FAI LUR E M ODE E FFE CT

ANA LY SIS
Con ten ts

 FMEA - Origin

 Types of FMEA

 Why we use FMEA

 When to use FMEA

 FMEA - Potential
Application

 Steps on Completing
FMEA
Fi rst O ri gi nat ed Fr om

 First known as Failure Mode Effects

and Critical Analysis inn 1950’s, was
designed for Aerospace and US
Military.

 Further developed by an Aerospace Industry in

1960’s for the Appolo Mission and spread to
Automotive industry & now used extensively
across all industry sectors.
Fa ilu re M od e…?

The way in which a specific

process input fails – if not detected and
either corrected or removed, will cause
an effect to occur.

The way in which something goes

WRONG…!
Effect: Impact on customer requirements.
Generally external customer focus, but can also
include downstream processes.
Types of FME A

Analytical Techniques

Design Process
(Design Team) (Manufacturing Team)
Component Proving Mistake Proofing
Process Techniques

FMEA

Continuous Improvement
Programs
Wh y we use FMEA
en tion
v
Pre etter
is b ure..!!
nC
tha

• Increase Probability of detection

• Identify biggest contributor to Failures &
eliminate them
• Reduce probability of failure occurring
• Build Quality into the product & process
Wh en t o u se FM EA
 Most beneficial as a “before the-event” action
 Use it when designing products or processes, to
identify and avoid failure-prone designs.
FMEA could be done for any processes
 Use it when investigating why existing
systems have failed
 Use it when investigating possible
solutions
 Use it when planning actions
 FM EA f low ch art
Finding Why existing
Identify Define Problem system have failed

Finding high Risk Cause

processes
Finding
potential
problem areas
Solution Implement

Finding risk in planned

actions
Review

Investigating Why
action failed to work
as expected Follow-up
FM EA – Pot en tial
Ap plica tion
 Service/Component Providing processes

 Outsourcing/Resourcing of product

 Develop suppliers to achieve Quality

Renaissance/Scorecard Targets

 Major process/Equipment/Technology Changes

 Cost Reduction

 Assists in analysis of a flat pareto chart

St ep s on Comp letin g FM EA
Step 1 Scope Project

Step 2 Brainstorm all possible Failure Modes

Step 3 Identify possible effect of failure

Step 4 Determine severity ranking

Step 5 Identify cause of failure

Step 6 Determine occurrence ranking

Step 7 Define current control method

Step 8 Determine detection ranking

Step 9 Calculate Risk priority numbers (RPN)

Step 10 Prioritize corrective actions

 Failure Modes Effects Analysis
Process or Product
Prepared by:
Name:
Process Owner: FMEA Date (Orig):

S O D R
Key Process Step Potential Failure Potential Failure Actions

effect to the customer?

E Potential Causes C Current Controls E P Resp.
or Input Mode Effects Recommended

the Failure Mode?

How well can you
V C T N

the Cause or
Howoftendoes cause
is the

occur
?
What is the In what ways can What is the impact What causes the What are the What are the Who is Responsible
Process Step or the Process Step on the Key Output Key Input to go existing controls actions for for the

HowSevere
Input? or Input fail? Variables once it wrong? and procedures reducing the recommended

or FM
fails (customer or that prevent either occurrence of the action?

detect
internal the Cause or the cause, or improving
requirements)? Failure Mode? detection?

0
Dynamic D ocu men t:

The single biggest failure people make with FMEAs is to

spend time
completing the document and then storing it in a file
cabinet
somewhere.  The FMEA is the ultimate dynamic
document meaning it
lives as long as the process or product it is associated
with does.

Please use them !