
Trigger margin = review trigger − risk priority number

Inputs explained

Severity Rating: Approved worksheet rating: 1 least severe, 10 most severe.
Occurrence Rating: Approved worksheet rating: 1 least frequent, 10 most frequent.
Detection Difficulty Rating: Approved worksheet rating: 1 easiest detection, 10 hardest detection.
Review Trigger: Review threshold from your approved failure-mode prioritization procedure.

How to use the result

Best suited to scale-up failure-mode review, control improvement prioritization.
Ordinal ratings do not produce failure probability, expected loss, or process qualification. This traditional product score does not implement an Action Priority lookup table.

Current U.S. benchmarks

The producer price index for plastic resins and materials stands at 280.569 (BLS, Aug 2026), up 6.6% from a year earlier. Quotes priced off last quarter's material cost miss this move.
Industrial electricity averages 9.77 cents per kWh across the U.S. (EIA, Jul 2026), up 4.7% from a year earlier. Energy-intensive steps carry this directly into unit cost.
The producer price index for industrial chemicals stands at 336.006 (BLS, Aug 2026), up 13.3% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 14,543 chemical manufacturing establishments employing about 911,245 workers (Census County Business Patterns, 2023).

Common questions

Does a score of 72 mean 72% risk? No. The product is a relative priority number from ordinal ratings. It has no probability or percentage interpretation.
Can this replace a scale-up trial? No. It organizes review of a documented failure mode. Mixer performance, heat transfer, material behavior, and product quality still require appropriate engineering and trial evidence.
What if our worksheet uses another rating scale? Use the method required by that worksheet. This calculator accepts only the traditional three ratings from 1 to 10, with higher detection values meaning harder detection.
Does a low score clear a severe failure? No. Review severity separately under your procedure. Different rating combinations can produce the same product score, concealing very different consequences.

Last reviewed 2026-10-01.