Failure Mode and Effect Analysis

Failure Mode and Effect Analysis


Jackie Harris, Josh Agusti, and Natasha Sommer

Jackie Harris, Josh Agusti, and Natasha Sommer

ObjectivesObjectives

What is FMEA?Why is an FMEA important?History of FMEABenefits of FMEALimitations of FMEAHow to conduct an FMEA?


Who is in Attendance?Who is in Attendance?

Anyone conducted an FMEA before?

Anyone completed a Risk Analysis Procedure?

Anyone conducted an FMEA before?

Anyone completed a Risk Analysis Procedure?

What is FMEA?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

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




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.

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 TermsFMEA 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.

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 an FMEA?Why do an FMEA?

Preventing problems is cheaper and easier than cleaning them up.

Some things are too risky or costly to incur mistakes.

Preventing problems is cheaper and easier than cleaning them up.

Some things are too risky or costly to incur mistakes.

The Reasons for FMEAThe 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

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:

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

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

BenefitsBenefits

Identify potential and known failures

Reduce the number of engineering changes

Reduce product development timeLower start-up costsGreater customer satisfaction Increased cooperation and

teamwork between various functions

Continuous improvement

Identify potential and known failures

Reduce the number of engineering changes

Reduce product development timeLower start-up costsGreater customer satisfaction Increased cooperation and

teamwork between various functions

Continuous improvement

HistoryHistory

An offshoot of Military Procedure MIL-P-1629, titled Procedures for Performing a Failure Mode, Effects and Criticality Analysis, dated November 9, 1949.

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 1960’s to improve and verify reliability of space program hardware.

An offshoot of Military Procedure MIL-P-1629, titled Procedures for Performing a Failure Mode, Effects and Criticality Analysis, dated November 9, 1949.

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 1960’s to improve and verify reliability of space program hardware.

Concept FMEAConcept 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.

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 FMEADesign 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

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 FMEAProcess 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

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 FMEATypes of FMEA

Resources NeededResources Needed

Commitment of top managementKnowledgeable individuals Individuals attentive to FMEA

timelinesPeople resources may be internal

or external to the business or a combination of both

Commitment of top managementKnowledgeable individuals Individuals attentive to FMEA

timelinesPeople resources may be internal

or external to the business or a combination of both

FMEA TimingFMEA 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

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

AdvantagesAdvantages

Enhance design and manufacturing efficiencies

Alleviate late change crisesMinimize exposure to product

failuresAugment business records Improve “bottom line” resultsAdd to customer satisfaction

Enhance design and manufacturing efficiencies

Alleviate late change crisesMinimize exposure to product

failuresAugment business records Improve “bottom line” resultsAdd to customer satisfaction

LimitationsLimitations

Employee training requirements Initial impact on product and

manufacturing schedulesFinancial impact required to

upgrade design, manufacturing, and process equipment and tools

▪These limitations should be recognized and treated as short term and minimal interruptions to a business.

Employee training requirements Initial impact on product and

manufacturing schedulesFinancial impact required to

upgrade design, manufacturing, and process equipment and tools

▪These limitations should be recognized and treated as short term and minimal interruptions to a business.

Risk Assessment FactorsRisk Assessment Factors

Severity (S): A number from 1 to 5, depending on the severity of the potential failure mode’s effect 1 = no effect5 = maximum severity

Probability of occurrence (O): A number from 1 to 5, depending on the likelihood of the failure mode’s occurrence1 = very unlikely to occur5 = almost certain to occur

Severity (S): A number from 1 to 5, depending on the severity of the potential failure mode’s effect 1 = no effect5 = maximum severity

Probability of occurrence (O): A number from 1 to 5, depending on the likelihood of the failure mode’s occurrence1 = very unlikely to occur5 = almost certain to occur

Risk Assessment FactorsRisk 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 detention5 = impossible to detect

Risk Priority Number (RPN): The failure mode’s 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).

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 detention5 = impossible to detect

Risk Priority Number (RPN): The failure mode’s 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 NumberRisk Priority Number

http://upload.wikimedia.org/wikipedia/commons/3/32/FMEA.png

Procedures for FMEAProcedures for FMEA

Necessity

“Process

Function”

Problem

“Failure Mode”

Effects How bad is it?

“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread

No PB


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread

No PB Jelly Sandwich


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread


5/5


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread


5/5 Out of Stock

Past Expiration


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread


5/5 Out of Stock

Past Expiration

2/5


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread


5/5 Out of Stock

Past Expiration

2/5 10


Necessity

“Process

Function”

Problem

“Failure Mode”


“Severity”

Causes How Likely?

“Occurrence”

Score Steps to

Prevent

Put PB on bread


5/5 Out of Stock

Past Expiration

2/5 10 Check Pantry

Check Expiration Date

Conduct an FMEAConduct an FMEA

Conduct a process FMEA on a paper airplane

Build a paper airplaneConduct a design FMEA on your

paper airplanePaper Airplane Competition

Conduct a process FMEA on a paper airplane

Build a paper airplaneConduct a design FMEA on your

paper airplanePaper Airplane Competition

ConclusionConclusion



ReferencesReferences

Lean Six Sigma - http://www.leansixsigma.com/

Stunell Technology - http://www.stunell.com/images/fmea.jpg

Lean Six Sigma - http://www.leansixsigma.com/

Stunell Technology - http://www.stunell.com/images/fmea.jpg

http://www.leansixsigma.com/

http://www.leansixsigma.com/

Documents

Failure Mode and Effect Analysis