Failure Mode Effect Analysis

1. FMEA is an analytical Technique (a paper test)

that combines the technology and experience of
people in identifying foreseeable failure modes of
a product or process.
2. FMEA can be defined as group of activities
intended to recognize and evaluate the potential
failure of a product or process and its effect.
3. FMEA is a “before-the-event” action requiring a
team effort to easily and inexpensively alleviate
changes in design and production.
 Types of FMEA
1. Design FMEA
2. Process FMEA
3. Equipment FMEA
4. Maintenance FMEA
5. Concept FMEA
6. Service FMEA
7. System FMEA
8. Environmental FMEA
 Definitions of the Design and
Process FMEA
1. Design FMEA:
it aids in the design process by identifying known and
foreseeable failure modes and then ranking failures
according to relative impact on product.
It helps to establish priorities based on expected
failures and severity of those failures and helps
uncover oversights, misjudgments, and errors that
may have been made.
It reduces development time and cost of
manufacturing processes by eliminating many
potential failure modes prior to operation of the
process & by specifying the appropriate tests to
prove the designed product
 Definitions of the Design and
Process FMEA
1. Process FMEA:
it is used to identify potential process failure
modes by ranking failures and helping to
establish priorities according to the relative
impact on the internal or external customer.
It helps to identify the potential manufacturing
or assembly causes in order to establish
controls for occurrence reduction and
detection.
 Categories of Process & System
FMEA
1. Process FMEA
 Equipment FMEA
 Service FMEA
 Environmental FMEA
2. System FMEA
 Design FMEA
 Process FMEA
 Reliability
1. Reliability is consistency of performance
over time.
2. Reliability can be defined as probability
of the product to perform as expected for a
certain period of time, under the given
operating conditions, and at a given set of
product performance characteristics.
 Benefits of FMEA
1. Systematic review of component failure to
produce minimal damage
2. Determining effects that any failure will have on
other items in the product or process and their
functions.
3. Determining those parts of the product or the process
whose failure will have critical effects on product
or process operation sign FMEA
4. Calculating the probabilities of failures in
assemblies
5. Establishing test programs requirements to
determine failure mode and rate data not available
from other sources.
 Benefits of FMEA
1. Establishing test program requirements to verify empirical
reliability predictions.
2. Providing input data for trade-off studies to establish the
effectiveness of changes in proposed product or process.
3. Determining how the high failure rate components of a
product or process can be adapted for higher reliability
components.
4. Eliminating or minimizing the adverse effects that assembly
failures could generate and indicating safeguards to be
incorporated if the product or the process can not be made
fail-safe or brought within acceptable failure limits
5. Helping uncover oversights, misjudgments, errors that
may have been made.
6. Helping reduce development time and cost of
manufacturing processes by eliminating many potential
modes prior to operation or process and by specifying the
appropriate test to prove the designed product.
 Stages of FMEA
1. Specifying possibilities
 Functions
 Possible Failure Modes
 Root causes
 Effects
 Detection/Prevention

 Quantifying Risk
 Probability of Cause
 Severity of Effect
 Effectiveness of control to prevent cause
 Risk Priority Number
 Stages of FMEA

 Correcting High Risk Causes

 Prioritizing work
 Detailing Action
 Assigning Action Responsibility
 Check Points on Completion

1. Re-evaluation of Risk
 Recalculation of Risk Priority Number