Failure Mode and Effect Analysis

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Failure Mode and Effect Analysis

• Jackie Harris, Josh Agusti, and Natasha Sommer

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Objectives

• What is FMEA?
• Why is an FMEA important?
• History of FMEA
• Benefits of FMEA
• Limitations of FMEA
• How to conduct an FMEA?

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Who is in Attendance?

• Anyone conducted an FMEA before?
• Anyone completed a Risk Analysis Procedure?

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What is FMEA?
Failure Mode and Effect Analysis

• A systemized group of activities designed to
• ? recognize and evaluate the potential failure
  of a product/process and its effects
• ? identify actions which could eliminate or
  reduce the chance of potential failure
• ? document the process

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Failure Mode and Effect Analysis

• 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.

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FMEA Terms

• 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.

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Why do an FMEA?

• Preventing problems is cheaper and easier than
  cleaning them up.
• Some things are too risky or costly to incur
  mistakes.

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The Reasons for FMEA

• Get it right the first time
• Indentifies any inadequacies in the development
  of the product
• Tests and trials may be limited to a few products
• Regulatory reasons
• Continuous improvement
• Preventive approach
• Team building
• Required procedures

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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

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Benefits

• Identify potential and known failures
• Reduce the number of engineering changes
• Reduce product development time
• Lower start-up costs
• Greater customer satisfaction
• Increased cooperation and teamwork between
  various functions
• Continuous improvement

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History

• An offshoot of Military Procedure MIL-P-1629,
  titled Procedures for Performing a Failure Mode,
  Effects and Criticality Analysis, dated November
  9, 1949.
• Used as a reliability evaluation technique to
  determine the effect of system and equipment
  failures.
• Failures were classified according to their
  impact on mission success and personnel/equipment
  safety.
• Formally developed and applied by NASA in the
  1960s to improve and verify reliability of space
  program hardware.

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Concept FMEA

• Used to analyze concepts in the early stages
  before hardware is defined (most often at system
  and subsystem)
• Focuses on potential failure modes associated
  with the proposed functions of a concept proposal
• Includes the interaction of multiple systems and
  interaction between the elements of a system at
  the concept stages.

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Design FMEA

• Aid in the objective evaluation of design
  requirements and design alternatives
• Aid in the initial design for manufacturing and
  assembly
• Increase the probability that potential failure
  modes have been considered
• Provide additional information to aid in the
  planning of efficient design testing

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Process FMEA

• Indentify potential product related process
  failure modes
• Assess the potential customer effects of the
  failures
• Indentify the potential manufacturing causes on
  which to focus on
• Develop a ranked list of potential failure modes
• Document the results of the manufacturing

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Types of FMEA
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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

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FMEA Timing

• FMEA should be updated
• ?at the conceptual stage
• ?when changes are made to the design
• ?when new regulations are instituted
• ?when customer feedback indicates a
• problem

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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

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Limitations

• Employee training requirements
• Initial impact on product and manufacturing
  schedules
• Financial impact required to upgrade design,
  manufacturing, and process equipment and tools
• ?These limitations should be recognized and
  treated as short term and minimal interruptions
  to a business.

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Risk Assessment Factors

• Severity (S) A number from 1 to 5, depending on
  the severity of the potential failure modes
  effect
• 1 no effect
• 5 maximum severity
• Probability of occurrence (O) A number from 1 to
  5, depending on the likelihood of the failure
  modes occurrence
• 1 very unlikely to occur
• 5 almost certain to occur

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Risk Assessment Factors

• Probability of detection (D) A number from 1 to
  5, depending on how unlikely it is that the fault
  will be detected by the system responsible
  (design control process, quality testing, etc.)
• 1 nearly certain detention
• 5 impossible to detect
• Risk Priority Number (RPN) The failure modes
  risk is found by the formula RPN S x O x D.
  RPN Severity x Probability of Occurrence x
  Probability of Detection. RPN will be a number
  between 1 (virtually no risk) and 125 (extreme
  risk).

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Risk Priority Number
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent

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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB Jelly Sandwich
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB Jelly Sandwich 5/5
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB Jelly Sandwich 5/5 Out of Stock Past Expiration
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB Jelly Sandwich 5/5 Out of Stock Past Expiration 2/5
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB Jelly Sandwich 5/5 Out of Stock Past Expiration 2/5 10
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Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent
Put PB on bread No PB Jelly Sandwich 5/5 Out of Stock Past Expiration 2/5 10 Check Pantry Check Expiration Date
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Conduct an FMEA

• Conduct a process FMEA on a paper airplane
• Build a paper airplane
• Conduct a design FMEA on your paper airplane
• Paper Airplane Competition

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Conclusion

• What is FMEA?
• Why is an FMEA important?
• History of FMEA
• Benefits of FMEA
• Limitations of FMEA
• How to conduct an FMEA?

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References

• Lean Six Sigma - http//www.leansixsigma.com/
• Stunell Technology - http//www.stunell.com/images
  /fmea.jpg