FMEA

What is an FMEA What areas typically use an FMEA and why How to set up an FMEA Steps to generate an FMEA Examples

What is an FMEA
FMEA is a method for identifying potential failure modes and determining their causes and effects and planning for its elimination (or reduction). Failure modes have scores (RPN value) that are calculated based on severity of the failure mode (S), likelihood of occurrence (O), and existing control to detect the failure (D). RPN = S*O*D

Failure Modes and Effects Analysis Elements

FMEA

What are the Failure modes?

What are the Failure Mechanisms?

What Is the Effect on The Customer? How Likely Will It Be Detected Before It Hurts the Customer How Serious Is the Effect

How Probable Is the Failure?

Probability (O)

Consequences (S)

avoidance of detection (D)

What areas typically use an FMEA and why

Manufacturing processes Management Systems Design of new products and processes Service industries to maximize customer satisfaction Defect minimization Identifying Safety Hazards

Each of these areas use FMEA to determine and minimize risk.

FMEA Template
Step Failure Mode Effect of Failure Mode Severity of Effect (1-10) Causes of Failure Likelihood of Cause (1-10) Control to Detect Failure Likelihood of Detection (1-10) RPN

Severity Scoring of FMEA

Effect of Failure Mode Catastrophic with warning Very High High Medium Severity of Effect Failure is catastrophic with warning Between 75%-100% of product is rejected. Customer is immediately lost if defect is detected. 50%-75% of product is rejected. Customer will eventually be lost if other options exist. 25-50% of the product is scrapped without sorting. Customer is aware of the issue and begins looking for other suppliers. 0% of product is rejected. 75%-100% of product reworked. Customer is dissatisfied, but loyal. 50%-75% of product is reworked. Greater than 50% of customers notice the defect if found. 25%-50% of product is re-worked. Between 25%50% of customer notice the defect if found. Less than 25% of product is re-worked. Less than 25% of customers notice the defect if found. No effect Rank 10 9 8 7 6 Catastrophic without warning Failure is catastrophic with no warning

Low Very Low Minor Very Minor None

5 4 3 2 1

Occurrence Scoring of FMEA

Likelihood of Cause Inevitable Very high High Moderately High Moderate Moderately Low Low Very Low Rare Extremely Rare Probability of Cause Between 90%-100% Between 75%-90% Between 50%-75% Between 25%-50% Between 5%-25% Between 1%-5% Between .001%-1% Between .0001%-.001% Between .000001%-.0001% Less than .000001% Rank 10 9 8 7 6 5 4 3 2 1

Detection Scoring of FMEA

Detection Not Detectable Very Rarely Rarely Low Moderately Low Moderate Moderately High High Very High Almost Certain Likelihood that Defect is Detected 0% chance of detecting defect 0%-5% chance of detecting defect 5%-10% chance of detecting defect 10%-25% chance of detecting defect 25%-40% chance of detecting defect 40%-60% chance of detecting defect 60%-75% chance of detecting defect 75%-95% chance of detecting defect 95%-99.999% chance of detecting defect Greater than 99.999% chance of detecting defect Rank 10 9 8 7 6 5 4 3 2 1

Steps to perform an FMEA

Determine the process and failure mode Determine the effect of the failure mode and the severity of the effect using rating scale Determine the causes of the failure and the likelihood using the rating scale Determine the control to detect the failure and the likelihood of detection Calculate the RPN for the failure mode RPN=Severity*Occurrence*Detection. The higher the RPN score the greater the failure mode. The RPN score will be utilized to prioritize the failure modes and develop actions to address their occurrence.

FMEA for Pressure Cooker

Safety Features
1 Weight Valve and Vent Tube
Used as a pressure controller and timing of the pressure cooking

2 Gasket System
Releases the pressure if dead weight fails to act

3 Safety Valve
Acts as a fusible plug when dead weight and gasket system fail to act

4 Proper Handle
for lifting the cooker (including contents) and to be heat resistant

FMEA Example
Step Failure Mode Effect of Failure Mode Must wait for open line Severity of Effect (1-10) 10 (catastrophic) Causes of Failure Likelihood (Occurrence) of Cause (1-10) 3 (very low) Control to Detect Failure Phone usage logs by phone company Budgeting for number of calls received Budgeting for number of calls received Time card system Likelihood of Detection (1-10) 6 (moderately low) 3 (high) RPN

Call 108

All lines are busy

Not enough phone lines Not enough operators

180

5 (moderately low)

150

Call is not answered

Ambulance not dispatched

10 (catastrophic)

Not enough operators

5 (moderately low)

3 (high)

150

All Operators are on lunch break

2 (rare)

2 (very high)

40