En PLATO E1ns E-Learning - Lesson 2 - FMEA Methodology Steps 1-4 With Practical Example

E-Learning Course for PLATO e1ns
Lesson 2: FMEA methodology and

practical example
06.01.2021
1
Lesson 2, part 1:
Creating the FMEA in 7 Steps
according to AIAG/VDA - Steps 1-4
06.01.2021
2
Watch this lesson as a video
Online videos for lesson 2
There are two videos available for this lesson. You can find both on the training content page
for this e-learning course:
▪ Part 1 – FMEA methodology steps 1-4 (in the video the following slides are explained in detail)
▪ Part 2 – Practical example for steps 1-4 (the video shows the practical example "live", without slides)
06.01.2021 © PLATO AG, e1ns Training
3
4
Types of FMEA
Type: Design-FMEA
According to AIAG/VDA
Also called Product-FMEA, DFMEA or Design FMEA.
▪ Goal of the DFMEA is to archive a robust and fault free product design.
▪ DFMEA is a systematic procedure during product development. Experience from

similar products (their FMEAs!) should be used.
▪ For new products, a DFMEA should be started at the beginning of development.
▪ For complete unknown products, information from a System-FMEA analysis should be

used.
▪ DFMEA never ends. It should be kept up to date when design changes occur.
5
Type: Process-FMEA
Process-FMEA or PFMEA identifies failures and their causes during the manufacturing and
assembly process
▪ The goal is to ensure fault free manufactured or assembled products
▪ Specifications for PFMEA originate from construction/product development, from drawings
▪ Is an important tool for manufacturing feasability test (Herstellbarkeitsprüfung).

06.01.2021 © PLATO AG, SCIO-FMEA, Moritz Steuernagel
For entirely new processes, a preliminary PFMEA can be done.
▪ In new projects, a PFMEA should be facilitated before the acquisition of tools for the plant.
6
Trigger for DFMEA and PFMEA
The following three cases trigger the application of an FMEA for

products or processes:
▪ Case 1: New design, new technology or new process
▪ Case 2: New application of existing design or process

▪ Case 3: Technical modifications to an existing design or process
7
Which FMEA type at which time?
And when are Process Flow Chart and Control Plan used?
Concept-FMEA
Concept
Design-FMEA
System-FMEA
Development
Product life cycle phase
Prototype Process-FMEA
(Manufacturing, Assembly)
Process Flow Chart
Production planning
Control Plan
Production
Machine-FMEA
Time t
8
Creating the FMEA: “7 Step Method“
1. Preparation
e1ns.actions
Project plan, 5Ts, collection of requirements, product description etc.
2. System analysis Structural analysis with system elements, block diagram
e1ns.architect/e1ns.aspects
3. Function analysis Specification of all system functions (function network)
4. Failure analysis Failure analysis including causes and effects (failure network)
5. Risk evaluation Risk identification by using S-O-D, AP, RPN, …

6. Optimization
e1ns.methods - FMEA Risk compensation by prioritizing actions
9
e1ns.dashboard/.output/.documents
7. Presentation Documentation of results, communication of remaining risk
10
Step 1: Planning and Preparation
The process of FMEA creation
Goal: Make sure to know the scope of the task!
▪ Definition of the scope: What is going to be analyzed? And what is not? Define the
boundaries by creating a block diagram
▪ Which priorities exist? (for Assemblies or Processes)
▪ Create a project plan: Team, Timing, Intent, Tools, Task („5T“)
▪ Find the right baseline FMEAs before you start → „Lessons Learned“
Should external persons take part in the FMEA (e.g. suppliers)?

▪ How shall the result be delivered: data or print-out, 1-pager or product file?
▪ Is there a time frame or gate until when the FMEA needs to be finished?
11
The process of FMEA creation: “FMEA is team work!“
▪ Preparation of the FMEA workshop by the moderator and the participants:

▪ Gather all required documents (drawings, functional specification doc, etc.), a trial product
sample, 3D CAD-models, …
▪ Select and invite participants
▪ Make failure analysis, risk evaluation and optimization in the team (perhaps define a
core team and invite specialists)
▪ Review the result at a later time to verify, if actions are as good as they were supposed
to be...!
12
Which e1ns modules to use
Which e1ns modules support you in step “Planning and Preparation”?
▪ e1ns.actions: for project plan, 5T’s and project related

action assignment
▪ e1ns.documents: for storage and sharing of all relevant

files for this project
▪ e1ns.aspects: for block diagram/boundary diagram
13
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Step 2: System Structure
System System/Product
Sub system
Assembly
Design
Component
Characteristics
© PLATO AG, e1ns Training
Process step
Operation Process
4M Elements
1/6/2021
15
Which e1ns modules support you in step “System Structure”?
▪ e1ns.architect: can create all kind of structures (system elements,

functions, failures)
▪ e1ns.flow: the graphical representation of the process flow as a

basis for the process structure
▪ e1ns.aspects: blocks of a block diagram can become system

elements
16
Results of the Structure Analysis
Result as tree view or as a net.

1/6/2021
17
18
Step 3: Function Analysis
Define and link functions across all levels
Assembly A has to fulfil upper

functions (e.g. legal requirements).
Assembly A has to fulfil it‘s own

System technical functions to support
upper system elements.
Sub System
X
Assembly
A
Component
1 2 3 4
Characteristics
from drawing
1/6/2021
= Focus Element
19
contribute to?
What does A
System
Sub System
X
Assembly
A
Component
1 2 3 4
Characteristics
from drawing
1/6/2021
= Focus Element
20
Step 3: Process Function Analysis
In a process FMEA, process steps are

created instead of functions.
This can be done as shown on the left, for

example in e1ns.flow.
A link to higher-level product functions or

process requirements is then created again
in e1ns.architect.
1/6/2021
21
Which e1ns modules support you in step “Function Analysis”?
▪ e1ns.architect: can create all kind of structures (system elements,

functions, failures)
▪ e1ns.flow: the graphical representation of operation steps inside

a process flow
▪ e1ns.methods: you could also write functions directly into the

FMEA table. But be careful: they would not be linked!
22
Step 3: Function Net
▪ Result as a function net/function tree.

▪ It is the starting point for failure analysis.
1/6/2021
23
24
Step 4: Failure Analysis
Define and link failures across all levels
System Failure Effect (FE): Impact of the failure on

superior systems, customers, etc.
Sub System
X
Failure Mode (FM): difference to specified
function (set value) of the assembly.
Assembly
A
Component Failure Cause (FC): failure / breakdown /

1 2 3 4 damage of a subsidiary system component.
Characteristics
from drawing
1/6/2021
= Focus Element
25
Step 4: Failure Analysis - Correlation
Effect Failure Cause Level 1: System (Electrical equipment)

Break Starter is not Voltage is
down running too low
Effect Failure Cause Level 2: Assembly (Accumulator/Battery)

Starter is not Voltage is Contact
running too low anchor is
corroding
Effect Failure Cause Level 3: Component (Contact anchor)

Voltage is Contact Wrong
too low anchor is material
corroding selected
1/6/2021
26 Result of the linking: failures can become effects or causes on another level!
▪ Result as a failure net/failure tree.
▪ It is required for the next step “Risk Evaluation”.

1/6/2021
27
Steps 2 to 4
Video Tutorial
Follow this link to open a PLATO video on Youtube which demonstrates how to fill data
into an empty FMEA form. The second part (starting around minute 20) shows how to
use e1ns.architect to conduct steps no. 2 to 4.
▪ https://youtu.be/5eGkvT-OhyQ
28
And now…
Let‘s jump into the software and learn how to conduct the first steps no. 1 to 4!
29
End of lesson 2, part 1
06.01.2021
30
Lesson 2, part 2:
Practical example
Steps 1-4 according to AIAG/VDA
06.01.2021
31
Watch this lesson as a video
Online videos for lesson 2
There are two videos available for this lesson. You can find both on the training content page
for this e-learning course:
▪ Part 1 – FMEA methodology steps 1-4 (in the video the following slides are explained in detail)
▪ Part 2 – Practical example for steps 1-4 (the video shows the practical example "live", without slides)
The following exercises are explained in detail in the accompanying video. You can play it and
work on your training environment at the same time.

If you would like it to be a little more challenging, then just try to do the exercises on your own
first!
32
Practical example for lesson 2
Steps 1-4 according to AIAG/VDA
A pen:
▪ Each of the following slides contains an exercise to build this example.

▪ The following slide shows the solution.
▪ By the end of this lesson, you have completed the first four steps of the FMEA analysis for the product
"Pen" and the process "Final Assembly".
33 Quelle: https://de.wikipedia.org/wiki/BIC_Group
34
Module: e1ns.architect
Exercise 1: e1ns.architect - Functions
▪ Create a new project in the structure tree for this example case.
▪ Add the top system element "Pen with cap" to this project.
▪ Assign meaningful master data.

Keep in mind to use unique names
▪ Following functions should be realized: for system elements in your
database!
▪ Ensure robustness
▪ High ergonomics
▪ Ensure durability
▪ Allow writing
35
Exercise 1: e1ns.architect - Functions
▪ Solution:
36
Exercise 2: e1ns.architect – System Elements
▪ The "Pen with cap" consists of following system elements (components):

▪ Housing
▪ Cap
▪ Refill
▪ Define connections (correlations) between functions and components / system

elements.
37
Exercise 2: e1ns.architect – System Elements
▪ Solution
38
Exercise 3: e1ns.architect - Refill
▪ Following functions need to be realized by the "Refill"(2nd level):

▪ Dispense appropriate amount of ink
▪ Ensure security against fracture
▪ Long durability
▪ Connect the functions of the system element "Refill" with the functions of the higher-
level system element "Pen with cap".
39
Exercise 3: e1ns.architect - Refill
▪ Solution
40
Exercise 4: e1ns.architect - Refill Sub-Elements
▪ In e1ns.architect focus on "Refill“ with a double-click.
▪ Add the following sub-system elements to the component "Refill":

▪ Tip
▪ Ink
▪ Refill housing
▪ Create the connections (correlations) between system elements and higher

functions.
▪ Add the function „Ensure consistant flow“ to the Ink.
41
Exercise 4: e1ns.architect - Refill Sub-Elements
▪ Solution
42
Exercise 5: e1ns.architect – Integrate Final Assembly
▪ So that the product functions can be realized, an assembly process should be created directly below
the product level. Name it "Final assembly pen".
▪ Assign meaningful master data.
▪ The process "Final assembly pen" contains the following steps:

▪ Assembly preparation
▪ Insert refill in housing
▪ Functional check
▪ Transport to warehouse
▪ Connect the functions of the "Final assembly pen" to the functions of the “Pen with cap"
(there are not many links ...).
43
Exercise 5: e1ns.architect – Integrate Final Assembly
▪ Solution:
44
Exercise 6: e1ns.architect – Cause Elements
▪ Put the focus on "Final assembly pen" and add two cause elements:
▪ Man
▪ Mounting device
▪ Assign meaningful master data (SE-Type: 4M)
▪ Give "Man" the function "Assembly" and link it with the process step "Insert refill in
housing" of the final assembly.
45
Exercise 6: e1ns.architect – Cause Elements
▪ Solution:
46
Exercise 7: e1ns.architect – Add Failures
▪ Add failures to all functions and connect them meaningfully across all levels!
47
Exercise 7: e1ns.architect – Add failures
▪ Solution
48
▪ Solution
49
▪ Solution
50
Quiz for lesson 2
Online self-test
▪ Click here to start a quiz for lesson 2. Good luck!

06.01.2021
51
End of lesson 2
... continue with lesson 3!
06.01.2021
52

En PLATO E1ns E-Learning - Lesson 2 - FMEA Methodology Steps 1-4 With Practical Example

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E-Learning Course for PLATO e1ns

Lesson 2: FMEA methodology and

Also called Product-FMEA, DFMEA or Design FMEA.

▪ DFMEA is a systematic procedure during product development. Experience from

▪ For new products, a DFMEA should be started at the beginning of development.

▪ For complete unknown products, information from a System-FMEA analysis should be

▪ The goal is to ensure fault free manufactured or assembled products

▪ Specifications for PFMEA originate from construction/product development, from drawings

▪ Is an important tool for manufacturing feasability test (Herstellbarkeitsprüfung).

For entirely new processes, a preliminary PFMEA can be done.

The following three cases trigger the application of an FMEA for

▪ Case 1: New design, new technology or new process

▪ Case 2: New application of existing design or process

▪ Case 3: Technical modifications to an existing design or process

2. System analysis Structural analysis with system elements, block diagram

5. Risk evaluation Risk identification by using S-O-D, AP, RPN, …

Goal: Make sure to know the scope of the task!

▪ Which priorities exist? (for Assemblies or Processes)

▪ Create a project plan: Team, Timing, Intent, Tools, Task („5T“)

Should external persons take part in the FMEA (e.g. suppliers)?

▪ Preparation of the FMEA workshop by the moderator and the participants:

▪ Select and invite participants

Which e1ns modules support you in step “Planning and Preparation”?

▪ e1ns.actions: for project plan, 5T’s and project related

▪ e1ns.documents: for storage and sharing of all relevant

▪ e1ns.aspects: for block diagram/boundary diagram

Which e1ns modules support you in step “System Structure”?

▪ e1ns.architect: can create all kind of structures (system elements,

▪ e1ns.flow: the graphical representation of the process flow as a

▪ e1ns.aspects: blocks of a block diagram can become system

Result as tree view or as a net.

Assembly A has to fulfil upper

Assembly A has to fulfil it‘s own

In a process FMEA, process steps are

This can be done as shown on the left, for

A link to higher-level product functions or

Which e1ns modules support you in step “Function Analysis”?

▪ e1ns.architect: can create all kind of structures (system elements,

▪ e1ns.flow: the graphical representation of operation steps inside

▪ e1ns.methods: you could also write functions directly into the

▪ Result as a function net/function tree.

System Failure Effect (FE): Impact of the failure on

Component Failure Cause (FC): failure / breakdown /

Effect Failure Cause Level 1: System (Electrical equipment)

Effect Failure Cause Level 2: Assembly (Accumulator/Battery)

Effect Failure Cause Level 3: Component (Contact anchor)

▪ Result as a failure net/failure tree.

▪ It is required for the next step “Risk Evaluation”.

work on your training environment at the same time.

▪ Each of the following slides contains an exercise to build this example.

▪ Assign meaningful master data.

▪ The "Pen with cap" consists of following system elements (components):

▪ Define connections (correlations) between functions and components / system

▪ Following functions need to be realized by the "Refill"(2nd level):

▪ In e1ns.architect focus on "Refill“ with a double-click.

▪ Add the following sub-system elements to the component "Refill":

▪ Create the connections (correlations) between system elements and higher

▪ Add the function „Ensure consistant flow“ to the Ink.

▪ Assign meaningful master data.

▪ The process "Final assembly pen" contains the following steps:

▪ Assign meaningful master data (SE-Type: 4M)

▪ Click here to start a quiz for lesson 2. Good luck!

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