Thought for the day

FMEA

Failure Mode and Effect Analysis

 Thought for the day

Let us not see

Where we failed,
Let us together see
Why we failed.
 What is an FMEA ?
Failure Modes and Effects Analysis.
Systematic Group of activities intended to

+ Recognize and Evaluate the potential failure of a product / process

and the effects of that failure,

+ Identify actions that could eliminate or reduce the chance of the

potential failure occurring &

+ Document the entire process.

All FMEAs focus on the design, whether it be of the product or process

 Evolution
• 1960’s:NASA moon program engineers devised a method of
forecasting problems.

• 1970’s: Method becomes known as FMEA and is adopted by various

quality organizations.

• 1980’s:With increased emphasis on quality, method spreads to large

corporations.

• 1990’s:
Large corporations are, in turn, pressing suppliers to adopt
the method.

• 2000’s: Method is being applied elsewhere such as HealthCare.

 FMEA Definitions

• Failure Modes & Effects Analysis

- A detailed document that identifies ways in which a process or

product can fail to meet critical customer requirements.
- A living document which lists all possible causes of failure.

- A document from which a list of items for a control plan can be

generated.
- A document which allows a team to track and prioritize the
actions required to improve the process.

• DFMEA… a design FMEA

• PFMEA… a process FMEA
 FMEA Terminology

• Failure Mode
- Ways in which the component/system/process could fail
- Team poses the question: “How could this part, system or process fail?”

• Failure Effect
- the effect a particular defect will have on the customer
- Team poses the question: “What does the customer experience as a results
of this failure mode?”

• Severity
- an assessment of the seriousness of the failure on the customer (may be
internal or external customers)
- 1 indicates minor nuisance; 10 indicates severe consequence
 FMEA Terminology

• Failure Cause
- something that can be controlled (X) that describes how the failure mode
could have occurred
- important because it points the way to preventive/ corrective action

• Occurrence
- An assessment of the frequency with which the failure occurs
- 1 indicates low probability, 10 indicates near certainty of occurrence

• Detection
- An assessment of the likelihood (or probability) that your current controls will
detect when the “X” fails or when the failure mode occurs
- 1 indicates very high probability of detection; 10 indicates low probability of
detection
 FMEA Terminology

• Risk Priority Number

- RPN = [Severity] x [Occurrence] x [Detection]
- RPN is used to prioritize recommended actions. Special
consideration should be given to high Severity ratings even if Occurrence
and Detection are low.
- Worst case RPN [10] x [10] x [10] = 1000

 Customer:
persons and organizations that are affected by the process.

• Failure:
any malfunction, defect or error that causes the process to not perform
its
intended function(s) or meet requirements satisfactorily.
 FMEA Terminology

• Failure Mode:
the appearance, manner or form in which the process failure

 FMEA Terminology
manifests itself. (Short circuit or handling damage)

• Cause(s) of the Failure:

Possible mechanism(s) and/or way(s) in which the failure mode can be
produced.

• Effect(s) of the Failure:

the experience the customer encounters as a result of the failure mode
 Why use FMEA

• It requires a team to follow a disciplined procedure in order to identify and

document:
- potential product related process failure modes (defects)

- potential effects on the customer (irritants)

- potential causes

- ways of reducing the occurrence level of these causes

- ways of improving the detection methods for these causes

 A Systematic Process

• FMEA provides a systematic process to:

- Identify and evaluate

• potential failure modes
• potential causes of the failure mode

- Identify and quantify the impact of potential failures

- Identify and prioritize actions to reduce or eliminate the

potential failure

- Implement action plan based on assigned responsibilities and completion

dates

- Document the associated activities

Use of FMEA
+ New Product Development

+ New Manufacturing Processes

+ Product with safety requirements

+ Product and Process changes

+ New Operating environment for existing products

+ In house rejection, 0-km complaint, Field failures.

+ Customer Requirements
 FMEA - Origin and Emerging of Failures

FMEA helps to solve the Failures at the Origin itself !

13
FMEA - Why FMEA ?

FMEA helps

to solve the

Failures With

low Cost!

14
 FMEA - Types of FMEA

FMEA Type Short Name Purpose

System FMEA SFMEA To meet Target Spec.

Design FMEA DFMEA To meet Target Spec.

Interface FMEA IFMEA* To function well with

Customer‘s Product

Process FMEA PFMEA To meet Design Specification

Transport/Logistic FMEA TFMEA* To ensure Quality in

Transport & Storage.
* Special Types of FMEA
 FMEA - Design and Process FMEAs

Design FMEA Process FMEA

Purpose : To meet To meet the specifications
target specifications in the drawings
Development Process Planning
Responsibility :
Objective : To avoid Quality To avoid Quality failures
failures in design in Process

Check for : Compliance with Compliance with drawings

target specifications

FMEA Start : After design selection With product release

FMEA End : Prior to the production Prior to series production

release start up
 FMEA - FMEA Team Members
System FMEA Design FMEA Process FMEA
Core team • System • Design (responsible) • Process planning
development • Testing laboratory (responsible)
(responsible) • Quality assurance
• Plant (Process
• Application planning or Quality • Production
• Moderator assurance) department
• Moderator • Moderator

Occasional • Product • Application/System • Development

participation development development (Design and/or
• Sales • Endurance testing testing)
• Central departments • Central
• Central
departments • Sales departments
• Plant • Purchasing
• Purchasing
• Purchasing

The FMEA is as good as its Team members !

 FMEA - Planning & Preparation

Points to be taken care for successful completion of FMEA :

+ Right moment to do FMEA

+ The team members’ Composition, Knowledge of FMEA Technique

and capability to work in a Team

+ Logical and transparent method of selecting the

Components/Processes to be considered in FMEA

+ Clear and complete preparations by structuring the functions, failure

modes and effects in the FMEA format

+ Collection of all necessary Documents and Papers.

 FMEA - Planning & Preparation

The following documents should be available for discussion and use in the FMEA :

Design FMEA Process FMEA

• System FMEA or System Description • Design FMEA or Functional Description

• Specifications - Target and Product • Process Layout, Product Quality Plan - PQP

• Development Drawings, Parts lists • Machine/Process Specifications

• Work Instruction Charts
• Risk/Spl. Characteristics list
• Manufacturing Drawings, Parts Lists
• Product Try-out & Validation plan
• Test results of samples - Plant & Customer
• Functional Analysis/Simulation results
• Structure Analysis/Strength Calculations • Machine and Process Capability Indices
• Machine and Process Try-out Results
• Test Results of Samples/Comparable Products
• Failure Rates of Comparable Products
• Technical Customer Documentation
• Training Plan for Operators
• Offer Drawing
• Tool and Fixture Drawings
 FMEA - System Structuring - Col. 1

Definition : No. = Numbering of the component or process

Comments : - System FMEA: the number of the system component as

per the component list or system block diagram

- Design FMEA: the number of the component being

ranked, according to the parts list (or structure list)

- Process FMEA: the number of the work or process step

according to the process plan

The identification of functions and failure causes are done

with supplemental digits separated by dots - e.g. xx.xx.xx.
 FMEA - System Structuring - Col. 2

Definition : Component or process = the object being analyzed

Comments : - System FMEA: a list of the system components to be analyzed

(e.g. according to the component list)

- Design FMEA: a list of the components to be analyzed,

according to the parts list

- Process FMEA: a list of the processes/process steps to be

analyzed,according to the process plan

The depth of detail for the FMEA and selection of the objects to be
analyzed must be done by the Core Team during the preparatory
phase and will be reviewed and ratified by the FMEA team.
 FMEA - System Structuring - Col. 2

2. Component or process
Examples

System FMEA Design FMEA Process FMEA

Motor Starter Final grinding of
Component Assembly Parts armature shaft
Process Process
steps

Starter complete final feed

armature shaft grinding

ECU winding clamp

Sensor lamination grind

Ignition switch Commutator remove

 FMEA - Functional Analysis - Function - Col. 3

Definition : Function = functions and characteristics that are fulfilled by

the component or process

Comments :
- The System FMEA covers all important functions, operating condition and
conditions of system components on the basis of the system design specification,
starting from a black-box point of view.

- The Design FMEA covers all important end functions and operating conditions
of components, on the basis of the component design specification, starting
from the initial prototypes.

- The Process FMEA covers all important process functions (process

plan) and part characteristics (drawing).
 FMEA - Functional Analysis - Function - Col. 3

3. Functions Examples
System FMEA Design FMEA Process FMEA
Moronic Starter Grinding armature shaft
Object: Starter Object: Armature Shaft Object: Grinding Process step
Functions Component Functions Characteristics
- Enable cold start - Receive lateral force - Maintain dim. Tolerances
- Supply torque - Position stator core - Maintain tolerance for
cylindricity

Operation conditions Operating conditions Process functions

- Temp. range - temp. range - Ease of maintenance
- Voltage range - Voltage range - Process capability
- Clamping forces
- Rpm range

Operating States
- Starting
- Driving
- Parked
 FMEA - Failure Analysis - Mode - Col. 4

Definition : Failure mode is the improper function or the type and way
required function or a characteristic could not be fulfilled.

Comments:
- The System FMEA examines all potential malfunctions and functional limitations that
result from the function of the system components and are functionally described.

- The Design FMEA examines all potential malfunctions and failure modes that result
from component functions and are described as a physical quantity. Design for
manufacturing must also be considered.

- The Process FMEA examines all potential process failures that result from the
required process functions and part characteristics and are described as a deviation.
 FMEA - Failure Analysis - Mode - Col. 4
4. Failure mode Examples

SFMEA DFMEA PFMEA

Moronic Starter Final grinding armature
shaft

Component: starter Component: Armature Process step: Grinding

shaft

• Poor cold starting • Armature shaft broken • Dimensional

tolerance exceeded
• No torque supplied • Armature shaft frozen • Form tolerance
tight exceeded
• Too noisy • Armature shaft axial • Cylindricity tolerance
play too large exceeded

• Creates too much heat • Stator core loose • Surface scratched

 FMEA - Failure Analysis - Effects - Col. 5

Definition : Failure effect = effect/consequence of the failure mode on the

system, from the customer‘s point of view

Comments :- As exactly as possible, describe all different failure effects on the

end customer
- Describe the functional effects on the highest level object being
ranked (system,vehicle,environment)
- Describe the failure effects as they are noticed/felt by the
customer/user (dissatisfaction/annoyance)
- Understandable depiction of the chain of effects
direct effect -> next effect -> final effect
(e.g. part -> sub-assembly ->
system)
- The „final“ effect is the basis for later ranking of the failure effect.

Which effects/consequences can be imagined for the failure mode?

 FMEA - Failure Analysis - Effects - Col. 5

5. Failure effects - Examples

System, Design and Process FMEA

• vehicle doesn‘t start • unstable vehicle performance

• sudden increase of engine speed • legal requirements not fulfilled

• sudden loss of engine power • emissions limit value exceeded

• unstable idle speed • problems with cold starts

• loss of fuel • increased fuel consumption

• vehicle can‘t be steered • 0-mileage complaint (OEM)

• brakes don‘t work • noise problem

• car radio doesn‘t work • odor problem

• loss of assist for brakes, steering • optical defects

 FMEA - Failure Assessment - Col. 10

Definition : The goal of the FMEA is to discover all potential weaknesses or

risks and to rank them with a critical assessment.

General Rules for critical assessment

- Go through the ranking tables from 10 (worst ranking) to 1.

- Do not lower the ranking unless there are reasons for this.

- If there is no consensus on the ranking, then the higher of the

possible rankings is used.

Attention: Critical ranking is a prerequisite for an effective FMEA!

Note : These Rules are applicable to ranking of S, O, & D (Col. 10,11 & 12)
 FMEA - Failure Assessment - Severity - Col. 10

Definition : The ranking for ‚S‘ - Severity, reflects the significance of the
effects of the failure mode on the end customer.

Comments :- To ensure correct ranking, it is to be assumed that the failure

mode has occurred and has not been detected in the plant.
- Rankings 10 and 9 are used if the safety and/or compliance with
legal requirements may be impaired or if the failure leads to a
stranded vehicle.
- Rankings 8 to 1 assess the impairment of the system and/or the
customer‘s reaction.
- Already implemented actions that limit the failure effects are
considered when ‚S‘ is ranked.
- The ranking table for severity applies to the System, Design and
Process FMEA, since in all FMEAs the effect on end customer is
ranked.
 FMEA - Failure Assessment - Severity - Col. 10
Severity (S) Ranking Table for System, Design and Process FMEA
General assessment criteria Ranking Application – Specific
Points assessment area

Extremely serious failure, which affects safety and/or violates legal requirements, 10
without warning.

Extremely serious failure, which probably affects safety and/or violates legal 9
requirements, with warning, or leads to a conked-out vehicle.
Serious failure, loss of primary functions, e.g. vehicle is conked-out. 8

Serious failure, function of the vehicle is strongly impaired, immediate servicing is 7

required. Limited function of important sub-systems.
Moderately serious failure, failure of important operational and comfort systems, 6
immediate servicing is not required.
Moderately serious failure, limited function of important operational and comfort 5
system.
Moderately serious failure, little loss of function of operational and comfort systems, 4
detected by any driver.

The failure is insignificant. The customer is only slightly bothered, and will probably 3
only notice slight interference, can be noticed by the average
driver.

It is unlikely, that the failure could have a noticeable effect on the behavior of the 2
vehicle or system. Only noticeable by experts/ experienced drivers.
No Effect 1
31
 FMEA - Failure Assessment - Col. 6

Definition : - Special characteristics (also called significant or critical characteristics),

ensure proper performance of the finished product during storage,
handling, installation and operation; some automobile manufacturers
identify them with proprietary symbols.
- Customer related characteristics are (customer-required or internally
defined) dimensions and characteristics that are especially important and
must be strictly met to ensure proper installation and operation of
products. They are also used for internal quality assurance.

Comments : - Product characteristics and process parameters can be special

characteristics.
- Selection based on the FMEA is currently under development.
 FMEA - Failure Assessment - Cause - Col. 7

Definition : Failure causes = causes and conditions that can lead to the failure
mode being considered.

Comments : - The System FMEA examines failure of functional groups or

components and their connections, including both layout and field
performance.

- The Design FMEA examines design, selection and layout

mistakes as well as manufacturing and assembly defects
which are influenced by the design.

- The Process FMEA examines all process-related failure causes.

Only an exact description of the actual failure cause will enable

correct ranking and definition of specific and effective improvement
actions.
 FMEA - Failure Assessment - Cause - Col. 7

7.Failure causes -Examples

System FMEA Design FMEA Process FMEA
Interfaces Dimensions Man
- Interruption - Diameter too small - Not meticulous enough
- Short-circuit - Length insufficient - Missing Information
- Reverse Polarity
- Loose Contact

Sub- Assembly Processes Machine

- Component Failure - Assembly sequence defined - Input material too large
- Loss of function wrong - Grinding wheel too small
- Limited function - Unsuitable fastening method
- Malfunction

Layout Material Method

- Unsuitable layout of the - Insufficient Strength - Process plan incomplete
components - No protective surface finish - Shipping damage
- Components not suitable
for application

Form; Position; Tolerance Material

- Roundness inadequate - Non- homogeneous
- Coaxially tolerance too large material
- Environment
 FMEA - Risk Analysis - Prevention - Col. 8

Definition : Failure prevention = already implemented actions that

- decrease the failure occurrence (O = )
- limit the failure severity (S = )

Comments : • The System FMEA (Field and layout) considers implemented actions
that minimize the risk of system layout mistakes or avoid or limit the
effects of these mistakes.

• The Design FMEA considers implemented actions that minimize or

avoid the risk of design mistakes.

• The Process FMEA considers implemented actions that minimize or

avoid the risk of process defects.
 FMEA Risk Analysis - Prevention - Col. 8
8. Failure prevention - Examples
System FMEA Design FMEA Process FMEA

Way to reduce effects (S =  ) Design Machine

- Redundancy
- Substitute functions
- Low chance of improper use - Machine, process capability
- Optimal, robust layout Utilizing - Maintenance/ services
experience
- Proven designs
- Expert advice

Optimization methods Method

- Calculation methods - Work instructions
- Optimization tests - Measurement system analysis

Way to limit occurrence Information to production Materials

(O =  ) - Drawings (Comments) - Order specification
- Power reserves - Order, test and process specifications - Lot documentation
- Robust layout
- Experience with similar system Use of internal & external standards and Environment
- Simulation guidelines - Ergonomic . Work station design
- Calculation - Clean room condition
- Exact functional definition
Man
- Mistake –proof design of work
stations
- Experience
 FMEA - Risk Assessment - Occurrence - Col. 11

Definition : The O ranking reflects the probability that the failure mode, as a
result of the failure cause being considered, will occur at the
customer/user, without being discovered beforehand.

Comments : - To avoid double ranking, it is assumed that the failure mode and
cause have not been detected before the customer accepts the
product.
- Implemented actions that prevent the failure cause are assumed
effective and are considered when O is ranked.
- The failure rates (e.g.   - rates, ppm) are based on the number of
failures that are expected within the required lifetime of the
product.
- Dependence on operating time (h), driving distance (km), number
of cycles, process capability (cpk), etc. must be considered.
 FMEA - Risk Assessment - Occurrence - Col. 11

System and Design FMEA

General assessment criteria Possible ppm* Ranking Application-
failure rate Points specific -
assessment criteria

Very high. It is almost certain that the 1/10 100.00 10

failure mode and cause will occur very 1/20 50.00 9
frequently.

High. The failure mode/cause occur 1/50 20.00 8

repeatedly. Problematic, not a mature 1/100 10.00 7
system/design.

Medium. The failure mode/cause occurs 1/200 5.000 6

occasionally. Advanced maturity of the 1/1.000 1.000 5
system/design. 1/ 2.000 500 4

Low. Occurrence of the failure mode/cause 1/15.000 67 3

is low, proven system/design layout. 1/150.000 6,7 2

Unlikely. Occurrence of the failure mode/cause is unlikely <1/1.500.00 <0,67 1

0

* per LT (LT = Lifetime of the product)

 FMEA - Risk Assessment - Occurrence - Col. 11

Process FMEA
General assessment criteria Possible ppm Cpk Ranking Application-
failure Points specific -
rate assessment
criteria

Very high. It is almost certain that the 1/10 100.00 - * 10

failure mode and cause will occur very 1/20 50.00 - * 9
frequently.

High. The failure mode/cause occur 1/50 20.00 - * 8

repeatedly. Process is not precise. 1/100 10.00 - * 7

Medium. The failure mode/cause occurs 1/200 5.000 0,94 6

occasionally. Can be compared with processes that 1/1.000 1.000 1,10 5
occasionally produce defects, but not to a significant 1/ 2.000 500 1,17 4
extent.

Low. Occurrence of the failure mode/cause 1/15.000 67 1,33 3

is low, proven process. 1/150.000 6,7 1,50 2

Unlikely. Occurrence of the failure mode/cause is <1/1.500.0 <0,67 >1,67 1

unlikely 00

* Cpk calculation is not significant

 FMEA - Risk Analysis - Detection - Col. 9

Definition : Failure detection = Test activities or symptoms that are suitable for
timely detection of a failure mode or cause.

Comments : - In the System FMEA (Layout), these are test activities and validation
done until the system release.
- In the System FMEA (Field), these are signs and symptoms that are
suitable for timely detection of the failure mode or cause.

- In the Design FMEA, these are tests and validation, as well as other
methods of detecting failures, until the product release.

- In the Process FMEA, these are all tests and possibilities of detecting
failures, until delivery to the customer.

Most accurate description of the effectiveness of the test activities or of

the symptoms regarding the probability of detecting the failure.
 FMEA - Risk Analysis - Detection - Col. 9
9. Failure detection - Examples

SFMEA DFMEA PFMEA

Field

Signs
- Warning lamp display
- Acoustic signal
- Fault memory readout
during service
Symptoms
- Loud noises
- Unsteady engine running
- Increased fuel consumption
Layout
- Vehicle testing
- Simulation
- Summer & winter testing
- Endurance testing - Measurement and
- Climatic testing tests at the work
- Initial sample testing station
(customer) - Process & visual tests
- Vibration testing - In- process and final
- Testing of individual testing
characteristics - Quality/ reliability
testing
- Technology analysis
- 100 % testing
- Random sample
testing
- Product audit
- System audit
 FMEA - Risk Assessment - Detection - Col. 12

Definition :The ‚D‘ ranking reflects the probability that the failure mode or cause is
detected before the product arrives at the customer or that the failure is
detected in the field by an implemented detection action and displayed
to the operator (e.g. driver).

Comments :- System FMEA:

• (Field) assessment of the possibilities of detection by the system
and display to the operator (e.g. driver).
• (Layout) assessment of the detection possibilities until system
release.

• Design FMEA: assessment of the detection possibilities until product

release.

• Process FMEA: assessment of the detection possibilities until transfer

to the customer.
The main ranking criterion is the effectiveness of testing as related to
detecting the failure characteristic.
 FMEA - Risk Assessment - Detection - Col. 12

Design FMEA
General assessment criteria Ranking Application –
Points Specific
assessment
area
Unlikely. It is impossible or improbable that the failure mode/cause will be 10
discovered during the development phase by testing or analysis activity
Very low. The probability is very low that the failure mode/cause will be 9
discovered during the development phase by testing or analysis 8
activities.
Low. The probability is low that the failure mode/cause will be discovered 7
during the development phase by testing or analysis activities. 6
Medium. The probability is moderate that the failure mode/cause will be 5
discovered during the development phase by testing or analysis activities. 4
High. The probability is high that the failure mode/cause will be discovered 3
during the development phase by testing or analysis activities. 2
Very high. It is certain that the failure mode/cause will be discovered during 1
the development phase by testing or analysis activities.

43
 FMEA - Risk Assessment - Detection - Col. 12

Process FMEA

General assessment criteria Certainty of Ranking Application-

test method Points Specific
assessment
criteria

Improbable. 10
The failure will not or cannot be detected.
Very low. 90% 9
The probability of detecting failure is very low.
Low. 98% 8
The probability of detecting failure is low. 7
Medium. 99,70% 6
The probability of detecting failure is moderate. 5
4

High. 99,90% 3
The probability of detecting failure is high. 2
Very High. 99,99% 1
The probability of detecting failure is very high.
 FMEA - Risk Assessment - RPN - Col. 13

Definition :The Risk Priority Number - RPN - is the product of the individual rankings
RPN = S x O x D

Comments : Actions Mandatory for

- RPN - as per priority ranking

-O>3

-S>8
 FMEA - Quality Improvement Actions - Col. 14

General Guidelines :
System FMEA

Design FMEA
• For high O-rankings, actions have to be implemented to ensure achievement
of the defined quality target for the product at SOP. This means that
generally O = 2 to 3 should be achieved. The target in future is O = 1 !
• Means of detection have to be performed to ensure achieving quality targets.

Process FMEA
• For safety parts, the target is O = 1. If this cannot be achieved, then suitable
means of detection must be installed to ensure that no defective parts are
delivered to the customer.
• If the probability of failure occurrence is high, then actions have to be
implemented to achieve the quality target. Generally, this requires controlled
processes, i.e. Cpk > 1,33 - 1,67 or O = 1 or 2
 FMEA - Quality Improvement Actions - Col. 14

Brain-storm and generate actions :

Definition : Actions decided and to be implemented serve to reduce risk of failure by :

1. Totally avoiding the failure cause
2. Totally avoiding the failure mode
3. Reducing the probability of the failure cause
4. Limiting the effects of the failure mode
5. Increasing the probability of detecting the failure mode or cause

Comments : - During this phase, the team should look for any imaginable improvement
ideas.
- FMEA is a creative technique and a helpful tool for this .
- Failure prevention actions always have priority.
- Failure detection is usually expensive and does not improve quality.
 FMEA - Quality Improvement Actions - Col. 14

Priorities and select actions :

Definition : The proposed actions are selected according to:

- sufficient reduction of the risk priority numbers and
- lowest possible costs and
- shortest date of introduction

Comments : - Actions to prevent the failure mode or cause have to be checked for
effectiveness.
- Actions to reduce S, O and D have to be assessed according to the FMEA
ranking tables.
- Actions to reduce S, O and D might be possible to be combined.
- Costs and deadlines have to be determined for the lowest risk numbers.
- Select the best-suited actions and, after agreeing to implement them, enter
the expected ranking in column 14 (in parenthesis).
- Responsibility (R:) and implementation date (I:) must be entered.
 FMEA - Quality Improvement Actions - Col. 14

Implement actions decided by FMEA Team and Update FMEA document :

Definition : Actions that have been selected and agreed upon must be implemented
according to schedule.

Comments :- After implementation of the action, the new rating for ‚O‘ and ‚D‘ is
compared with the old estimated rating and the accepted ratings
and RPN are entered in the respective columns (Col. 11,12,13).
- The current, applicable rating is always written without parenthesis.
- The original rating remains for comparison and is written in
rectangular brackets [ ].
 FMEA - Management Reporting

FMEA-Monitoring and Reporting Method

50
 FMEA - Efficiency of FMEA

Efficiency of FMEA

 Correct Analysis is guaranteed by precise definition and knowledge of

the concepts of the design / process,
 Systematic procedure for complete coverage of the product and
production sequences,
 Clear and un-ambiguous method of Analysis and Evaluation,
 Exchange of information and opinion forming in the working group,
 Preventive avoidance of Failures in Development and in Production
 Cost saving due to reduction in subsequent product or process
changes,

 Clear documentation of causes and measures for avoiding Failures

and its repetition
 FMEA - Mistakes in FMEA

Mistakes of FMEA
 Incomplete and/or Pseudo FMEA,

 Inadequate FMEA - not all Failure modes considered & too few Failure
causes listed,
 Actions for Failure prevention not considered,
 Description of Failure Modes, effects, causes, prevention & detection
actions are inadequate and/or ambiguous,
 Failure mode, effect, cause mixed-up,
 Product function (Target requirements) and Process function
(Drawing requirements) mixed-up,
 Too long time taken for brain-storming for Causes and actions,
 Casual involvement of Team members in discussions.
 FMEA - Additional Information

FMEA must be supported :

- Organizational structure - Co-ordinators in Corporate and Dept.
levels
- Encouraging and releasing engineers for FMEA training
- Inclusion of FMEA in deadline schedules

FMEA must be demanded :

- Corporate objective : Preventive Quality Assurance
- As a safeguard in respect of producer liability
- More stringent customer requirements

FMEA must be understood :

- Training in FMEA basic seminar and refresher course
- Advanced seminar for Co-ordinators
- Exchange of experience between FMEA users.
 FMEA - Summary

FMEA is
- A systematic method for early, analysis of functional failure,
- Applicable to SYSTEMS, PRODUCTS and PROCESSES,
- A structured method for farsighted, all-embracing investigation of all
potential failure modes, failure causes and their effects,
- A method of qualitative failure evaluation and revealing risks of failure,
- A method for avoiding or reducing risks of failure by introducing suitable
improvement measures.

Conclusion :
- FMEA is an up-to-date & effective technique for failure prevention and
reducing development cost and time, which leads to customer satisfaction.
Thank You

55