AQM Assignment - 2

FMEA

by Eishita Mehta, Radhika Chandak, and Shivani Gupta

Submitted on May 5, 2022

Dept. B.F.Tech

NIFT, New Delhi

Failure Mode and Effects Analysis
(FMEA) is a step-by-step approach for identifying all possible failures in a design, a
manufacturing or assembly process, or a product or service. It is a common process
analysis tool.

​ "Failure modes" means the ways, or modes, in which something might fail.
Failures are any errors or defects, especially ones that affect the customer, and
can be potential or actual.
​
​ "Effects analysis" refers to studying the consequences of those failures.

History of FMEA
For decades, FMEAs have been utilised as a risk detection and mitigation method.
The US military devised the method in the late 1940s, and it has been employed for
nearly 70 years with very minor evolutionary changes. In 2019, significant adjustments
were made when AIAG and VDA "harmonised" their FMEA-conducting disparities.

FMEAs were initially widely used by the US military around the end of the 1940s. The
technique was created by the military to decrease sources of variation and potential
failures in munitions production, and it proved to be a highly effective instrument.
After it was discovered that the military's use of FMEAs reduced project risk, NASA
adopted the methodology as a critical project planning technique as well. FMEAs
were critical to the Apollo (and later) NASA missions' success. The civil aviation
industry frequently employs FMEAs to assess aircraft safety.

FMEAs were also widely used in the automotive industry. As an internal response to
their safety and public relations concerns with the Ford Pinto model in the mid-1970s,
Ford Motor Company led the way. Other automakers in the United States, Europe, and
the United Kingdom quickly followed Ford's lead.

AIAG was founded in 1982 to bring together and agree on common quality
improvement methods and procedures such as FMEAs, SPC (statistical process
control), MSA (measurement system analysis), and related practises among tough (US)
auto industry competitors.
Types of FMEA
FMEA may be divided into three categories depending on the situation:

● The goal of design failure mode and effects analysis (DFMEA) is to make
things that last. It evaluates how the product could fail at various points along
its life cycle.

● The process failure mode and effects analysis (PFMEA) examines each
process phase. Consider sourcing, assembly, shipping, data processing, and so
on. It identifies potential points of failure in the process.

● The functional failure mode and effects analysis (FFMEA) examines the entire
system. Instead of fixing the problem, it seeks to avoid it totally. (Remember
how we avoided broken levers on paper towel dispensers by switching to
motion sensors?

When to use FMEA ?

● After quality function deployment, when a process, product, or service is being
created or redesigned (QFD)
● When a previously existing method, product, or service is used in a novel way.
● Before creating control plans for a new or changed process, consider the
following factors.
● When goals for improving an existing process, product, or service are set,
● When looking at the shortcomings of a current process, product, or service,
● Periodically during the process, product, or service's lifetime
How to implement FMEA
Process steps in FMEA
• Step 1: Identify potential failures and effects
• Step 2: Determine severity
• Step 3: Gauge likelihood of occurrence
• Step 4: Failure detection
• Risk priority number (RPN)

Step 1: Identify possible failures and their consequences.

To identify all failure modes, the first FMEA stage is to examine functional
requirements and their implications. Failure modes in one component might cause
failure modes in other components.
In technical words, list all failure modes per function, taking into account the final
consequence(s) of each failure mode and identifying the failure effect (s).

Step 2: Establish the severity

The severity of failure consequences is determined by the severity of failure effects.
Failure effect severity (S) is usually rated on a scale of one to ten, with one being the
least severe and ten being the most severe. The severity ratings and their meanings
are shown in the table below:

Step 3: Determine the probability of occurrence

Examine the cause(s) of each failure mode, as well as the frequency with which it
happens. Examine similar processes or products for failure mechanisms that have
been reported. In technical words, all probable failure reasons should be identified
and recorded. Failure reasons are frequently suggestive of design flaws.
Step 4: Detecting Failure
Following the determination of corrective activities, they should be evaluated for
efficacy and efficiency. The design should also be checked, and inspection processes
should be established.
1. Engineers look into present system controls to see whether they can prevent failure
modes or identify faults before they affect the user or client.
2. Identify failure detection strategies used with similar products/systems.
Engineers can use these procedures to estimate the possibility of discovering or
recognising faults. The detection value (D) is then assigned to each combination from
stages one and two, indicating how probable it is that failures will be found and
ranking the capacity of specified actions to rectify or eliminate flaws or identify
failures. The greater the D value, the less likely the failure will be recognised.

Priority of the risk (RPN)

Risk assessors compute Risk Priority Numbers after completing the above basic
processes (RPNs). These factors determine how you respond to failure modes. RPN is
computed as follows using the values of S, O, and D:

RPN = S * O * D (or RPN = S x O x D)

RPN should be estimated and recorded in the FMEA for the whole design and/or
process. The most problematic regions should be identified, and repair activities
should be prioritised for the greatest RPNs. New inspections, testing, or processes,
design adjustments, changed components, extra redundancy, updated limitations,
and other activities are examples of these measures. Corrective action goals include,
in order of desirability:
• Minimise the severity of failure modes by eliminating them (some are more
avoidable than others).
• Decrease the frequency of failure modes
• Improve failure mode detection
RPN is computed again once remedial actions are taken, and the findings are noted in
the FMEA.

Failure Modes and Effects

Analysis Procedure Example

● Assemble a cross-functional team with a diversified understanding of the

process, product or service, and client requirements. Design, production,
quality, testing, dependability, maintenance, purchasing (and suppliers), sales,
marketing (and customers), and customer service are all common functions.
● Determine the FMEA's scope. Is it for the concept, the system, the design, the
process, or the service? What are the limitations? How specific should we go?
Use flowcharts to establish the scope and ensure that each team member fully
comprehends it.
● Fill in your FMEA form's identifying information at the top. (A typical format is
shown in Figure 1.) The subsequent stages require information that will be
entered into the form's columns.
● Determine your scope's functions. Inquire, "What does this system, design,
process, or service serve? What do our clients anticipate from it?" It should be
named after a verb and a noun. Typically, the scope is broken down into
subsystems, objects, components, assemblies, or process stages, with each
function identified.
● Identify all possible failure scenarios for each function. These are examples of
possible failure modes. Rewrite the function with greater information if required
to ensure that the failure modes signal a loss of that function.
● Identify the repercussions on the system, associated systems, process, related
processes, product, service, customer, or rules for each failure scenario. These
are some of the consequences of failure. Inquire, "What is the impact of this
failure on the customer? What happens if there is a failure?"
● Determine the severity of each effect. The severity rating, or S, is this. The
severity of an event is traditionally measured on a scale of one to ten, with one
being inconsequential and ten being disastrous. If a failure mode has several
effects, only record the greatest severity rating for that failure mode in the
FMEA table.
● Determine all possible root causes for each failure mode. Utilize cause analysis
tools, as well as the team's collective expertise and experience. On the FMEA
form, include all probable reasons for each failure mode.
● Determine the occurrence rating, or O, for each cause. This grade indicates the
likelihood of failure for that cause happening over the scope's lifespan. The
likelihood of an event is commonly measured on a scale of one to ten, with one
being exceedingly unlikely and ten being unavoidable. List the occurrence
rating for each cause on the FMEA table.
● Determine the existing process controls for each cause. These are the tests,
processes, or mechanisms in place currently to prevent failures from reaching
the client. These controls may prevent the cause from occurring, minimise the
chance of it occurring, or detect failure after it has occurred but before the
customer is impacted.
● Determine the detection rating, or D, for each control. This score indicates how
well the controls can detect the cause or failure mode after it has occurred, but
before the consumer is impacted. Detection is commonly graded on a scale of
one to ten, with one indicating that the control is certain to detect the problem
and ten indicating that the control is certain not to detect the problem (or no
control exists). List the detection rating for each cause on the FMEA table.
● Most industries have the option of: "Is this failure mode linked to a critical
characteristic?" you might wonder. (Critical features are measures or indications
that represent safety or government regulatory compliance and require
additional controls.) If this is the case, a Y or N is entered in the "Classification"
field to indicate whether extra restrictions are required. Critical qualities usually
include severity ratings of 9 or 10 and incidence and detection values of more
than 3.
● Calculate the RPN (risk priority number), which is equal to S O D. Criticality can
also be calculated by multiplying severity by occurrence, S O. These figures
can be used to prioritise probable failures in the order in which they should be
handled.
● Determine the suggested steps. These steps might be modifications in design
or procedure to reduce severity or incidence. They might be extra controls to
help with detection. Note who is accountable for the actions and when they are
expected to be completed.
● Note outcomes and the date on the FMEA form as activities are finished. New
 S, O, or D ratings, as well as new RPNs, should be noted.

Example -

On their ATM system, a bank did a procedure FMEA. Part of it is shown in Figure 1: the
function "dispense cash" and a few of its failure possibilities. The "Classification"
column was left blank. Only the titles for the rightmost (action) columns are
displayed.

RPN and criticality prioritise causes in distinct ways. The main and second biggest
hazards, according to the RPN, are "machine jams" and "intense computer
network traffic."

A high RPN is generated by a single high value for severity or incidence times a
detection rating of 10. Because criticality does not take into account detection, the
sole cause with medium to high severity and occurrence values is "out of cash." To
select acceptable action priorities, the team should rely on their expertise and
judgement.

CASE STUDY
INTRODUCTION
As technologic improvements change day by day, the competition between
production companies leads to necessity to conduct error-free production. Customers
pay attention to obtaining the performance they expected from the product they
bought. The seeking of qualified product became a priority of customers. Under such
conditions, the efforts of producers to produce qualified products have increased. The
high quality of product is not enough for clients. One of the characteristics being
sought is the price of the product. In this point, there is a challenge standing in front of
producers. It is to produce a qualified product with cheap price. It may be possible to
solve this problem with using more than one solution method. One of those methods
is Failure Mode and Effects Analysis (FMEA).

MATERIAL AND METHOD

Material
In this study, poly/cotton (50-50) tablecloths and poly/viscose (50-50) dress fabrics
were used.

Method

Identification of Fault Types Faults Resulting from the Weaving Machine:

Temple Mark - Needles are located on the temples, and these needles perforate the
cloth and stretch it outward by shrinking it. The temple needles leave marks on the
fabric if they do not rotate properly.

Foot Ladder - It is the inward shrinkage of one selvedge caused by the overextension
of one or more wefts.

Baggy Selvedge - It refers to selvedge bagginess caused by selvedge warp thread

bagginess or a mismatch between selvedge knitting and floor knitting.

Faults Related to the Warp

Warp Breaks - They refer to the fault of forming a basket-like shape due to the break
of one the threads entering into the knitting from the warp.

Loose Warp Thread - One or several ends which are not adequately tight.

Faults Related to the Weft

Weft Deformity - It's a flaw caused by short, elliptical deformations in close wefts
caused by the tightness of the weft thread or a difference in size take-up.

Weft Loop - It refers to little loops formed on the weft thread's own surface as a result
of excessive twisting or failure of the braking function.

CONTROL MEASURES THAT ARE APPLIED

1)The operators undertake manual fabric quality checking in this manner.

2) On an illuminated board moving at a pace of between 8 and 20 metres per minute,
the operator performs fabric quality checking.
3) When the control of the whole fabric is completed, the fabric is classified by the
number of faults per meter along the fabric.
4) In general, the fabric's width spans from 1.60 to 2.00 inches. As a result, detecting
flaws on a cloth with the above-mentioned breadth and moving at a pace of 10 m per
minute is quite challenging.

RESULTS
Implementation of the Scoring System In the subsequent steps, fault possibilities,
density values and detectability values study for the relevant product were
calculated.

Identifying of Risk Priority Number (RPN)

RPN CALCULATION = OXSXD

Foreign Fiber in Weft - RPN = 6X6X2 = 72

RPN is determined by multiplying S (severity), O (occurrence), and D (detectability) for

each type of error, as previously stated. We can decide to start working on the type of
mistake to improve based on the PRN value.

This type of inaccuracy is frequently caused by a lack of personnel training. The

training should focus on work schedules, locations, and company plans. The worker
must comprehend and adhere to the goal. The business manager should make it a
priority to train for that scenario.

CONCLUSION
The main premise of developing quality is to reduce expenses by increasing customer
happiness. It is not enough to manufacture a flawless and complete product and sell it
to customers; customers' expectations must also be met. The most crucial aspect of
the HTEA research is to ensure that the executives in charge of the implementation
process give the project their complete support.

Another crucial aspect of the project is its systematic execution. Predetermination of

phases and assigning a defined time for each step are beneficial in terms of project
follow-up and completing the study within the stipulated time frame.
Individuals interested in the topic should be chosen at the same time as the
implementation team. If these individuals are chosen from among employees who
work on different stages of the process, the team will be able to generate new ideas
and opinions. A successful HTEA study will only be possible if everyone involved in
the process, including the HTEA team, supports it.
REFERENCES :

● https://polarion.plm.automation.siemens.com/hubfs/Docs/Guides_and_
Manuals/Siemens-PLM-Polarion-How-to-conduct-a-failure-modes-and-ef
fects-analysis-FMEA-wp-60071-A3.pdf
● https://asq.org/quality-resources/fmea
● https://limblecmms.com/blog/fmea-and-fmeca/
● file:///C:/Users/Lenovo/Downloads/DOKUMA%20KUMA__%20__RET__
M__%20YAPAN%20B__R%20TEKST__L%20FABR__KASINDA%20HTE
A%20ANAL__Z__%20VE%20UYGULAMASI[%23251875]-218251%20(4).
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