FMEA Introduction

Introduction
- FMEA -
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FMEA - Introduction
FMEA
Failure Modes & Effects Analysis
2 HONEYWELL - CONFIDENTIAL
FMEA - Introduction
1. Introduction
FMEA development (design or process) uses a common approach to

address:
• Potential product or process failure to meet expectation

• Potential consequences
• Potential cause of failure mode
• Application of current control
• Level of risk
• Risk reduction
Before the FMEA document is started, the team must define the scope of
the project and collect all necessary information for an efficient & effective
FMEA
What is an FMEA (from research)
This is not a one man job !!!
FMEA definitions
It is a systemised group of activities intended to:-
• Recognise and evaluate the potential failure of a product or

process and its effects
• Identify actions which could eliminate or reduce the chance
of a potential failure occurring.
• Focuses on prevention of a failure
• Results in a coordinated/ document team effort of the process
Defines what a design or process must do to satisfy a customer :-

• Allows the team to evaluate controls and the need to mitigate
risk by changes to design or the manufacturing control plan.
• A method to determine the need for and a priority of actions
• The deliverable is to prevent failures from reaching customers,
improving customer satisfaction.
FMEA’s identify or confirm potential critical and significant characteristics to be

addressed by, design changes, process changes or to be included in the process
Control Plan
FMEA - Introduction
Basic Structure
Fundamentally, the format utilized should address:
• Functions, requirements, and deliverables of the product or process being

analyzed
• Failure modes when functional requirements are not met
• Effects and consequences of the failure mode
• Potential cause of the failure mode
• Actions & Control for causes of the failure mode
• Actions to prevent recurrence of the failure mode
Specific formats may vary based on the need of the organization and
the requirements of the customer
FMEA - Introduction
Identify the Team
A team approach is recommended to benefit the FMEA

development process to ensure input and collaboration
from all affected areas
The FMEA team leader should select team members

with the relevant experience and necessary authority.
TEAM STRUCTURE
• As a minimum, the team should include:-

include:-
• Design or process owner
• Devils advocate or contrarian
• Peer or expert who challenges the current
Design process
• Data owner
• Quality expert
• Other subject matter experts as necessary
• Testing
• Metrology
•Optional
• Expert facilitator
• Recorder
• Key supplier Implementing roles
Establish the roles - particular attention to the team formation and
• Services functions by:
•Purchasing •Getting to know each other, including individual strengths/ weaknesses
and preferences for working.
•Identifying roles and responsibilities
•Establishing ground rules for behaviour
•Clarifying the team's goals and tasks
•Scheduling tasks, meetings and deadlines
•Learning to use different group methods at meetings
FMEA - Introduction
Define the Scope
The following may assist the team in defining the SCOPE

of the FMEA:
• Functional model •Process Flow diagrams

• Block diagrams (Boundary) •Interrelationship matrices
• Parameter diagrams (P) •Schematics
•Bill of Materials (BOM)
• Interface diagrams
Scope establishes the boundary of the FMEA analysis and defines what is
included or not
The scope needs to be established at the start of the process to assure
consistent direction and focus
Preparation tool
5
Assembly Process
4 Supplier
0
Fuite Corps Bracket
carter etranger tordu suite
central dans a chute
actuator OP20
Ppm Pareto
before
Boundery / Interface diagram
after
Check Lists
Visual Management tool

FMEA - Introduction
Structure of FMEA
System FMEA
Subsystem FMEA
Component FMEA
A system FMEA is made up of various subsystems. Examples: Chassis

System, Power-train System etc
FMEA - Introduction
System FMEA
The focus of the System FMEA is to address all interfaces and interaction
among systems, subsystems, the environment and the customer
Subsystem FMEA
The focus of the Subsystem FMEA is to address all interfaces and

interactions among the subsystem components and interactions with other
subsystems or systems. Example – front suspension subsystem, which is a
subset of the chassis system
Component FMEA
Component FMEA is a subset of a Subsystem FMEA. Example – a brake

pad is a component of the brake assembly, which is a subsystem of the
chassis system
FMEA - Introduction
Define the Customer
There are four major customers to be considered in

the FMEA process:
• END USER – the person or organization that will utilize the product.
Example – durability
•OEM Assembly & Manufacturing Centers (Plants)

•Supply Chain Manufacturing – including fabricating production, service
parts, assemblies and processes as welding, painting or other finishing
services
•Regulators – government agencies that define requirements and monitor

compliance to safety and environmental specifications which can impact the
product or process
FMEA - Introduction
Identify Functions, Requirements and Specifications
● The purpose of this activity is to clarify the item design intent or process
purpose.
● This assists in the determination of the potential failure mode for each
attribute or aspect of the function.
FMEA - Introduction
Identify Potential Failure Modes
● Defined as the way or manner in which a product or process could fail

to meet design intent or process requirements.
● A concise and understandable failure definition is important since it

properly focuses the analysis.
● Potential failure modes should be described in technical terms and

not as a symptom necessarily noticeable by the customer.
● A large number of failure modes identified for a single requirement

may indicate that the defined requirement is not concise.
FMEA - Introduction
Identify Potential Effects
● Potential Effects = Effects of the failure mode as

perceived by the customer
● The customer can be internal as well as End User
● Potential Effects includes the analysis of the consequences of the

failures and the severity or seriousness of those consequences
The effects or impact of the failure are described in terms of what the
customer might notice or experience
FMEA - Introduction
Identify Potential Causes
● Potential Causes = indication of how the failure could

occur ( in terms of something that
can be corrected or controlled)
● Identifying the root causes of the failure mode enables the

identification of appropriate controls and action plans
A separate potential causes analysis is performed for each cause if

there are multiple causes
FMEA - Introduction
Identify Controls
● Control are those activities that prevent or detect the cause of the
failure or failure mode.
● In developing controls it is important to identify what is going wrong,

why, and how to prevent or detect it
● Controls are applicable to product design or manufacturing

processes
Controls focused on prevention will provide the greatest return
FMEA - Introduction
Identifying and Assessing Risk
One of the important steps in the FMEA process in the assessment of

risk. This is evaluated in three ways:
● Severity – level of impact in of a failure on the customer.
● Occurrence – how often the cause of a failure may occur.
● Detection – how well the product or process controls detect the cause
of the failure or the failure mode.
Organizations need to understand their customer requirements for

risk assessment.
FMEA - Introduction
Recommended Actions & Results
The following can be used to assure that the appropriate actions are
taken, including but not limited to:
● Ensuring design requirements including reliability are achieved
● Reviewing engineering drawing & specifications
● Confirming incorporation in assembly / manufacturing processes
● Reviewing related FMEAs, control plans and operations instructions
Once actions are completed and result captured, the updated rating
for severity, occurrence and detection should be recorded
FMEA - Introduction
Management Responsibility
● Management owns the FMEA process.
● Management has the ultimate responsibility of selecting and applying

resources and ensuring an effective risk management process
including time
● Management responsibility also includes providing direct support to

the team through on-going reviews, eliminating roadblocks and
incorporating lessons learned

FMEA Introduction

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Introduction

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FMEA development (design or process) uses a common approach to

• Potential product or process failure to meet expectation

This is not a one man job !!!

• Recognise and evaluate the potential failure of a product or

Defines what a design or process must do to satisfy a customer :-

FMEA’s identify or confirm potential critical and significant characteristics to be

Fundamentally, the format utilized should address:

• Functions, requirements, and deliverables of the product or process being

Identify the Team

A team approach is recommended to benefit the FMEA

The FMEA team leader should select team members

• As a minimum, the team should include:-

Define the Scope

The following may assist the team in defining the SCOPE

• Functional model •Process Flow diagrams

Boundery / Interface diagram

Visual Management tool

A system FMEA is made up of various subsystems. Examples: Chassis

The focus of the Subsystem FMEA is to address all interfaces and

Component FMEA is a subset of a Subsystem FMEA. Example – a brake

Define the Customer

There are four major customers to be considered in

•OEM Assembly & Manufacturing Centers (Plants)

•Regulators – government agencies that define requirements and monitor

Identify Functions, Requirements and Specifications

Identify Potential Failure Modes

● Defined as the way or manner in which a product or process could fail

● A concise and understandable failure definition is important since it

● Potential failure modes should be described in technical terms and

● A large number of failure modes identified for a single requirement

Identify Potential Effects

● Potential Effects = Effects of the failure mode as

● The customer can be internal as well as End User

● Potential Effects includes the analysis of the consequences of the

Identify Potential Causes

● Potential Causes = indication of how the failure could

● Identifying the root causes of the failure mode enables the

A separate potential causes analysis is performed for each cause if

● In developing controls it is important to identify what is going wrong,

● Controls are applicable to product design or manufacturing

Controls focused on prevention will provide the greatest return

Identifying and Assessing Risk

One of the important steps in the FMEA process in the assessment of

● Severity – level of impact in of a failure on the customer.

● Occurrence – how often the cause of a failure may occur.

Organizations need to understand their customer requirements for

Recommended Actions & Results

● Ensuring design requirements including reliability are achieved

● Reviewing engineering drawing & specifications

● Confirming incorporation in assembly / manufacturing processes

● Reviewing related FMEAs, control plans and operations instructions

● Management owns the FMEA process.

● Management has the ultimate responsibility of selecting and applying

● Management responsibility also includes providing direct support to

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