Failure Modes and Effects Analysis

(FMEA)

Present by
Mr. Kittiwat Sirikasemsuk

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

1 ,CU-KMITL 2 ,CU-KMITL

FMEA Form – 6 Sigma Definition of FMEA

„ FMEA is a systematic technique

S O D R
Process Actions
Potential Failure Mode Potential Failure Effects E Potential Causes C Current Controls E P
Step/Input Recommended
V C T N
How often does cause
How Severe is the
effect to the

How well can you

detect cause or FM?
cusotmer?

or FM occur?

What is the In what ways does the Key What is the impact on the Key What causes the Key Input to What are the existing controls and What are the actions

for assessing the risks associated

process step/ Input go wrong? Output Variables (Customer go wrong? procedures (inspection and test) for reducing the
Input under Requirements) or internal that prevent eith the cause or the occurrance of the
investigation? requirements? Failure Mode? Should include an Cause, or improving
SOP number. detection? Should

with defective products reaching

have actions only on
high RPN's or easy
fixes.

0 the marks.
0

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

3 ,CU-KMITL 4 ,CU-KMITL

Usefulness Objective.
1. Review and analysis product / process when
„ Overall Aspect : For quality assurance revise or make new.
early , which prevent or reduce failure
modes and cause of defective. 2. Anticipate failure and cause which may
occur from experience and team work.
„ Product/Process Aspect : A disciplined
3. Specify risk and priority RPN.
review and analysis of a new or revised
product/process is promoted to anticipate, 4. Reduce RPN by eliminated that cause
resolve or monitor potential problems formerly.
within the product or process. 5. Provides a discipline/methodology for
Created by Kittiwat Sirikasemsuk
documenting Created by Kittiwat Sirikasemsuk
5 ,CU-KMITL 6 ,CU-KMITL

1
 Characteristics of FMEA Characteristics of FMEA
1. Prioritizes Potential Failures according 3. By its self, an FMEA is not a problem solve.
to their risk and drives actions to It is used in combination with other problem
eliminate or reduce their likelihood of solving tools “The FMEA presents the
occurrence.
opportunity but does not solve the
problem.”
2. Provides a discipline/methodology for
documenting this analysis for future use Process Flowchart , C&E Diagram ,
and continuous process improvement. Pareto Diagram , Action Plan ,
Team Work Management, Risk Management
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
7 ,CU-KMITL 8 ,CU-KMITL

Special Characteristics
Involution
Analysis Risk
„ In reality, FMEA is such a basic tool that Effects of failure Severity
any model to investigate Reliability,
Reliability
Maintainability or Safety cannot be
completed without FMEA at some stage. Causes Occurrence

Current controls or Detection

design verification
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
9 ,CU-KMITL 10 ,CU-KMITL

Implementation
Note
„ An FMEA utilizes occurrence and Choice 1 : Correction
detection probability in conjunction with => Problem Solving
severity criteria to develop a Risk Priority
Number(RPN) for prioritization of Choice 2 : Prevention
corrective action considerations. => None of Problem yet.
Note to achieve the maximum benefit,
RPN = S x O x D organization need to conduct FMEAs
before a failure is unknowingly instituted
Created by Kittiwat Sirikasemsuk into a process or design. Created by Kittiwat Sirikasemsuk
11 ,CU-KMITL 12 ,CU-KMITL

2
 Where is FMEA used?

„ QS 9000 , Big Three(Chryler, Ford Motor, General Motors)

„ APQP Manual (Advanced Product Quality Planning)
„ ISO/TS 16949 , IATF
(International Automotive Task Force)

„ DMAIC , Six Sigma

The Role of FMEA in a QS
„ Product / Process Design
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
13 ,CU-KMITL 14 ,CU-KMITL

QS9000 Tool

Created by Kittiwat Sirikasemsuk

15 ,CU-KMITL

APQP
ISO/TS16949

Created by Kittiwat Sirikasemsuk

18 ,CU-KMITL

3
 S4 Types of FMEA

System Design Process Service

Components Components Manpower Man / HR
Subsystems Subsystems Machine Machine
Mainsystem Mainsystem Method Method
Material Material
Focus : Minimize failures Measurement Measurement
Environment Environment

Created by Kittiwat Sirikasemsuk

Note The most people separate FMEA to be Created by Kittiwat Sirikasemsuk
19 Phase of Smart Six Sigma Solution.(S4) ,CU-KMITL two
20 type in Automotive. (DFMEA & PFMEA) ,CU-KMITL

Add explanation Caution!

„ FMEA for System :
is used to analysis mainsystem and
subsystem in step early. Do not mix :
FMEA for Design :
„

is used to analysis product before do

DFMEA with PFMEA
manufacturing.
„ FMEA for Process :
is used to analysis process manufacturing
and assembly. Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
21 ,CU-KMITL 22 ,CU-KMITL

Automotive FMEA Timeline Automotive FMEA Timeline

„ DFMEA :
Design FMEA Process FMEA Start early in process.Complete by the
time preliminary drawing are done but
before any tooling is initiated.
„ PFMEA :

Concept Design go- Design Prototype Eng./Mfg. Production Start as soon as basic manufacturing
ahead completion build Sign off start
methods have been discussed. Complete
prior to finalizing production plans and
releasing for production.
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
23 ,CU-KMITL 24 ,CU-KMITL

4
 Relationship of system, design, Origins mid-1960’s FMECA
and process FMEA.
Failure Modes Effect cause
System The ramifications The Problem The causes of the
FMEA of the problem. problem.

Design
The causes of the The effects from the New root causes
problem from the system FMEA with for the design
FMEA system FMEA.. a better definition. failure modes.

Process The causes of the The same effects as Specific root causes
problem from the the design FMEA of the process
FMEA design FMEA.. failure modes.
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
25 ,CU-KMITL 26 : Failure Mode Effects and Criticality Analysis.
FMECA ,CU-KMITL

Origins Criticality Matrix.

•About using Criticality Matrix.
mid-1960’s FMECA •Aerospace of NASA in Apollo 4
and Navy US. Military.
•Addressed safety issues.
3

end-1980’s FMEA •About using RPN 2

•using in Automotive Industrial.

•For the reliability analysis. O 1

now FMEA •using almost all Industrial Type. 1

S
2 3 4 5

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

27 : Failure Mode Effects and Criticality Analysis.
FMECA ,CU-KMITL 28 ,CU-KMITL

Set Team before make FMEA.

„ Team should / may consist of

„ Design Engineer,
„ Manufacturing Engineer,
„ Assembly Engineer,

„ Quality Engineer,

„ Reliability Engineer,

„ and else which people are related with it.

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

29 ,CU-KMITL 30 ,CU-KMITL

5
 Creating an FMEA
1. Set the level of the analysis.
2. Learn about the design/process.
Perspective - draw functional diagram/process flowchart.
Perspective 3. Describe the desired functions or process.
4. List / Identify the Item-Function for DFMEA
or Process Function-Requirements for PFMEA.
5. List all potential failure modes.
6. Identify the effect(s) of each failure mode.
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
31 ,CU-KMITL 32 ,CU-KMITL

Creating an FMEA (continue)

Title
7. List all possible causes of each failure mode. DFMEA

8. List the current controls of each cause, if have.

9. Give severity, occurrence and detection rating.
10. Multiply these together to give RPN
PFMEA
11. Rank by RPN and state recommended action,
and responsibilities.
12. Revise RPN in line with completed actions.

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

33 ,CU-KMITL 34 ,CU-KMITL

DFMEA Title PFMEA Title

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

35 ,CU-KMITL 36 ,CU-KMITL

6
 Setting the level of analysis.

1. Setting the level of analysis.

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

37 ,CU-KMITL 38 ,CU-KMITL

Setting the level of analysis. •The fundamental problem with FMEA is that,
being a “Bottom-Up” technique.
System
1 2 3 4
Level
Failure Mode
Failure Effect
Subsystem
1 2 3
Level
Failure Mode
Failure Effect
Component
1 2 3
Level
Created by Kittiwat Sirikasemsuk Failure Mode FailureMode
Failure Mode
Created by Kittiwat Sirikasemsuk
39 ,CU-KMITL 40 ,CU-KMITL

Design Block Diagram Example

If the product function is
complex, break it down. 2. Learn about
System Body
the design/process.

Sub-System Doors Exterior Window Interior

- draw functional diagram/process flowchart.
Component Door Inner Glass Sealing Latch /
Panel with Strip Lock

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

41 ,CU-KMITL 42 ,CU-KMITL

7
 Mechanical System

evaporator

Circuit Diagram

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

43 ,CU-KMITL 44 ,CU-KMITL

Assembly Drawing I Assembly Drawing II

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

45 ,CU-KMITL 46 ,CU-KMITL

Process
Flow Chart
/ Mapping
9. Give severity, occurrence
and detection rating.

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

47 ,CU-KMITL 48 ,CU-KMITL

8
 Severity
Occurrence

Note : Severity will not change

when
49 do FMEA finish.
Created by Kittiwat Sirikasemsuk
,CU-KMITL 50
Created by Kittiwat Sirikasemsuk
,CU-KMITL

Detection Example RPN

S O D
9 1 1

1 9 1

1 1 9
Note : Select RPN more than 90 to correct.

51
Created by Kittiwat Sirikasemsuk
,CU-KMITL 52 : RPN Maximum is 1000. Created by Kittiwat Sirikasemsuk
,CU-KMITL

This case Process Flow Chart

Example PFMEA

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

53 ,CU-KMITL 54 ,CU-KMITL

9
 Show detail or function.
1. Receive material is the first step for this process. When we
receive ingot of Aluminium grade Si 9 % ,Cu 3 %, next we will check
quality of material to ahead for standard and check quantity to follow
ordering.
2. Melting is procedure to transform ingot to be liquefy of
Aluminium by melting by a electricity blast furnace, then do cleaning
Aluminium by filling flux Subsequent, is transportation to next station.
4. Decorate is procedure for beautify work product after injection
which have three step so that file, trimming hole and shot blast.
5. Packing will bring finish product into the tray and will check
quality lastly and quantity
6. Stock is an arrangement of finish product to go at inventory.

3. Diecasting is procedure to inject liquid to be work product by 7. Delivery is transfer of finish product into customer.
injection machinery no. DC 350 T.
Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk
55 ,CU-KMITL 56 ,CU-KMITL

EX. C&E Diagram

Station2. Al Melting &Molten Al transferred Addition :http://www.fmeca.com/ffsoft/download.htm

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

57 ,CU-KMITL 58 ,CU-KMITL

FMEA : ( AFTER ACTION TAKEN )

FMEA : ( BEFORE ACTION TAKEN )

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

59 ,CU-KMITL 60 ,CU-KMITL

10
 Reference
1. “Failure Modes and Effects Analysis Reference Manual”, Big Three

Show PFMEA 2.
3.
“Failure Mode and Effect Analysis”, บ.แอลวีเอ็ม (เอเชีย) จํากัด , กรุงเทพฯ
“Six Sigma for Shopfloor Management”, บ.ซีเกทเทคโนโลยี (ประเทศไทย) จํากัด
สาขาโคราช
4. “Failure Mode and Effect Analysis”, www.16949.com
5. Breyfogle, Forrest W., “Implementing Six Sigma : Smarter Solutions Using
Statistical Methods”, John Wiley & Sons, Canada, c1946
6. รศ. ดํารง ทวีแสงสกุลไทย , “Failure Mode and Effect Analysis”, ซีตประกอบการ
สอนวิชา Quality Engineering Techniques
7. รศ.ดร. ปารเมศ ชุติมา , “Failure Mode and Effect Analysis”, ซีตประกอบการสอน
Created by Kittiwat Sirikasemsuk
วิชา PPD Created by Kittiwat Sirikasemsuk
61 ,CU-KMITL 62 ,CU-KMITL

Deming Prize

Thank you for listening.

Created by Kittiwat Sirikasemsuk Created by Kittiwat Sirikasemsuk

63 ,CU-KMITL 64 ,CU-KMITL

11