Assignment No.

Failure Mode and Effects Analysis of Product

Submitted By:

Outline
Failure Mode and Effects Analysis
What is it? Need FMEA Methods Example

FMEA in-class exercise

What is an FMEA?
Description: A procedure that examines each item in a system, considers how that item can fail and then determines how that failure will affect (or cascade through) the system Acronyms FMEA: Failure Modes and Effects Analysis FMECA: Failure Modes and Effects and Criticality Analysis

Need for Conducting a FMEA

Improves design by discovering unanticipated failures Highlights the impact of the failures Potentially helpful during legal actions Provides a method to characterize product safety

Method to Conduct an FMEA

Identify all components or systems at given level of the design hierarchy. List the function of each identified component or system. Identify failure modes for each component/system. Typically there will be several ways in which a component can fail. Determine the effect (both locally and globally) on the system.

Method to Conduct an FMEA

Classify the failure by its effects on the system operation. Determine the failures probability of occurrence. Identify how the failure mode can be detected (may point out what needs to be inspected on a regular basis). Identify any compensating provisions or design changes to mitigate the failure effects.

DESIGN FMEA (DFMEA)

The Design FMEA is used to analyze products before they are released to production. It focuses on potential failure modes of products caused by design deficiencies.

Design FMEAs are normally done at three levels system, subsystem, and component levels
This type of FMEA is used to analyze hardware, functions or a combination

PROCESS FMEA (PFMEA)

The Process FMEA is normally used to analyze manufacturing and assembly processes at the system, subsystem or component levels. This type of FMEA focuses on potential failure modes of the process that are caused by manufacturing or assembly process deficiencies.

What to Do
Function comes from Functional Analysis, Functional Decomposition Potential Failure Mode comes from things that have gone wrong in the past, concerns of designers, and brainstorming. Possible considerations are partial function, intermittent function, excess function. Potential Effects are consequences to the design, the user, and the environment. Safety and regulation noncompliance are critical issues.

IN-CLASS PROBLEM 1
Most cars have a fuel filter between the fuel tank and the engine. Consider the consequences of a) Anti-function (opposite of filtering) b) Partial function c) Intermittent function d) Excess function

What to Do
Potential Causes of failure should be engineering related such as incorrect material, corrosion, wear and human related such as inexperience, misuse, etc. Current Design Controls are things like inspections, testing, poke yoke, and other design checks that are intended to prevent the problem.

What to Do
Assign values to Severity, Occurrence, and Detection using the tables. Determine the Risk Priority Number (Severity* Occurrence * Detection) Develop an action plan Implement an action plan

In-Class Problem 2
Coffee Machine Process Map
Inputs
Hot Water Soap Scrubber Clean Carafe Cold Water Measuring Mark Full Carafe Clean Carafe

Outputs
Cleaned Carafe Dirty Water Wet Scrubber Full Carafe

Inputs
Customer Order Size Specification Complete Order Hot Coffee Cup Filled Cup Customer Cream Sugar Amount Desired Complete Order Money Receive Coffee Order

Outputs
Complete Order

Fill Carafe w/Water

Pour Coffee into Cup

Filled Cup

Pour Water into Maker Place Filter in Maker Put Coffee in Filter

Filled Maker Empty Carafe Maker w/Filter Maker w/Filter & Coffee Operating Maker Heat Brewed Coffee Hot Coffee

Filter Maker w/Filter Fresh Coffee Dosing Scoop Maker w/Filter & Coffee Brewing Coffee

Offer Cream & Sugar

Customer Reply Amount Specified Complete Order

Complete Transaction

Turn Maker On

Make Change Temperature Taste Strength Smile Happy Customer 15

Coffee Delivery

Say Thank You

Select Temperature Setting

Determine Failure Modes

Step 1: For Each Input, Determine the Potential Failure Modes

16

Identify Effects and Severity

Step 2: For Each Failure Mode, Identify Effects and Assign Severity

17

Identify Failure Causes and Score

Step 3: Identify Potential Causes of Each Failure Mode and Assign Score

18

Step 4: List Current Controls for Each Cause and Assign Score

Identify Controls and Score

19

RPNs

Step 5: Calculate RPNs

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Identify Actions and Responsibilities

Step 6: Develop Recommended Actions, Assign Responsible Persons, and Take Actions

21

Compare RPNs

Step 7: Assign the Predicted Severity, Occurrence, and Detection Levels and Compare RPNs

22

Severity Ranking
Effect None Very Slight Slight Minor Moderate Rank 1 2 3 4 5 Criteria No effect Negligible effect on Performance. Some users may notice. Slight effect on performance. Non vital faults will be noticed by many users Minor effect on performance. User is slightly dissatisfied. Reduced performance with gradual performance degradation. User dissatisfied.

Severe
High Severity Very High Severity Extreme Severity Maximum Severity

6
7 8 9 10

Degraded performance, but safe and usable. User dissatisfied.

Very poor performance. Very dissatisfied user. Inoperable but safe. Probable failure with hazardous effects. Compliance with regulation is unlikely. Unpredictable failure with hazardous effects almost certain. Non-compliant with regulations.

Occurrence Ranking
Occurrence Extremely Unlikely Remote Likelihood Very Low Likelihood Low Likelihood Moderately Low Likelihood Medium Likelihood Moderately High Likelihood Rank 1 2 3 4 5 6 7 Criteria Less than 0.01 per thousand 0.1 per thousand rate of occurrence 0.5 per thousand rate of occurrence 1 per thousand rate of occurrence 2 per thousand rate of occurrence 5 per thousand rate of occurrence 10 per thousand rate of occurrence

Very High Severity Extreme Severity

Maximum Severity

8 9
10

20 per thousand rate of occurrence 50 per thousand rate of occurrence

100 per thousand rate of occurrence

Detection Ranking
Detection Extremely Likely Very High Likelihood High Likelihood Moderately High Likelihood Medium Likelihood Moderately Low Likelihood Low Likelihood Very Low Likelihood Remote Likelihood Extremely Unlikely Rank 1 2 3 4 5 6 7 8 9 10 Criteria Can be corrected prior to prototype/ Controls will almost certainly detect Can be corrected prior to design release/Very High probability of detection Likely to be corrected/High probability of detection Design controls are moderately effective Design controls have an even chance of working Design controls may miss the problem Design controls are likely to miss the problem Design controls have a poor chance of detection Unproven, unreliable design/poor chance for detection No design technique available/Controls will not detect

Advantages
As a systematic approach, the Process Potential FMEA parallels and formalizes
the mental discipline that an engineer goes through in any manufacturing planning process. The Process Potential FMEA identifies potential product related process failure modes. The Process Potential FMEA assesses the potential customer effects of the failures. The Process Potential FMEA identifies potential manufacturing and/or assembly process causes. The Process Potential FMEA identifies significant process variables to focus

controls for occurrence reduction and detection of failure conditions.

The Process Potential FMEA develops a list of potential failure modes ranked according to their affect on the customer, thus establishing a priority system for corrective and preventive action considerations.

Drawbacks
The required detail makes the process time consuming. Some complex processes can take hours or days to complete the FMEA. Assumes the causes of problems are all single event in nature (combinations of events are captured as a single initiating event). Requires open communication and cooperation of the participants to be

effective.
The personnel involved need to be candid about issues in their own area. The process relies on recruiting the right participants.

Without the follow up sessions, the process will not be effective.

Examination of human error is limited and sometimes overlooked.