Fmea Handbook

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 (Design Team)

Process (Manufacturing Team)

Mistake Proofing Techniques

Component Proving Process

FMEA Continuous Improvement Programs

Wh y we use FMEA tion n e 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 Identify

Define

Problem

Finding Why existing system have failed

Cause

Finding high Risk processes Finding potential problem areas

Solution

Finding risk in planned actions

Implement

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

Step 2

Step 3

Step 4

Step 5

Scope Project

Brainstorm all possible Failure Modes

Identify possible effect of failure

Determine severity ranking

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 Name:

Prepared by:

What is the impact on the Key Output Variables once it fails (customer or internal requirements)?

What causes the Key Input to go wrong?

O C C

Current Controls

What are the existing controls and procedures that prevent either the Cause or the Failure Mode?

D E T

detect the Cause or

In what ways can the Process Step or Input fail?

Potential Causes

or FM occur ?

What is the Process Step or Input?

S E V

Howoftendoes cause

Potential Failure Effects

HowSevere is the

Potential Failure Mode

effect to the customer?

Key Process Step or Input

the Failure Mode?

FMEA Date (Orig):

How well can you

Process Owner:

R P N

Actions Recommended

Resp.

What are the Who is Responsible actions for for the reducing the recommended occurrence of the action? cause, or improving detection?

0 0 0 0 0 0 0 0 0 0 0 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 document meaning it

is

the

ultimate

dynamic

lives as long as the process or product it is associated with does. Please use them !