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Introduction To Failure Mode

The document provides an introduction to Failure Mode and Effects Analysis (FMEA). FMEA is a method used to identify potential failures, causes, and effects. There are two main types: process FMEA, which examines quality issues and hazards, and design FMEA, which examines potential product malfunctions. Conducting an FMEA helps detect failures early to reduce costs and improve quality. The steps to complete an FMEA include identifying failure modes and effects, determining causes, assigning severity, occurrence, and detection rankings, calculating a risk priority number, developing and implementing an action plan, and recalculating the risk.

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AMIT THAKKAR
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40 views

Introduction To Failure Mode

The document provides an introduction to Failure Mode and Effects Analysis (FMEA). FMEA is a method used to identify potential failures, causes, and effects. There are two main types: process FMEA, which examines quality issues and hazards, and design FMEA, which examines potential product malfunctions. Conducting an FMEA helps detect failures early to reduce costs and improve quality. The steps to complete an FMEA include identifying failure modes and effects, determining causes, assigning severity, occurrence, and detection rankings, calculating a risk priority number, developing and implementing an action plan, and recalculating the risk.

Uploaded by

AMIT THAKKAR
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Introduction to Failure Mode (FMEA)

Many high-profile recalls of products are the result of poorly designed products or
processes. This product recalls are discussed in public forums. Manufacturers, suppliers, and
service providers are shown as being incapable of providing safe products. FMEA (Failure
ModeA failure mode is the manner in which a process could potent... Learn More... and Effects
Analysis) is a method that allows organizations to identify all possible failures during the design
phase.
FMEA was developed in the 1950s and is one of the oldest structured reliability improvement
techniques. It is still an effective way to lower the chance of failure.
What is Failure Mode Analysis (FMEA)?
Failure ModeThe mode is the value that appears most often in a set of ... Learn More... and
Effects Analysis (FMEA) is a structured approach that identifies potential failures in the design of
a product, processThere are many ways to organize your lean six sigma processe..., or product.
Failure modes refer to the possible failures of a process. These failures can
cause wasteMuda (無駄, on'yomi reading) is a ... Learn More..., defectsMuda (無
駄, on'yomi reading) is a ... Learn More..., or other negative outcomes for customers. Failure
Mode and Effects Analysis is used to identify, prioritize, and limit these failure modes.
FMEA does not replace good engineering. FMEA enhances engineering rather than replacing it.
It uses the expertise and knowledge of a Cross-Functional Team to review the progress of a
product/process and assess its risk of failing.
Two main types of FMEA
Process FMEA
Process FMEA (PFMEA), identifies product quality and reliability issues, customer dissatisfaction,
safety, or environmental hazards.
 Machines utilized
 Acceptance is affected by measurement systems
 Process performance is affected by the environment
 Human Factors
 Processing methods
 Materials used
Design FMEA
Design FMEA (DFMEA), which examines the potential for product malfunctions, reduced
product lives, and safety and regulatory concerns derived:
 Tolerances
 Interfaces with other components or systems
 Engineering Noise: Environments, user profiles, degradation, and systems interactions
 Material Properties
 Geometry
Why perform Failure Mode and Effects Analysis?
The cost of a failure will be lower if it is detected early. The impact of a failure discovered later
in product development and launch is more severe.
FMEA is one tool that can be used to detect failure early in product and process design. FMEA is
a tool that allows you to identify a product development (PD) failure early.
 Improved Design for Manufacturing and Assembly (DFM/A)
 Solutions at a lower cost
 Standard Work, Legacy, Tribal Knowledge, and Tribal Knowledge
 There are many options for reducing the risk
 Higher capacityCapacity refers to the maximum amount of work, output, or a ... Learn
More... for Validation and Verification of Changes
 Design of the product and manufacturing process requires collaboration
This methodology can be used to identify and correct process failures early so you can avoid
the negative consequences of mediocre performance.
When to perform Failure Mode and Effects Analysis
It is an innovative idea to conduct a Failure Mode AnalysisFailure mode analysis (FMA) is an
essential process aimed at... Learn More... and Effects Analysis at least once in your life.
 If you set a goal to improve the quality of a particular process,
 You need to learn from and fix the mistakes in a process
 Designing a new product, service, or process
 If you plan to perform an existing process in another way
It is also a clever idea to conduct FMEA periodically throughout the life of a process. For optimal
results, quality and reliability must always be checked and improved.
FMEA Relationship to Problem-Solving
FMEA’s Failure Modes are the same as the Problem Statement and Problem Description
in Problem Solving. FMEA causes are the same as potential root causes in Problem
Solving. FMEA failures are problem symptoms in Problem Solving. This relationship is illustrated
by:
 FMEA’s design and process controls are used to verify the root cause of an issue and
Permanent Corrective ActionCorrective action (also known as a Corrective Action Plan
(C... Learn More... (PCA).
 FMEA and Problem Solving can reconcile every failure and cause by cross-documenting
failure modes, problem statements, and plausible causes.
 Both the problem statements and descriptions can be linked between the two
documents. You can solve problems faster by using easy-to-find, pre-brainstormed
information in FMEA.
 For future planning of new products and process quality, data from problem-solving can
be added to an FMEA. FMEAs can now be able to identify actual failures and their
causes. This makes them more efficient and complete.
 To jump-start Fishbone and Ishikawa diagrams, it is possible to identify potential causes
of FMEA. It is not an innovative idea to brainstorm information that is already known.
The Steps to Complete a FMEA (Failure Modes and Effects
Analysis)
Review and label the Process Steps (using your process map) and the intended function or
functions of those steps.

Consider the Potential Failure Modes


Consider the Potential Failure Modes for each component and its corresponding function.
 A potential failure mode represents any way the component or process step could fail to
perform its intended function or functions.
Determine the Potential Failure Effects
Determine the Potential Failure Effects associated with each failure mode. The effectIt's the
change in the average value of the output caused by... Learn More... is related directly to the
ability of that specific component to perform its intended function.
 The effectIt's the change in the average value of the output caused by... Learn
More... should be stated in terms meaningful to product or system performance.
 If the effects are defined in general terms, it will be difficult to identify (and reduce) true
potential risks.

Determine Potential Root Causes


For each failure mode, determine all the Potential Root Causes. Use tools classified as root
cause analysis tools, as well as the best knowledge and experience of the team.
Identify Current Process Controls
For each cause, identify Current Process Controls. These are tests, procedures, or mechanisms
that you now have in place to keep failures from reaching the customer.

Assign a Severity ranking


Assign a Severity ranking to each effect that has been identified.
 The severity ranking is an estimate of how serious an effect would be should it occur.
 To determine the severity, consider the impact the effect would have on the customer,
on downstream operations, or on the employees operating the process.
The severity ranking is based on a relative scale ranging from 1 to 10.
 A “10” means the effect has a dangerously high severity leading to a hazard without
warning.
Sample of a
Severity Scale
Assign the Occurrence Ranking
 The Occurrence ranking is based on the likelihood, or frequency, that the cause (or
mechanism of failure) will occur.
 Once the cause is known, capture data on the frequency of causes. Sources of data may
be scrap and rework reports, customer complaints, and equipment maintenance
records.
Assign the Detection Rankings
 To assign detection rankings, identify the process or product related controls in place
for each failure mode and then assign a detection ranking to each control. Detection
rankings evaluate the current process controls in place.
 A control can relate to the failure mode itself, the cause (or mechanism) of failure, or the
effects of a failure mode.
To make evaluating controls even more complex, controls can either prevent a failure mode or
cause from occurring or detect a failure mode, cause of failure, or effect of failure after it has
occurred.
Calculate the Risk Priority Number (RPN)
 The RPN is the Risk Priority NumberDefinition: Failure Modes and Effects Analysis
(FMEA) is a s... Learn More.... The RPN gives us a relative risk ranking. The higher the
RPN, the higher the potential risk.
 The RPN is calculated by multiplying the three rankings together. Multiply the Severity
ranking times the Occurrence ranking times the Detection ranking
 Calculate the RPN for each failure mode and effect
Prioritize the Risks by Sorting the RPN from Highest Score to Lowest Score. This will help the
team determine the most critical inputs and the causes for their failure.

Develop Action Plan


 Acting means reducing the RPN. The RPN can be reduced by lowering any of the three
rankings (severity, occurrence, or detection) individually or in combination with one
another
Who is Responsible
 This is an especially crucial step in Acting!
 Be sure to include person(s) responsible and the deadline

Act
 The Action Plan outlines what steps are needed to implement the solution, who will do
them, and when they will be completed.
 Most Action Plans identified during a PFMEA will be of the simple “who, what, & when”
category.
 Responsibilities and target completion dates for specific actions to be taken are
identified.

Recalculate the Resulting RPN


 This step in a PFMEA confirms the action plan had the desired results by calculating the
resulting RPN.
 To recalculate the RPN, reassess the severity, occurrence, and detection rankings for the
failure modes after the action plan has been completed.

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