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    FMEA2002

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    deleep6132
    The document discusses Failure Mode and Effects Analysis (FMEA). FMEA is a systematic methodology to analyze potential failures in systems, designs, processes, and services. It involves identifying possible failures and their causes, and assessing the severity and likelihood of their occurrence. The analysis allows organizations to take actions to prevent failures from occurring or reduce their impact. The document outlines the FMEA process, types of FMEAs, timing of analyses, uses, advantages, and limitations.

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    FMEA2002

    Uploaded by

    deleep6132
    115 views22 pages
    The document discusses Failure Mode and Effects Analysis (FMEA). FMEA is a systematic methodology to analyze potential failures in systems, designs, processes, and services. It involves identifying possible failures and their causes, and assessing the severity and likelihood of their occurrence. The analysis allows organizations to take actions to prevent failures from occurring or reduce their impact. The document outlines the FMEA process, types of FMEAs, timing of analyses, uses, advantages, and limitations.

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    The document discusses Failure Mode and Effects Analysis (FMEA). FMEA is a systematic methodology to analyze potential failures in systems, designs, processes, and services. It involves identifying possible failures and their causes, and assessing the severity and likelihood of their occurrence. The analysis allows organizations to take actions to prevent failures from occurring or reduce their impact. The document outlines the FMEA process, types of FMEAs, timing of analyses, uses, advantages, and limitations.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    115 views22 pages

    FMEA2002

    Uploaded by

    deleep6132
    The document discusses Failure Mode and Effects Analysis (FMEA). FMEA is a systematic methodology to analyze potential failures in systems, designs, processes, and services. It involves identifying possible failures and their causes, and assessing the severity and likelihood of their occurrence. The analysis allows organizations to take actions to prevent failures from occurring or reduce their impact. The document outlines the FMEA process, types of FMEAs, timing of analyses, uses, advantages, and limitations.

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    Failure Mode Effects Analysis

    Alex Kurian 6th Sem. MBA PT SMS

    FMEA
    F failure : when a system or part of a system performs in a way that is not intended or desirable. M Mode : the way or manner in which something such as a failure, can happen. Failure mode is the manner in which something can fail. E - Effect :the results or consequences of a failure mode. A - Analysis : The detailed examination of the elements or structure of a process

    Failure Mode and Effects Analysis


    1. 2. 3. 4. Define failure mode. Identify cause of failure. Identify effects of failure. Corrective action.

    History of FMEA
    November 9, 1949. US Military Procedure for reliability analysis NASA in the 1960s to improve and verify reliability of space program hardware. 1980s automobile industry

    Ford Pinto
    The car tended to erupt in flame in rear-end collisions. The Pinto is at the end of one of autodom's most notorious paper trails, the Ford Pinto memo , which ruthlessly calculates the cost of reinforcing the rear end ($121 million) versus the potential payout to victims ($50 million).

    FMEA
    A methodology to analyze and discover: all potential failure modes of a system, The effects these failures have on the system and how to correct and or mitigate the failures or effects on the system. [The correction and mitigation is usually based on a ranking of the severity

    What is FMEA?
    Systematic analysis of potential failure modes aimed at preventing failures. Preventive action process. Corrective actions required to prevent failures from reaching the customer and to assure the highest possible yield, quality and reliability.

    Purpose of FMEA
    FMEA provides a basis for identifying root failure causes and developing effective corrective actions. The FMEA identifies reliability/safety critical components It facilitates investigation of design alternatives at all stages of the design Provides a foundation for other maintainability, safety, testability, and logistics analyses

    Benefits of FMEA
    Assists in determining the best possible design and development options to provide high reliability and manufacturability potential. Assists in considering the possible failure modes and their effect on the reliability and manufacturability of the product. Provides a well-documented record of improvements from corrective actions implemented. Provides information useful in developing test programs and in-line monitoring criteria. Provides historical information useful in analyzing potential product failures during the manufacturing process. Provide new ideas for improvements in similar designs or processes.

    Purpose of FMEA
    To identify possible failure modes that could occur in the design or manufacturing of a product. To identify corrective actions that could reduce or eliminate the potential for failures to occur. To provide documentation of the process. To quantify the risk level associated with each potential failure mode.

    How FMEA is performed?

    Occurrence (O) Severity (S) Detection (D) Risk Priority Number (RPN) = OxSxD

    How FMEA is done?


    The FMECA Analysis Process: 1) Define the system 2) Define ground rules and assumptions 3) Construct system block diagrams 4) Identify failure modes 5) Analyze failure effects / causes 6) Feed results back into design process 7) Classify failure effects by severity(SEV) 8) Perform criticality calculations

    How FMEA is done?


    9) Rank failure mode criticality 10) Determine critical items 11) Feed results back into design process 12) Identify means of failure detection (DET), isolation and compensating provisions 13) Document the analysis. Summarize uncorrectable design areas, identify special controls necessary to mitigate risk. 14) Make recommendations 15) Follow up on corrective action implementation / effectiveness

    Engineering Quality

    Development Purchasing Org. and Eff. Proc. Impr. Team

    "POOL" of remarks

    New Remarks

    FMEA Maintain the FMEA Library Maintenance Filter the remarks team

    FMEA Library
    FMEA Tool

    FMEA Reports Follow-up actions

    Designer

    Consult the Library Search for solutions

    Consult
    Fill in Consult

    FMEA Facilitator

    FMEA Session

    Failure Mode and Effect Analysis

    Page: Date:
    Proje ct: Function/System: Phase/Mode: Assembly Name: Simple Flashlight Example

    1 8 Nov 2006

    Flashlight
    Normal Operation Flashlight Reference Drawing: Assembly RD: FL164578-1 1

    Ref Des 1

    Name & Function Flashlight - No Data

    FMI FAAA

    Failure Mode constant flashlight output flashlight output dim

    Local Effect

    Next Higher Sev. End Effect Effect 1 constant flashlight output 3 flashlight output dim

    Detection Method Compensating Provisions Remarks Comp / Prov: None Det. Method: None Remarks: None Comp / Prov: None Det. Method: None Remarks: None

    Failure Cause Stuck closed

    RD

    Item Causing

    1A2 Switch

    FAAB

    dim light

    1A1 Bulb

    FAAC

    flashlight sometimes will not turn on no flashlight output

    3 flashlight Comp / Prov: None sometimes Det. Method: None will not turn Remarks: None on 2 no flashlight Comp / Prov: None output Det. Method: None Remarks: None

    poor contact low power intermittent

    1A3 Contact 1A4 Battery 1A2 Switch

    FAAD

    intermittent no light

    1A3 Contact 1A1 Bulb

    Stuck open no contact no power

    1A2 Switch 1A3 Contact 1A4 Battery

    Types of FMEA
    Process: analysis of manufacturing and assembly processes Design: analysis of products prior to production Concept: analysis of systems or subsystems in the early design concept stages Equipment: analysis of machinery and equipment design before purchase Service: analysis of service industry processes before they are released to impact the customer System: analysis of the global system functions Software: analysis of the software functions

    Timing of FMEA
    The FMEA should be updated whenever:
    A new cycle begins (new product/process) Changes are made to the operating conditions A change is made in the design New regulations are instituted Customer feedback indicates a problem

    Uses of FMEA
    Development of system requirements that minimize the likelihood of failures. Development of methods to design and test systems to ensure that the failures have been eliminated. Evaluation of the requirements of the customer to ensure that those do not give rise to potential failures. Identification of certain design characteristics that contribute to failures, and minimize or eliminate those effects. Tracking and managing potential risks in the design. This helps avoid the same failures in future projects. Ensuring that any failure that could occur will not injure the customer or seriously impact a system. To produce world class quality products

    Advantages
    Improve the quality, reliability and safety of a product/process Improve company image and competitiveness Increase user satisfaction Reduce system development timing and cost Collect information to reduce future failures, capture engineering knowledge Reduce the potential for warranty concerns Early identification and elimination of potential failure modes Emphasize problem prevention Minimize late changes and associated cost Catalyst for teamwork and idea exchange between functions Reduce the possibility of same kind of failure in future Reduce impact of profit margin company

    Limitations of FMEA
    1) Significant staff time and resources are typically needed to conduct FMEA 2) Organization leadership must be committed to providing those resources, or else the analysis is doomed to fail. 3) It cannot reveal the complete consequential and causal sets of any singular error or adverse outcome. 4) FMEA allows a team to consider only on failure at a time.

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