Failure Mode Effect Analysis (FMEA)

Training Program
on

FMEA
Failure Mode and Effects Analysis

Presented by : - Mr. Deepak Sahoo
Prepared by :- Mr. Deepak Sahoo , Consultant

Day Plan @ 5th Jan 2013.
Start time – 10.15 AM End Time : 1 PM

FMEA Part 1 – 10.15 AM – 11.45 PM
FMEA Part 2 – 12.15 PM - 01.00 PM

Break time @ 11.45 PM for 30 minutes

FMEA Part - 1 Break FMEA Part - 2


Agenda
 FMEA History
 What is FMEA
 Definitions
 What it Can Do For You
 Types of FMEA
 Team Members Roles
 FMEA Terminology
 Getting Started with an FMEA
 The Worksheet
 FMEA Scoring


Why we need FMEA video


Do it right the first time.

Why does it
always seem we
have plenty of
time to fix our
problems, but
never enough
time to prevent
the problems by
doing it right
the first time?


Accident Rate in Aviation industry.
The 2011 global accident rate (measured in
hull losses per million flights) was 0.37,
the equivalent of one accident every 2.7
million flights.
ACCIDENT RATE IN AVIATION INDUSTRY
8
7 7.41
6
5
4
3
2
1.87
1
0.1 0.45 0.34 0.8 0.72
0
NORTH EUROPE NORTH ASIA- MIDDLE LATIN AFRICA
AMERICA ASIA PACIFIC EAST AND AMERICA
NORTH
AFRICA Data collected from IATA.
http://www.iata.org/pressroom/pr/pages/2011-02-23-01.aspx


Murphy’s Law

“Everything that can fail, shall fail”
This is known as Murphy’s Law and is one of the main reasons
behind the FMEA technique.

Consequently, during the design of a system or product, the
designer must always think in terms of:

 What could go wrong with the system or process?
 How badly might it go wrong?
 What needs to be done to prevent failures?


The Bathtub curve


FMEA Video - 1


How it Origin ?
• This “type” of thinking has been around for hundreds of
years. It was first formalized in the aerospace industry
during the Apollo program in the 1960’s.
• Department of Defense developed and revised the MIL-STD-
1629A guidelines during the 1970s.
• Ford Motor Company published instruction manuals in the
1980s and the automotive industry collectively developed
standards in the 1990s.


What is FMEA ?
• FMEA Stands for Failure mode effect Analysis.

• FMEA is a tool that allows you to:
• Prevent System, Product and Process problems before
they occur
• Reduce costs by identifying system, product and process
improvements early in the development cycle
• Create more robust processes
• Prioritize actions that decrease risk of failure
• Evaluate the system, design and processes from a new
vantage point


A Systematic Process
FMEA provides a systematic process to:

 Identify and evaluate
potential failure modes
potential causes of the failure mode
 Identify and quantify the impact of potential failures
 Identify and prioritize actions to reduce or eliminate the
potential failure
 Implement action plan based on assigned responsibilities
and completion dates
 Document the associated activities


Published Guidelines
• J1739 from the SAE for the automotive industry.
• AIAG FMEA-3 from the Automotive Industry Action Group
for the automotive industry.
• ARP5580 from the SAE for non-automotive applications.

Other industry and company-specific guidelines exist. For
example:
• EIA/JEP131 provides guidelines for the electronics
industry, from the JEDEC/EIA.
• P-302-720 provides guidelines for NASA’s GSFC
spacecraft and instruments.
• SEMATECH 92020963A-ENG for the semiconductor
equipment industry.


Rule of Ten (10)
If the issue costs $10,000 when it is discovered in the field,
then…

It may cost $1000 if discovered during the final test…

But it may cost $100 if discovered during an incoming
inspection.

Even better it may cost $10 if discovered during the design or
process engineering phase.


Benefits of FMEA.
Contributes to improved designs for products and
processes.
 Higher reliability
 Better quality
 Increased safety
 Enhanced customer satisfaction
 Contributes to cost savings.
 Decreases development time and re-design costs
 Decreases warranty costs
 Decreases waste, non-value added operations
 Contributes to continuous improvement


Type of FMEAs.
System/Concept “S/CFMEA”- (Driven by System functions) A system
is a organized set of parts or subsystems to accomplish one or more
functions. System FMEAs are typically very early, before specific hardware
has been determined.

Design “DFMEA”- (Driven by part or component functions) A Design /
Part is a unit of physical hardware that is considered a single replaceable
part with respect to repair. Design FMEAs are typically done later in the
development process when specific hardware has been determined.

Process “PFMEA”- (Driven by process functions & part characteristics)
A Process is a sequence of tasks that is organized to produce a product or
provide a service. A Process FMEA can involve fabrication, assembly,
transactions or services.


FMEA Terminology 1
1.) Failure Modes: (Specific loss of a function) is a concise description of
how a part , system, or manufacturing process may potentially fail to
perform its functions.
2.) Failure Mode “Effect”: A description of the consequence or
Ramification of a system or part failure. A typical failure mode may have
several “effects” depending on which customer you consider.
3.) Severity Rating: (Seriousness of the Effect) Severity is the numerical
rating of the impact on customers.
4.) Failure Mode “Causes”: A description of the design or process
deficiency (global cause or root level cause) that results in the failure
mode.
5.) Occurrence Rating: Is an estimate number of frequencies or
cumulative number of failures (based on experience) that will occur (in our
design concept) for a given cause over the intended “life of the design”.


FMEA Terminology 2
6.) Failure Mode “Controls”: The mechanisms, methods, tests,
procedures, or controls that we have in place to PREVENT the Cause of the
Failure Mode or DETECT the Failure Mode or Cause should it occur.
7.) Detection Rating: A numerical rating of the probability that a given
set of controls WILL DISCOVER a specific Cause of Failure Mode to
prevent bad parts leaving the facility or getting to the ultimate customer.
8.) Risk Priority Number (RPN): Is the product of Severity,
Occurrence, & Detection.
Risk= RPN= S x O x D
9.) Action Planning: A thoroughly thought out and well developed
FMEA With High Risk Patterns that is not followed with corrective actions
has little or no value, other than having a chart for an audit


FMEA Video - 2


FMEA Process
Step 1 - Select a process to evaluate
Step 2 - Recruit a multidisciplinary Team
Step 3 - Have the team meet to list all the steps in the process
Step 4 - Have the team list failure modes and causes
Step 5 For each failure mode have the team assign a numeric
value (Risk Priority Number (RPN)) for likelihood of
occurrence, likelihood of detection and severity.
Step 6 - Evaluate the results - Identify the failure modes with
the top 10 highest RPNs.
Step 7 - Use RPNs to plan improvement efforts


The FMEA Team Roles
Champion / Sponsor
Provides resources & support
Attends some meetings
Promotes team efforts
Shares authority / power with team
Kicks off team
Implements recommendations

FMEA Core Team Facilitator
Team Leader 4 – 6 Members “Watchdog“ of the process
“Watchdog” of the project
Good leadership skills Keeps team on track
Expertise in Product / Process FMEA Process expertise
Respected & relaxed Cross functional
Leads but doesn’t dominate Encourages / develops team dynamics
Honest Communication Communicates assertively
Maintains full team participation Active participation
Typically lead engineer Ensures everyone participates
Positive attitude
Respects other opinions
Participates in team decisions

Recorder
Keeps documentation of teams efforts
FMEA chart keeper
Coordinates meeting rooms/time
Distributes meeting rooms & agendas

21

Risk Priority Number(RPN)

RPN = Severity x Occurrence x Detection
 RPN is used to prioritize concerns/actions
 The greater the value of the RPN the greater the concern
 RPN ranges from 1-1000
 The team must make efforts to reduce higher RPNs through
corrective action
 General guideline is over 100 = recommended action


RPN Considerations
Rating scale example:
Severity = 10 indicates that the effect is very serious and is “worse”
than Severity = 1.
Occurrence = 10 indicates that the likelihood of occurrence is very
high and is “worse” than
Occurrence = 1.
Detection = 10 indicates that the failure is not likely to be detected
before it reaches the end user and is “worse” than Detection = 1.

RPN ratings are relative to a particular analysis.
An RPN in one analysis is comparable to other RPNs in the same
analysis …but an RPN may NOT be comparable to RPNs in another
analysis.

Risk Guidelines


Occurrence Ranking


Detection Ranking


FMEA Video - 3


Exercise (Perform A DFMEA on a pressure cooker)


Pressure Cooker Safety Features
1. Safety valve relieves pressure before it reaches dangerous
levels.
2. Thermostat opens circuit through heating coil when the
temperature rises above 250° C.
3. Pressure gage is divided into green and red sections.
"Danger" is indicated when the pointer is in the red section.
Pressure Cooker FMEA
Define Scope:
1. Resolution - The analysis will be restricted to the four major
subsystems (electrical system, safety valve, thermostat, and
pressure gage).
2. Focus - Safety

Pressure cooker block diagram


Inputs for FMEA
 Process flow diagram
 Assembly instructions
 Design FMEA
 Current engineering drawings and specifications
 Data from similar processes
 Scrap
 Rework
 Downtime
 Warranty

Process Function Requirement
Brief description of the manufacturing process or operation
The PFMEA should follow the actual work process or sequence,
same as the process flow diagram etc.

Team Members for a FMEA
 Process engineer
 Manufacturing supervisor
 Operators
 Quality
 Safety
 Product engineer
 Customers
 Suppliers


Assumptions & Potential Failure Mode
 The design is valid
 All incoming product is to design specifications
 Failures can but will not necessarily occur

Potential Failure Mode
 How the process or product may fail to meet design or
quality requirements
 Many process steps or operations will have multiple failure
modes
 Think about what has gone wrong from past experience and
what could go wrong

Common & Potential Failure Modes
Assembly Machining Drilling holes
Missing parts Too narrow Missing
Damaged Too deep Location
Orientation Angle incorrect Deep or shallow
Contamination Finish not to Over/under size
Off location specification Concentricity
Flash or not cleaned angle
Sealant
Torque
Loose or over torque Missing

Missing fastener Wrong material applied
Insufficient or excessive
Cross threaded
material
Dry

Potential Effects
• End user • Next operation
• Noise • Cannot assemble
• Leakage • Cannot tap or bore
• Odor • Cannot connect
• Poor appearance • Cannot fasten
• Endangers safety • Damages equipment
• Loss of a primary • Does not fit
function • Does not match
• performance • Endangers operator


Severity Ranking
How the effects of a potential failure mode may impact the
customer
Only applies to the effect and is assigned with regard to any
other rating

 Potential effects of failure
 Severity
 Cannot assemble bolt(5)
 Endangers operator(10)
 Vibration (6)

Take the highest effect ranking (10)

Potential Causes
Equipment Operator
• Tool wear • Improper torque
• Inadequate pressure • Selected wrong part
• Worn locator • Incorrect tooling
• Broken tool • Incorrect feed or
• Gauging out of speed rate
calibration • Mishandling
• Inadequate fluid • Assembled upside
levels down
• Assembled
backwards


Occurrence Ranking

 How frequent the cause is likely to occur
 Use other data available
 Past assembly processes
 SPC
 Warranty
 Each cause should be ranked according to the
guideline


Detection

 Probability the defect will be detected by process
controls before next or subsequent process, or
before the part or component leaves the
manufacturing or assembly location
 Likely hood the defect will escape the
manufacturing location
 Each control receives its own detection ranking,
use the lowest rating for detection


RPN
 RPN provides a method for a prioritizing process concerns
 High RPN’s warrant corrective actions
 Despite of RPN, special consideration should be given when
severity is high especially in regards to safety
 An RPN is like a medical diagnostic, predicting the health of
the patient
 At times a persons temperature, blood pressure, or an EKG
can indicate potential concerns which could have severe
impacts or implications


Recommended actions

Control

Influence

Can’t control or influence at this time


Recommended actions
Definition: tasks recommended for the purpose of reducing
any or all of the rankings

Examples of Recommended actions

Perform:
Process instructions
Training
Can’t assemble at next station
Visual Inspection
Torque Audit


FMEA Video - 4


FMEA Video - 5


Thank You !!!!

Any
Questions?
Connect With Me @
Mobile :- +974 – 3370 8982
Email :- dksahoo2@gmail.com
LinkedIn :- www.linkedin.com/in/dksahoo

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