FMEA

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FMEA
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Course Updates

• Today - Introduction to FMEA
• No class on Thursday - work on your projects
• Next Tuesday - Personal Development
• Christmas Break
• Class will resume on Thursday, January 24

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What is FMEA?

• Failure
• Modes
• Effects
• Analysis
• -See page 551 of your book

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Reasons to do FMEA

• Define and guide a logical design process
• Identify, quantify, and reduce design risk
• Provide a traceable document for design and
  development
• Justify design activities
• Provide a means for continuous product improvement

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Scope of FMEA

• The FMEA is a team function
• All team members must participate
• Multi-disciplinary expertise and input is
  beneficial
• Input from all engineering fields is desirable
• Representatives from all areas (not just
  technical disciplines) are generally included as
  team members
• The DFMEA is not a one meeting activity
• The DFMEA will be refined and evolve with the
  product
• Numerous revisions are required to obtain the
  full benefit of the DFMEA
• The DFMEA should include all systems,
  sub-systems, and components in the product design

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FMEA Methodology

• List items and functions
• Start with the system, then subsystems, and
  finally components
• Document potential failure modes
• How could the design potentially fail to meet the
  design intent?
• Note this might be the cause of failure at a
  higher level (i.e. component to subsystem) or the
  effect of a failure at a lower level.
• Consider all types of failure
• Document the potential effects of failure - How
  would the design potentially fail to meet the
  design intent?

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FMEA Methodology

• Rate the severity of the failure effect
• Document potential causes and mechanisms of
  failure Potential failure modes are the
  consequences of the failure causes
• A single failure mode may have multiple failure
  mechanisms
• Use group brainstorming sessions to identify
  possible failure mechanisms
• Do not be afraid to identify as many potential
  causes as you can
• This section of the DFMEA will help guide you in
  necessary design changes
• The output of the DFMEA will indicate on which
  item to focus design efforts

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FMEA Methodology

• Rate the occurrence
• Are any elements of the design related to a
  previous device or design?
• How significant are the changes from a previous
  design?
• List the design controls, which are intended to
  
• Prevent the cause of the failure mode
• Detect the cause of the failure mode
• Detect the failure mode directly
• Applicable design controls include
• Predictive code analysis, simulation, and
  modeling ? Tolerance stack-up studies ? Prototype
  test results

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FMEA Methodology

• Repeat undertake the next revision of the FMEA
• Your FMEA is an evolving document! (as is a QFD)
• Revise your FMEA frequently!
• Diligence will eliminate design risk!
• Include documentation of your results!

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Frequency Ranking
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Severity Rankings
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Classification of Risk
High Risk
Possibility Of Occurrence
Moderate Risk
Severity of Outcome
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FMEA (Failure Mode and Effects Analysis)

• Method for analyzing the causes and effects of
  failures.
• Highlights designs and assemblies most likely to
  cause failures.
• Helps identify and prioritize corrective action
• Indicates where the most improvement in terms of
  severity, frequency, and detectability can be
  made.
• Widely used manufacturing technique (Mil
  standards, SAE, ANSI Specs)

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Course Schedule

• Failure Modes and Effects Analysis (FMEAplus)
  Software developed by Ford Motor Company. An FMEA
  can be described as a systemized group of
  activities intended to (a) recognize and
  evaluate the potential failure of a
  product/process and its effects, (b) identify
  actions which could eliminate or reduce the
  chance of the potential failure occurring, and
  (c) document the process. It is complementary to
  the design process of defining positively what a
  design must do to satisfy the customer.

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Course Schedule
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Course Schedule
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Course Schedule

• No class on Tuesday Nov. 13
• Thursday Nov. 15
• More team QA
• Formula team
• Ethanol team
• LANL-controls team

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Course Schedule

• No class on Tuesday Nov. 13
• Thursday Nov. 15
• More team QA
• Formula team
• Ethanol team
• LANL-controls team

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Steps in the Process

• QFDs
• If you have not done one yet, you should start
  one
• If you did one for the proposal, you should
  update it with new information
• A QFD expands as you get new data
• New customer requirements
• New engr. Specs
• New benchmarks