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Failure Mode and Effects Analysis (Fmea)

The document provides an introduction to Failure Mode and Effects Analysis (FMEA). FMEA is a systematic process for identifying potential failures, their causes and effects. It is used during product design and development. Potential failures are called failure modes. Each failure mode is assigned a risk priority number based on the severity, occurrence, and detection of the failure's effects. There are two types of FMEAs - Design FMEA which focuses on product design failures, and Process FMEA which focuses on process failures. The FMEA process involves identifying failure modes, analyzing their effects and risks, developing corrective actions, and reevaluating risks after improvements.

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Chaudhary Hassan Ali
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145 views

Failure Mode and Effects Analysis (Fmea)

The document provides an introduction to Failure Mode and Effects Analysis (FMEA). FMEA is a systematic process for identifying potential failures, their causes and effects. It is used during product design and development. Potential failures are called failure modes. Each failure mode is assigned a risk priority number based on the severity, occurrence, and detection of the failure's effects. There are two types of FMEAs - Design FMEA which focuses on product design failures, and Process FMEA which focuses on process failures. The FMEA process involves identifying failure modes, analyzing their effects and risks, developing corrective actions, and reevaluating risks after improvements.

Uploaded by

Chaudhary Hassan Ali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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FAILURE MODE AND EFFECTS

ANALYSIS (FMEA)

1
Introduction to FMEA
• Failure Mode and Effects Analysis (FMEA) is a systematic
procedure for identifying and preventing problems before
they have a chance to occur.
• FEMA can be applied to a product or to a process and is
customarily applied during the product design and
development or process design stages.

2
Introduction to FMEA (Contd.)
• A failure can occur due to a malfunction in Operation, a
design error, or when a human makes a mistake in either
using a product or operating a process.
• All the ways in which a process or product failure can occur
are called failure modes.

3
Introduction to FMEA (Contd.)
• Associated with each failure mode is a failure effect-the
consequences that a failure mode has on the operation,
function, or status of a product or process.
• All effects are not equally likely thus for each failure mode
a relative risk is assigned.
• The relative risk is expressed as a risk priority number
(RPN) which is the product of three factors: severity,
occurrence, and detection.
• These factors are defined as follows:

4
Introduction to FMEA (Contd.)
 Severity – an assessment of how serious the effect of the
failure mode is on the customer.
 Occurrence – an assessment of the likelihood that a
particular cause of a failure mode will occur during the life
of a product or process.
 Detection – an assessment of the likelihood that the failure
mode or its cause will be detected before the impact of the
effect reaches the customer.

5
Type of FMEA
• There are two types of FMEAs:
Design Failure Mode and Effects Analysis (DFMEA)
Process Failure Mode and Effects Analysis (PFMEA)

6
Type of FMEA (Contd.)
• Design Failure Mode and Effects Analysis (DFMEA)
• The primary objective of a DFMEA is to identify potential
failures associated with a product’s design that would lead
to;
 Product malfunctions or reduced product reliability
 A shortened product life
 Safety hazards to customers while using the product

7
Type of FMEA (Contd.)
• A PFMEA is applied for the purpose of discovering any
potential failures in a process
 Impact product quality or reliability
 Reduce process Reliability
 Cause Customer dissatisfaction
 Create safety hazards or case injury to workers
 Cause harm to the environment

8
FMEA Process

9
Conducting FMEA
Step1 Review the design using blueprints or schematics (DFMEA) or
the process using flowcharts (PFMEA) to identify key components.

Step2 Brainstorm potential modes by consulting existing


documentation and data, looking for clues.
Step3 List potential effects of failure, keeping in mind that there may be
more than one for each failure mode.

Step4 Consult the severity rating guidelines and assign severity ratings
based on the perceived severity of the consequences of each failure.

Step5 Consult the occurrence rating guidelines and assign occurrence ratings
based on the perception of how frequently each failure is likely to occur.

Step6 Consult the detection rating guidelines and assign


detection ratings based on the chances the failure will be detected
prior to a product design being released to production (DFMEA) or
a process failure would be detected before its consequences
would be felt by a customer (PFMEA)
10
Conducting FMEA (Contd.)

Step7 Calculate the risk priority number (RPN) for each failure mode by multiplying the
product of the relevant severity, occurrence, and detection ratings.

Step8 Develop an action plan that defines who will do what and by when.

Step9 Implement the improvements identified by the DFMEA or PFMEA team.

Step10 Calculate the resulting RPN by reevaluating each of the


potential failures after improvements have been made and have
had time to take effect, recalculating the relevant severity,
occurrence, and detection ratings, and their corresponding RPNs.

11

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