Failure Modes and Effects Analysis

Failure modes and effect Analysis
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History of FMEA
The FMEA process was originally developed by the US military in
1949 to classify failures "according to their impact on mission

success and personnel/equipment safety".
FMEA has since been used on the 1960s Apollo space missions.
In the 1980s it was used by Ford to reduce risks after one model of
car, the Pinto, suffered a fault in several vehicles causing the fuel
tank to rupture and subsequently burst into flames after crashes.
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Definition:
FMEA is a step-by-step approach for identifying possible failures in a
design, a manufacturing or assembly process, or a product or service.

FMEA is a integrated component of Reliability centered Maintenance.
(RCM) is a process used to determine the maintenance requirements of
any physical asset in its operating context.
FMEA is a systematic system:
to identify how a part or product can fail,
what is the probability of failure,
what will be the effect on the rest of the system if such a failure
occurs,
and
what action is necessary to prevent the failure.
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Types of FMEA:
Process FMEA: Used to analyze transactional processes. Focus is on
failure to produce intended requirement, a defect. Failure modes may

stem from causes identified.
System FMEA: A specific category of Design FMEA used to analyze
systems and subsystems in the early concept and design stages.
Focuses on potential failure modes associated with the functionality of a
system caused by design.
Design FMEA: Used to analyze component designs. Focuses on
potential failure modes associated with the functionality of a component
caused by design. Failure modes may be derived from causes identified
in the System FMEA.
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Vocabulary:
Failure mode : manner in which the process could fail to meet the
process requirements.
The way in which a specific process input fails - if not detected
and either corrected or removed, will cause an effect to occur.
Cause : a deficiency that results in a failure mode
sources of variation
Effect : effect of the failure mode on the product, process or
customer.
Severity : how severe is the effect on customer?
Occurrence : how often does the cause/failure mode occur?
Detectability : how well can you detect the cause/failure mode?
RPN : Risk Priority Number
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FMEA Standardized Rating System:
Rat
ing
DEGREE OF SEVERITY
LIKELIHOOD OF
OCCURRENCE
Freq
( 1 in )
ABILITY TO DETECT
Detn.
Cert.
( %)
Customer will not notice the adverse effect or it is

insignificant.
Likelihood of occurrence is
remote.
1,000,000
Sure that the potential failure will

be found or prevented before
reaching the next customer.
100
Customer will probably experience slight annoyance.
Low failure rate with

supporting documentation.
20,000
Almost certain that the potential

failure will be found or prevented
before reaching the next
customer.
99
Customer will experience annoyance due to slight

degradation of performance.
Low failure rate without

5,000
Low likelihood that the potential

failure will reach the next
customer undetected.
95
Customer dissatisfaction due to reduced

performance.
Occasional failures.
2,000
Controls may not detect or

prevent the potential failure from
90
Customer is made uncomfortable or their productivity

is reduced by the continued degradation of the effect.
Relatively moderate failure

rate with supporting
documentation.
500
Moderate likelihood that the

potential failure will reach the
next customer.
85
Warranty repair or significant manufacturing or

assembly complaint.
Moderate failure rate without

100
Controls are unlikely to detect or

prevent the potential failure from
80
High degree of customer dissatisfaction due to

component failure without complete loss of function.
Productivity impacted by high scrap or rework levels.
Relatively high failure rate

with supporting
documentation.
50
Poor likelihood that the potential

failure will be detected or
prevented before reaching the
next customer.
70
Very high degree of dissatisfaction due to the loss of

function without a negative impact on safety or
governmental regulations.
High failure rate without

20
Very poor likelihood that the

potential failure will be detected
or prevented before reaching the
next customer.
60
Customer endangered due to the adverse effect on

safe system performance with warning before failure
or violation of governmental regulations.
Failure is almost certain

based on warranty data or
significant DV testing.
10
Current controls probably will not

even detect the potential failure.
50
10
Customer endangered due to the adverse effect on

Assured of failure based on
safe system performance without warning before
warranty data or significant
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failure or violation of governmental regulations.
DV testing
Absolute certainty that the

current controls will not detect
the potential failure.
<50
FMEA - Example
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FMEA Example (contd)
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FMEA - Example (contd)
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Industry Standards:
SAE Standard: J-1739
Automotive Systems
SAE Standard: ARP-5580
Aerospace Recommended Practice
Military Standard: MIL-STD-1629A
Failure Mode, Effects and Criticality Analysis (FMECA)
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Effective FMEA Process:
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Benefits of
Captures the collective knowledge of a team
FMEA:
Improves the quality, reliability, and safety of the process

Reduces process development time, cost
Provides historical records; establishes baseline
Helps to increase customer satisfaction and safety
Assists in determining the best possible design and development
options to provide high reliability and manufacturability potential.
Assists in considering the possible failure modes and their effect
on the reliability and manufacturability of the product.
Improves the collaboration not only between the members working
together inside the company but also between externals such as
suppliers and customers.
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Disadvantages:
Time consuming and high cost involved process.
It cannot be used efficiently when a rapid development process of
a product is needed or in the case of small batch number

production.
It can not be identified all the failure modes that can lead to
unsucces.
It contains a large amount of subjectivism, so can not be assured
that the stated weight of failure chain corresponds with the reality
It is not able to discover complex failure modes involving multiple
failures or subsystems, or to discover expected failure intervals of
particular failure modes.
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Failure Modes and Effects Analysis

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Failure modes and effect Analysis

The FMEA process was originally developed by the US military in

1949 to classify failures "according to their impact on mission

FMEA is a step-by-step approach for identifying possible failures in a

design, a manufacturing or assembly process, or a product or service.

failure to produce intended requirement, a defect. Failure modes may

FMEA Standardized Rating System:

Customer will not notice the adverse effect or it is

Sure that the potential failure will

Customer will probably experience slight annoyance.

Low failure rate with

Almost certain that the potential

Customer will experience annoyance due to slight

Low failure rate without

Low likelihood that the potential

Customer dissatisfaction due to reduced

Controls may not detect or

Customer is made uncomfortable or their productivity

Relatively moderate failure

Moderate likelihood that the

Warranty repair or significant manufacturing or

Moderate failure rate without

Controls are unlikely to detect or

High degree of customer dissatisfaction due to

Relatively high failure rate

Poor likelihood that the potential

Very high degree of dissatisfaction due to the loss of

High failure rate without

Very poor likelihood that the

Customer endangered due to the adverse effect on

Failure is almost certain

Current controls probably will not

Customer endangered due to the adverse effect on

Absolute certainty that the

FMEA Example (contd)

FMEA - Example (contd)

FMEA - Example (contd)

FMEA - Example (contd)

Effective FMEA Process:

Improves the quality, reliability, and safety of the process

a product is needed or in the case of small batch number

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