Failure Mode and Effect Analysis

PRESENTED BY M.MAHENDRAN
Objectives
What is FMEA
Why is an FMEA important
History of FMEA
Benefits of FMEA
Limitations of FMEA
How to conduct an FMEA

FOR OUR AWARENESS
Anyone conducted an FMEA before
Anyone completed a Risk Analysis Procedure?
What is FMEA
A systemized group of activities designed to:
recognize and evaluate the potential failure of
a product/process and its effects
identify actions which could eliminate or
reduce the chance of potential failure
document the process
Failure Mode and Effect Analysis
Failure Mode and Effect Analysis
Simply put FMEA is:
a process that identifies all the possible types
of failures that could happen to a product and
potential consequences of those failures.

FMEA Terms
Failure mode - the way in which something
might fail

Effects analysis studying the consequences
of the various failure modes to determine
their severity to the customer.
Why do We need an FMEA
Preventing problems is cheaper and easier
than cleaning them up.
Some things are too risky or costly to incur
mistakes.
The Reasons for FMEA
Get it right the first time
Indentifies any inadequacies in the development of
the product
Tests and trials may be limited to a few products
Regulatory reasons
Continuous improvement
Preventive approach
Team building
Required procedures
FMEA Provides the Potential to:
Reduce the likelihood of customer complaints
Reduce the likelihood of campaign changes
Reduce maintenance and warranty costs
Reduce the possibility of safety failures
Reduce the possibility of extended life or
reliability failures
Reduce the likelihood of product liability claims
Benefits
Identify potential and known failures
Reduce the number of engineering
changes
Reduce product development time
Lower start-up costs
Greater customer satisfaction
Increased cooperation and teamwork
between various functions
Continuous improvement
History
.
Used as a reliability evaluation technique to determine
the effect of system and equipment failures.
Failures were classified according to their impact on
mission success and personnel/equipment safety.
Formally developed and applied by NASA in the 1960s to
improve and verify reliability of space program hardware.

Concept FMEA
Used to analyze concepts in the early stages before
hardware is defined (most often at system and
subsystem)
Focuses on potential failure modes associated with
the proposed functions of a concept proposal
Includes the interaction of multiple systems and
interaction between the elements of a system at the
concept stages.

Design FMEA
Aid in the objective evaluation of design
requirements and design alternatives
Aid in the initial design for manufacturing and
assembly
Increase the probability that potential failure
modes have been considered
Provide additional information to aid in the
planning of efficient design testing
Process FMEA
Indentify potential product related process failure
modes
Assess the potential customer effects of the failures
Indentify the potential manufacturing causes on
which to focus on
Develop a ranked list of potential failure modes
Document the results of the manufacturing


Types of FMEA
Resources Needed
Commitment of top management
Knowledgeable individuals
Individuals attentive to FMEA timelines
People resources may be internal or external
to the business or a combination of both
FMEA Timing
FMEA should be updated:
at the conceptual stage
when changes are made to the design
when new regulations are instituted
when customer feedback indicates a
problem
Advantages
Enhance design and manufacturing
efficiencies
Alleviate late change crises
Minimize exposure to product failures
Augment business records
Improve bottom line results
Add to customer satisfaction
Limitations
Employee training requirements
Initial impact on product and manufacturing
schedules
Financial impact required to upgrade design,
manufacturing, and process equipment and
tools



Risk Assessment Factors
Severity (S): A number from 1 to 5, depending on the severity of
the potential failure modes effect
1 = no effect
5 = maximum severity

Probability of occurrence (O): A number from 1 to 5, depending
on the likelihood of the failure modes occurrence
1 = very unlikely to occur
5 = almost certain to occur

Risk Assessment Factors
Probability of detection (D): A number from 1 to 5, depending on
how unlikely it is that the fault will be detected by the system
responsible (design control process, quality testing, etc.)
1 = nearly certain detention
5 = impossible to detect

Risk Priority Number (RPN): The failure modes risk is found by
the formula RPN = S x O x D. RPN = Severity x Probability of
Occurrence x Probability of Detection. RPN will be a number
between 1 (virtually no risk) and 125 (extreme risk).

Risk Priority Number
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB Jelly Sandwich
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB Jelly Sandwich 5/5
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB Jelly Sandwich 5/5 Out of Stock

Past
Expiration
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB Jelly Sandwich 5/5 Out of Stock

Past
Expiration
2/5
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB Jelly Sandwich 5/5 Out of Stock

Past
Expiration
2/5 10
Procedures for FMEA
Necessity

Process
Function
Problem

Failure
Mode
Effects How bad
is it?

Severity
Causes How Likely?

Occurrence
Score Steps to
Prevent
Put PB on
bread
No PB Jelly Sandwich 5/5 Out of Stock

Past
Expiration
2/5 10 Check
Pantry

Check
Expiration
Date

Conduct an FMEA
Conduct a process FMEA on a paper airplane
Build a paper airplane
Conduct a design FMEA on your paper
airplane
Paper Airplane Competition



Conclusion-Now we know the
following
What is FMEA
Why is an FMEA important
History of FMEA
Benefits of FMEA
Limitations of FMEA
How to conduct an FMEA