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Abstract--- The study has attempted to present an effective an engineering design, production process and new product in
tool for solving the problem of manufacturing process quality planning and production sphere in product life cycle. Purpose
by executing process FMEA with proposed process control of FMEA is founding links between causes and effects of
practices. This paper aims to identify and eliminate current defects, as well as searching, solving and drawing the best
and potential problems from a manufacturing process of decisions regarding solicitation of applicable action.
cylinder head in the company through the application of
Failure Mode and Effects Analysis (FMEA) for improving the II. LITERATURE REVIEW
reliability of sub systems in order to ensure the quality which In 1950s the increasing attention paid to safety and the
in turn enhances the bottom line of a manufacturing industry. need to prevent predictable accidents in aerospace industry led
Thus the various possible causes of failure and their effects to the development of the FMEA methodology. Later, it was
along with the prevention are discussed in this work. Severity introduced as key tool for increasing quality and efficiency in
values, Occurrence number, Detection and Risk Priority manufacturing processes [10]. In 1977, Ford Motors
Number (RPN) are some parameters, which need to be introduced FMEA to address the potential problems in the
determined. Furthermore, some actions are proposed which Research and Development (R&D) in the early stage of
require to be taken as quickly as possible to avoid potential production and published the Potential Failure Mode and
risks which aid to improve efficiency and effectiveness of Effects Analysis Handbook in 1984 to promote the method.
cylinder head manufacturing processes and increase the Later on the automobile manufacturers in America also
customer satisfaction. The prevention suggested in this paper introduced the FMEA into the management of suppliers, and
can considerably decrease the loss to the industry in term of took it as a key check issue [13]. Find out reasons behind the
both money time and quality. failure of some subjects of mechanical engineering course and
Keywords--- Cylinder Head, Failure Mode Effect Analysis, after analyzed the system through FMEA and they suggested
Potential Effect of Failure, Potential Failure Mode, Risk recommend to solve the problem [15]. Execute FMEA to
Priority Number develop an effective quality system and to improve the current
production processfor the better quality of the products [14].
Applied FMEA model in salmon processing and packing
industry in joint with ISO 22000 and they got the valuable
I. INTRODUCTION result from implementation [7].The FMEA has the potential to
H. Current Design Control • Typical actions are design of experiments, revised test
The control activities generally include Prevention plans, revised material specifications, revised design
Measures, Design Validation, and Design Verification etc.
Supported by physical tests, mathematical modeling, • Important to mark “None” in case of no
prototype testing, and feasibility reviews etc. recommendation for future use of FMEA document.
I. Detection L. Responsibilities and Completion Dates
• Relative measures of the ability of design control to Individual or group responsible for the recommended
detect wither a potential cause/mechanism or the actions and target completion date to be entered.
subsequent failure mode before production. M. Actions Taken
• Supported by physical tests, mathematical modeling,
Brief descriptions of the action taken to be entered after
prototype testing, feasibility reviews etc.
actual actions are taken by the team.
Table 3: Table of Detection
N. Revised RPN
Detection Rank Criteria Recalculation of Severity, Occurrence and Detection
Can be corrected prior to
Extremely rankings after implementation of recommended actions and
1 prototype/ Controls will almost
Likely thus calculation of revised RPN.
certainly detect
Can be corrected prior to design Revised RPN=revised (Severity× Occurrence × Detection)
Very High
2 release/Very High probability of
Likelihood
detection V. FMEA PROCEDURE [6]
High Likely to be corrected/High
3 The process for conducting FMEA can be divided into
Likelihood probability of detection
Moderately following steps. These steps are briefly explained as follows.
Design controls are moderately
High 4
Likelihood
effective • Step 1: Collect the functions of system and build a
Medium Design controls have an even hierarchical structure. Divide the system into several
5 subsystems, having number of components.
Likelihood chance of working
Moderately • Step 2: Determine the failure modes of each
Design controls may miss the
Low 6 component and its effects. Assign the severity rating
problem
Likelihood (S) of each failure mode according to the respective
Low Design controls are likely to miss effects on the system.
7
Likelihood the problem • Step 3: Determine the causes of failure modes and
Very Low Design controls have a poor estimate the likelihood of each failure occurring.
8
Likelihood chance of detection
Assign the occurrence rating (O) of each failure mode
Very Low Unproven, unreliable design/poor
9 according to its likelihood of occurrence.
Likelihood chance for detection
Extremely No design technique • Step 4: List the approaches to detect the failures and
10 evaluate the ability of system to detect the failures
Unlikely available/Controls will not detect
prior to the failures occurring. Assign the detection
J. Risk Priority Numbers (RPN) rating (D) of each failure mode.
RPN is the indicator for the determining proper corrective • Step 5: Calculate the risk priority number (RPN) and
action on the failure modes. It is calculated by multiplying the establish the priorities for attention.
severity, occurrence and detection ranking levels resulting in a • Step 6: Take recommended actions to enrich the
scale from 1 to 1000.After deciding the severity, occurrence performance of system.
and detection numbers, the RPN can be easily calculated by • Step 7: Conduct FMEA report in a tabular form.
multiplying these 3 numbers: RPN = Severity × Occurrence ×
Detection. The small RPN is always better than the high RPN. VI. CASE STUDY AND FMEA ANALYSIS
The RPN can be computed for the entire process and/or for the
design process only. Once it is calculated, it is easy to A cylinder head is the closed, and often detachable, end of
determine the areas of greatest concern. The engineering team a cylinder located in an internal combustion engine. It is
generates the RPN and focused to the solution of failure typically found on the top portion of the engine block as
modes. shown in Figure 1.
K. Recommended Actions
Beginning with high RPN and working in descending
order
• The objective is to reduce one or more of the criteria
that make up the RPN.
The cylinder head is an integral component of internal • Front & rear side face finish
combustion engines. It conveys air and gasoline to the • Top Side
combustion chamber and serves as a cover for the cylinders. • Bottom Side
The main function of the cylinder head is to help the head • Inlet & Exhaust face Drilling
gasket seal the cylinders properly so that they are able to • Water Outlet Face Drilling
build enough compression for engine operation. • Core Plug Drilling
In the vast majority of four stroke engines, the cylinder • Injector Bore etc.
head mounts the entire valve gear and provides the basic Criteria for ranking of severity occurrence and detection
framework for housing the valves as well as the spark plugs are selected suitably by analyzing the past failure records of
and injectors. the machine. Firstly, the basic requirements of the
Case study is conducted and FMEA technique is applied manufacturing processes are studied and then the potential
to the cylinder head manufacturing process industry. There failure mode of the specific process is found out. After that
are various operation and processes carried out by various the potential effects of the failure mode are noted with their
machine for manufacturing cylinder head. Facing, drilling severity value. The occurrence value for the potential
and tapping are the main manufacturing operations of the causes and their prevention is also calculated. The
cylinder head. Following manufacturing operations are Detection value is assigned to the failure mode and finally
carried out on the cylinder head: the R.P.N value is calculated. The sample calculations are if
S = 4, O = 3, & D = 4
• Bottom Face Finish
Then, R.P.N = S × O × D = 4 × 3 ×4 = 48
• Top Face Finish
• Inlet & Exhaust face finish FMEA Chart of Cylinder head is shown in Table 4.
Table 4: Process FMEA
PROCESS FAILURE MODE AND EFFECT ANALYSIS
Part / Product No. : X-Cylinder Head Key Contact Person :*** Doc. No. : X/FMEA/**
Part / Product Description : Engine Cylinder Head Key Contact : **** Rev. No. :
Customer Name (If any) : *** Core Team : **** Revision Date :
Customer Drawing No. (If any) : ***
Other Details (if any) :
Potential Current Current
Operation Process Potential Potential
Effect of SEV. OCC. Control Control DET. RPN
No. Description Failure Mode Causes
Failure Prevention Detection
Improper
Inprocess
Height ± Smoke Setting,
Process inspection
then problem, Fuel 6 Improper 2 3 36
drawing, (inspect 1
specification problem material
1 Bottom work after 5)
removal
Face Finish instruction,
Fitment Improper
Flatness out first piece
problem & setting, 100 %
of 6 2 inspection 1 12
functional Improper tool inspection
specification
problem select
Oil leakage Improper
Inprocess
Height ± problem, Setting,
Process inspection
then Function 6 Improper 2 3 36
drawing, (inspect 1
specification problem at material
2 Top Face work after 5)
customer end removal
Finish instruction,
Fitment Improper
Flatness out first piece
problem & setting, 100 %
of 2 inspection 1 12
functional Improper tool inspection
specification
problem select
Deburring, Inprocess
Cleaning, Functional inspection
Dust & Rust Improper work
18 Inspection, problem at 6 2 & pre- 3 36
Inside Cleaning Instruction
Oiling, customer end dispatch
Packing inspection
[5] Carl S. Carlson, “Understanding and applying the fundamental of
FMEAs”, IEEE, January 2014.
VII. CONCLUSION [6] Dr. D.R.Prajapati, “Application of FMEA in Casting Industries: A
FMEA provides a discipline/methodology for case study”, UdyogPragati, vol.35, Issue 4, pp. 6-14,December 2011.
[7] Ioannis S. Arvanitoyannis and Theodoros H. Varzakas, “Application
documenting this analysis for future use and continuous
of ISO 22000 and failure mode and effect analysis [FMEA] for
process improvement. It is a systematic approach to the industrial processing of salmon: A case study”, Critical reviews in
analysis, definition, estimation, and evaluation of risks. Food science and Nutrition, Volume 48, pp. 411-429,2008.
Following a standard setup procedure will reduce setup [8] K.G. Johnson and M.K.Khan, “A study into the use of the process
failure mode and effects analysis (PFMEA) in the automotive
time and improve part accuracy thereby increasing the
industry in the UK”, Journal of Materials Processing Technology,
quality and efficiency of processes. Many measures like Volume 139, pp. 348–356, 2003.
standard operating procedures, Master piece of Correct [9] M. Dudek-Burlikowska, “Application of FMEA method in
Depth is Provide for Setting, Inprocess inspection, process enterprise focused on quality”, Journal of Achievements in Materials
and Manufacturing Engineering, Volume 45, Issue 1, pp. 89-102,
drawing, and first piece inspection. FMEA analysis may
March 2011.
easily help in improving the efficiency of the manufacturing [10] Namdari M. and rafiw, “Using the FMEA method to Optimize fuel
process and quality of product thus decreasing the number consumption in Tillage by Moldboard Plow”, International Journal
of defective products and saving of rework cost and time. Of Applied Engineering Research, Volume 1, Issue 4, pp. 734-742,
2011.
For each specific process the preventions suggested in the
[11] Ping-Shun Chen and Ming-Tsung Wu, “A modified failure mode and
table can considerably decrease the loss to the effects analysis method for supplier selection problems in the supply
manufacturing industry in terms of both money and time. chain risk environment: A case study”, Computers & Industrial
Engineering, Issue 66, pp. 634–642, 2013.
[12] R.S.Mhetre and R.J.Dhake, “Using Failure Mode Effect Analysis In
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