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FMEA

FMEA is a method to analyze potential failures in products or processes. There are different types including design FMEA (DFMEA) and process FMEA (PFMEA). A DFMEA identifies potential failure modes during the design process and ranks them by impact on the product. A PFMEA identifies potential process failures and ranks them by impact on internal or external customers. An FMEA involves defining potential failures, causes, effects, severity, occurrence, detection, and risk priority numbers (RPNs) to establish priorities for improvement actions. Benefits of FMEA include preventing failures before they happen and improving quality, reliability, and safety.

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Dhivakar S K
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151 views

FMEA

FMEA is a method to analyze potential failures in products or processes. There are different types including design FMEA (DFMEA) and process FMEA (PFMEA). A DFMEA identifies potential failure modes during the design process and ranks them by impact on the product. A PFMEA identifies potential process failures and ranks them by impact on internal or external customers. An FMEA involves defining potential failures, causes, effects, severity, occurrence, detection, and risk priority numbers (RPNs) to establish priorities for improvement actions. Benefits of FMEA include preventing failures before they happen and improving quality, reliability, and safety.

Uploaded by

Dhivakar S K
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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FMEA –Failure Mode and Effect Analysis

FMEA is the analysis of potential failure of a product or process that affects the function
partially or completely
Types of FMEA
• DFMEA – Design
• PFMEA – Process
• Others (Concepts, Systems, Service, etc,.)
Design FMEA
• Design FMEA aids in the design process by identifying known and upcoming
Failure modes and then ranking failures according to relative impact on the product.
• Hence Design FMEA focuses on relative impact of the failure mode on the product
Process FMEA
• Process identifies potential process failure modes by ranking failures and helping to establish
Priorities according to the relative impact on the internal or external customer.
• Hence Process FMEA focuses on relative impact of the failure mode on internal or external
Customer.
Effect Define Cause
Failure mode
S, O, D

Re-calculate Recommended Calculate Control


RPN action, if need. RPN Process

• Severity - Classification of failure by severity of the effects


• Occurrence - How often they occur
• Deduction - How easily can they deducted

RPN (Risk priority number) = Severity X Occurrence X Deduction


• The RPN gives us a relative risk ranking.
• The higher the RPN, the higher the potential risk.
• An organization may decide any RPN above a maximum target of 200 presents
an unacceptable risk and must be reduced.
• Severity will not change, when recalculating RPN.
Stages of FMEA documentation

1) Specifying possibilities 3) Correcting high causes


• Functions • Prioritizing work
• Possible feature modes • Detailing action
• Root causes • Assigning action responsibility
• Effects • Check point on completion
• Deduction / Prevention

2) Quantifying Risk 4) Re-evaluating Risk


• Severity of effect • Recalculation of RPN
• Occurrence of failure (probability of cause)
• Deduction (effectiveness of control to prevent cause)
• RPN (Risk priority number)
FAILURE MODE AND EFFECTS ANALYSIS

FMEA
Responsibility:
Item: number:
Model: Prepared by: Page :
Core FMEA Date
Rev:
Team: (Orig):

Action Results
Potential Responsibility
Potential Potential Current
Process Cla Cause(s)/ Occu Det Recommended and Target
Failure Effect(s) of Sev Process RPN Actions
Function ss Mechanism(s) of r ec Action(s) Completion Sev Occ Det RPN
Mode Failure Controls Taken
Failure Date
FAILURE MODE AND EFFECTS ANALYSIS

Item: Drill Hole Responsibility: AAA FMEA number: 123456


Model: Current Prepared by: BBB Page : 1 of 1
FMEA Date
Rev: 1
Core Team: AAA (Engineering), BBB (Production), CCC (Quality) (Orig): 1/1/2021

Action Results
Potential
Potential Potential Cause(s)/ Current Responsibility and
Process Cl Occu Det Recommended
Failure Effect(s) of Sev Mechanism Process RPN Target
Function ass r ec Action(s)
Mode Failure (s) of Controls Completion Date Actions Taken Sev Oc Det RPN
Failure c

Break
Improper
Drill Blind Hole too through Operator training
7 machine 3 3 63 0
Hole deep bottom of and instructions
set up
plate

Incomplete Improper
Hole not Operator training
thread 5 machine 3 3 45 0
deep enough and instructions
form set up
hole Broken Install Tool
Tool life 5 5 None 9 225 BBB 3/1/2021 5 5 1 25
missing Drill Detectors
0 0
0 0
Benefits of FMEA
• Prevent failures before they happen.
• Identifies where to focus
• Improves the quality, reliability, and safety of the process
• Reduces process development time, cost
• Documents and tracks risk reduction activities
• Helps to identify critical-to-quality characteristics
• Provides historical records; establishes baseline
• Helps increase customer satisfaction and safety

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