Failure mode effect analysis
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This document provides an overview of failure mode and effects analysis (FMEA). It defines key terms like failure mode and effects analysis. It explains that FMEA is a process to identify all possible product failures and their consequences. The document notes that FMEA helps prevent problems, reduce costs, and improve customer satisfaction. It outlines the resources, process, types of FMEA, advantages, and limitations of FMEA.
Failure mode effect analysis
- 1. Prepared by.. Janaki Patel(140110105033) Jay Patel(140110105034) Kevin Patel(140110105035) Mihir Patel(140110105036)
- 2. What is FMEA? • Failure mode - the way in which something might fail • Effects analysis – studying the consequences of the various failure modes to determine their severity to the customer.
- 3. Simply put FMEA is: • A process that identifies all the possible types of failures that could happen to a product and potential consequences of those failures.
- 4. Why do an FMEA? • Preventing problems is cheaper and easier than cleaning them up. • Some things are too risky or costly to incur mistakes.
- 5. Resources Needed • Commitment of top management • Knowledgeable individuals • Individuals attentive to FMEA timelines • People resources may be internal or external to the business or a combination of both
- 6. FMEA Provides the Potential to: • Reduce the likelihood of customer complaints • Reduce the likelihood of campaign changes • Reduce maintenance and warranty costs • Reduce the possibility of safety failures • Reduce the possibility of extended life or reliability failures • Reduce the likelihood of product liability claims
- 7. Advantages • Enhance design and manufacturing efficiencies • Alleviate late change crises • Minimize exposure to product failures • Augment business records • Improve “bottom line” results • Add to customer satisfaction
- 8. Limitation • Employee training requirements • Initial impact on product and manufacturing schedules • Financial impact required to upgrade design, manufacturing, and process equipment and tools
- 10. Back Ground Task for PFMEA (Process FMEA) 1. Details of the manufacturing process/Process flow chart 2. List of critical process parameters (Temperature, Pressure, etc.) 3. Properties of device material (brittleness, density etc.) 4. Manufacturing environment details 5. Manufacturing Tool details 6. Batch to batch variation
- 11. Back Ground Task for DFMEA (Design FMEA) 1. Detail design of Device 2. Part/Component list 3. Functions of components 4. Theory/principle for the positioning of different components at their respective places (pin, sieve etc) 5. Operating environment conditions (Humidity level, Pressure, Temp etc) 6. Design Specifications (with Tolerances) 7. Details of operating methods (pin movement fidelity, fatigue effects etc) 8. Critical parameters of design and its dimensions
- 12. FMEA Procedure 1. For each process input (start with high value inputs), determine the ways in which the input can go wrong (failure mode) 2. For each failure mode, determine effects ▫ Select a severity level for each effect 3. Identify potential causes of each failure mode ▫ Select an occurrence level for each cause 4. List current controls for each cause ▫ Select a detection level for each cause 12 Process Steps
- 13. FMEA Procedure (Cont.) 5. Calculate the Risk Priority Number (RPN) 6. Develop recommended actions, assign responsible persons, and take actions ▫ Give priority to high RPNs ▫ MUST look at severities rated a 10 7. Assign the predicted severity, occurrence, and detection levels and compare RPNs 13 Process Steps
- 14. FMEA Inputs and Outputs 14 FMEA C&E Matrix Process Map Process History Procedures Knowledge Experience List of actions to prevent causes or detect failure modes History of actions taken Inputs Outputs Information Flow
- 15. The FMEA Form 15 Identify failure modes and their effects Identify causes of the failure modes and controls Prioritize Determine and assess actions A Closer Look