How do you calculate the swage force risk score?

Multiply each rating by its weight and add them: severity times 0.40, occurrence times 0.35, detection times 0.25. With scores of 6, 4, and 3 the weighted risk score is 4.55.

How is this different from a standard FMEA RPN?

A classic RPN multiplies severity, occurrence, and detection equally. This model weights them (0.40/0.35/0.25) so high-severity swaging failures rank higher, giving a more decision-useful ranking.

What is a high swaging risk score?

On a 1-10 rating scale the weighted score also runs about 1-10. Around 4.55 is moderate; scores driven by high severity (8-10) demand action regardless of how detectable the defect is.

Why is severity weighted more than detection?

Because a failure that hurts safety or function matters more than one that's merely hard to catch. The 0.40 severity weight ensures those failure modes rise to the top of the swaging FMEA.

How do I score detection for a swaging defect?

Higher detection scores mean the defect is harder to catch before it reaches the customer. A robust inline gauge lowers the score; a defect only found at final assembly raises it.

Can I use this score to compare different swaging failure modes?

Yes — that's its purpose. Score each failure mode the same way and rank by the weighted result; the highest scores, like ones above 6-7, head the corrective-action list.

Tube, Pipe & Profile Forming calculator

Swage Force Estimate Calculator

This tool turns the three classic FMEA ratings — severity, occurrence, and detection — into a single weighted risk score for tube swaging operations. Quality and process engineers in tube and profile forming use it to prioritize which swaging failure modes to attack first, from cracked ends to undersized reductions. Unlike a plain RPN that just multiplies the three, this weighted model emphasizes severity most, then occurrence, then detection, so safety- and function-critical failures rise to the top. The result is a defensible, repeatable ranking for your swaging process FMEA and corrective-action queue.

What this calculator does

This tool turns the three classic FMEA ratings — severity, occurrence, and detection — into a single weighted risk score for tube swaging operations.
Use it when swage force estimate in tube, pipe and profile forming needs a defensible ranking against other tube, pipe and profile forming risks for the next review.
It computes a weighted swaging risk score as severity times 0.40 plus occurrence times 0.35 plus detection times 0.25.

Formula used

Swage Force Estimate risk score = severity × 0.40 + occurrence × 0.35 + detection × 0.25

Inputs explained

Swage defect severity rating:
Swage defect occurrence rating:
Swage defect detection rating:

How to use the result

Use it during a swaging process FMEA, a PPAP risk review, or when triaging which forming defects to correct first.
Scores are subjective ordinal ratings, so the number ranks and prioritizes failure modes but is not a physical force or an absolute probability of failure.

Current U.S. benchmarks

The producer price index for steel mill products stands at 348.53 (BLS, May 2026), up 6.7% from a year earlier. Quotes priced off last quarter's material cost miss this move.

Common questions

How do you calculate the swage force risk score? Multiply each rating by its weight and add them: severity times 0.40, occurrence times 0.35, detection times 0.25. With scores of 6, 4, and 3 the weighted risk score is 4.55.
How is this different from a standard FMEA RPN? A classic RPN multiplies severity, occurrence, and detection equally. This model weights them (0.40/0.35/0.25) so high-severity swaging failures rank higher, giving a more decision-useful ranking.
What is a high swaging risk score? On a 1-10 rating scale the weighted score also runs about 1-10. Around 4.55 is moderate; scores driven by high severity (8-10) demand action regardless of how detectable the defect is.
Why is severity weighted more than detection? Because a failure that hurts safety or function matters more than one that's merely hard to catch. The 0.40 severity weight ensures those failure modes rise to the top of the swaging FMEA.
How do I score detection for a swaging defect? Higher detection scores mean the defect is harder to catch before it reaches the customer. A robust inline gauge lowers the score; a defect only found at final assembly raises it.

Last reviewed 2026-05-12.