What is FMEA?

FAILURE MODE AND EFFECT ANALYSIS

• FMEA is a Procedure of analyzing the potential failure in a
product, Design or in Process and Rectify the Failure or
Defects before it reaches to the Customer, their by
enhancing the Quality of the Product

• Failure Mode is any error or Defects in a Process, design or

in a product which affect the customer is called the Failure
mode.

• Effect Analysis is refers to studying the Consequences of

that Failure.

• FMEA is simply called Risk Analysis

• FMEA is “Before-the-Event” Process

• FMEA is A Never-Ending-Process and it is Improvement

Tool

• FMEA methodology is a Team Effect.

TYPES OF FMEA

In practice there are mainly two types of FMEA

DESIGN FMEA – It involves in the analysis of the potential Failure

in design stage itself, this can be done by previous data collection
and through Experience.

PROCESS FMEA – It involves in failure analysis in manufacturing

Process, Here Critical Process involved in manufacturing is
analyzed and it is emphasized for more reliable process.
DATA INPUTS FOR FMEA

The Date for above the process collected through

People Inputs
• A Team of Assembly, manufacturing, material, Quality,
service, supplier and customer

Data Inputs
The Data inputs needed to prepare FMEA are

• Product Inputs
• Process Specification
• Customer Data
• Process Variability data
• Process Description
• Inspection Data

What is Risk Priority Number?

STEPS INVOLVED

STEP1: SEVERITY (S)

It is the assessment of the serious of the Failure effect.
Details Severity Ratings
10 Dangerous and life-threatening effect. Without warning.
9 Major Costs. Safety risk. With warning.
8 No Product function.
7 Alternative supplier?
6 Partial failure.
5 Complains.
4 Irritated and contacts Service.
3 Irritated. Self repair.
2 Noticed but no influence.
 1 Not notice failure.

STEP2: OCCURANCE (O)

It the chance of failure that likely to be occurs
Details OCCURANCE Ratings
10 Large Number Of Failures Will Occur.
9
8 Principles that might cause problems.
7
6 Principles that very rarely cause problems.
5
4
3 Known principles that only cause few problems
2
1 Unlikely

STEP3: DETECTION (D)

It involves in how likely a failure can be detected, if the Failure is
hard to detect then it is given with Hi-rating and Vice versa. Here
the Rating Numbers Varies with (1 – 10)

RISK PRIORITY NUMBER

RPN do not play an important role in rectifying the problem, it
gives the Priority of the Failure which should be taken as more
emphasized.
RPN = S × O × D

ACTIONS TAKEN
Some of the Action taken to reduce the RPN is

• Specific Inspection
• Testing
• Changing Quality Procedure
• Redesign
• Changing the Process etc
FMEA CYCLE

FEW LOGICAL POINTS to Remember

• Try to Eliminate Failure Modes

• Minimize the Severity of the Failure
• Reduce the occurrence of failure Mode
• Improve the Detection

EXAMPLE

 Bread Toaster

Uses of FMEA

• Minimize The Likelihood Of Failures.

 • Development of Design and Test Systems to Ensure That the Failures Have
Been Eliminated.
• Ensure The Customer 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 OF FMEA
• 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

LIMITATION
 • Since FMEA is effectively dependent on the members of the
committee +6which examines product failures, it is limited
by their experience of previous failures. If a failure mode
cannot be identified, then external help is needed from
consultants who are aware of the many different types of
product failure

CONCLUSION
• So FMEA is type of quality tool which should be continuously
updated and need more experienced committee member to
involve in prediction and to avoid the Failure. Their by
enhancing the Quality

PREPARED BY

M. SURIYA

M.E – MANUFACTURING ENGG

ANNA UNIVERSITY