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Fema Notes

FMEA (Failure Modes and Effects Analysis) is a proactive method for identifying potential failures in products or processes to minimize risks before they occur. The FMEA process involves steps such as identifying failure modes, assessing their effects, and implementing corrective actions, with two main categories: Design FMEA (DFMEA) and Process FMEA (PFMEA). The approach emphasizes the importance of Risk Priority Number (RPN) for prioritizing risk reduction efforts and improving overall reliability and safety.

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Abhishek Adhikari
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4 views

Fema Notes

FMEA (Failure Modes and Effects Analysis) is a proactive method for identifying potential failures in products or processes to minimize risks before they occur. The FMEA process involves steps such as identifying failure modes, assessing their effects, and implementing corrective actions, with two main categories: Design FMEA (DFMEA) and Process FMEA (PFMEA). The approach emphasizes the importance of Risk Priority Number (RPN) for prioritizing risk reduction efforts and improving overall reliability and safety.

Uploaded by

Abhishek Adhikari
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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FEMA

Slide 1: Introduction to FMEA

• FMEA (Failure Modes and Effects Analysis) is a systematic approach to


identifying potential failures in a product or process before they happen.
• It helps teams predict, prevent, and minimize risks rather than reacting after failures
occur.

Exam Notes:

• Define FMEA
• Purpose: Identify failure risks, assess their impact, and implement preventive
measures.
• Proactive, not reactive approach.

Slide 2: Steps in the FMEA Process

1. Identify failure modes – What could go wrong?


2. Determine failure causes – Why might it happen?
3. Assess failure effects – What are the consequences?
4. Evaluate and prioritize failures
5. Take corrective actions

Exam Notes:

• List the steps in FMEA.


• Key focus: Prevent issues before implementation.

Slide 3: Categories of FMEA

• Design FMEA (DFMEA): Focuses on failures in the product’s design (e.g., material
selection, geometry, tolerances).
• Process FMEA (PFMEA): Focuses on failures in the manufacturing or operational
process (e.g., human error, machine failure, environmental factors).

Exam Notes:

• Two types: DFMEA (product design) & PFMEA (process execution).


• DFMEA deals with product malfunctions; PFMEA focuses on production issues.
Slide 4: DFMEA (Design FMEA)

• Used to identify risks in product design before production.


• Evaluates how material properties, system interactions, or environmental factors
can lead to failures.
• Uses Risk Priority Number (RPN) to measure risk levels.

Exam Notes:

• Purpose of DFMEA: Improve design reliability and safety.


• Factors: Material properties, tolerances, environmental stress.
• Importance of RPN: Helps prioritize risk reduction efforts.

Slide 5: PFMEA (Process FMEA)

• Identifies process-related failures (e.g., incorrect assembly, human errors, machine


breakdowns).
• Helps to improve quality control and reduce customer dissatisfaction.
• Uses detection rankings to assess if failure can be caught before reaching customers.

Exam Notes:

• Focuses on process failures, unlike DFMEA (product failures).


• Detection rankings assess how well failures can be caught.

Slide 6: 10 Steps of FMEA

1. Review the process (Flowchart, components).


2. Identify failure modes (Brainstorm potential failures).
3. List failure effects (Impact on customers/process).
4. Assign severity ranking (How serious is the failure?).
5. Assign occurrence ranking (How often will it happen?).
6. Assign detection ranking (How likely is it to be caught?).
7. Calculate RPN (Severity × Occurrence × Detection).
8. Develop action plan (Who will fix what?).
9. Implement improvements.
10. Recalculate RPN (Measure improvement).

Exam Notes:

• 10 steps must be memorized.


• RPN formula: Severity × Occurrence × Detection.
Slide 7: FMEA Scoring & Risk Priority Number (RPN)

• Severity (S): How dangerous is the failure?


• Occurrence (O): How often does it happen?
• Detection (D): How easily can it be detected?
• Formula: S × O × D = RPN

Exam Notes:

• RPN formula must be memorized.


• High RPN → High risk → Immediate action required.

Slide 8: Benefits of FMEA

• Helps create safer, more reliable designs and processes.


• Prevents costly failures and customer dissatisfaction.
• Provides systematic problem-solving and decision-making.

Exam Notes:

• Key benefits: Risk reduction, cost savings, reliability improvement.


• Used before launching new products or process changes.

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