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Basic Concepts of FMEA and FMECA

Failure Mode and Effects Analysis (FMEA) and Failure Modes, Effects and Criticality Analysis (FMECA) are methodologies used to identify potential failures, assess their risks, rank issues, and identify corrective actions. They involve identifying items, functions, failures, effects, causes, controls, and recommended actions. Risk is evaluated using methods like Risk Priority Numbers (RPNs) or Criticality Analysis to prioritize issues. Standards like SAE J1739 and AIAG FMEA-4 provide guidelines. The basic steps are assembling a team, establishing ground rules, identifying items/processes, failures/effects/causes/controls, evaluating risk, prioritizing actions, and updating the analysis.

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135 views4 pages

Basic Concepts of FMEA and FMECA

Failure Mode and Effects Analysis (FMEA) and Failure Modes, Effects and Criticality Analysis (FMECA) are methodologies used to identify potential failures, assess their risks, rank issues, and identify corrective actions. They involve identifying items, functions, failures, effects, causes, controls, and recommended actions. Risk is evaluated using methods like Risk Priority Numbers (RPNs) or Criticality Analysis to prioritize issues. Standards like SAE J1739 and AIAG FMEA-4 provide guidelines. The basic steps are assembling a team, establishing ground rules, identifying items/processes, failures/effects/causes/controls, evaluating risk, prioritizing actions, and updating the analysis.

Uploaded by

Peddy Nesa
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Basic Concepts of FMEA and FMECA

Failure Mode and Effects Analysis (FMEA) and Failure Modes, Effects and
Criticality Analysis (FMECA) are methodologies designed to identify
potential failure modes for a product or process, to assess the risk
associated with those failure modes, to rank the issues in terms of
importance and to identify and carry out corrective actions to address the
most serious concerns.
Although the purpose, terminology and other details can vary according
to type (e.g. Process FMEA, Design FMEA, etc.), the basic methodology is
similar for all. This article presents a brief general overview of FMEA /
FMECA analysis techniques and requirements.
FMEA / FMECA Overview
In general, FMEA / FMECA requires the identification of the following
basic information:
 Item(s)
 Function(s)
 Failure(s)
 Effect(s) of Failure
 Cause(s) of Failure
 Current Control(s)
 Recommended Action(s)
 Plus other relevant details

Most analyses of this type also include some method to assess the risk
associated with the issues identified during the analysis and to prioritize
corrective actions. Two common methods include:
 Risk Priority Numbers (RPNs)
 Criticality Analysis (FMEA with Criticality Analysis = FMECA)

Published Standards and Guidelines


There are a number of published guidelines and standards for the
requirements and recommended reporting format of FMEAs and FMECAs.
Some of the main published standards for this type of analysis include SAE
J1739, AIAG FMEA-4 and MIL-STD-1629A. In addition, many industries and
companies have developed their own procedures to meet the specific
requirements of their products/processes. Figure 1 shows a sample
Process FMEA in the Automotive Industry Action Group (AIAG) FMEA-4
format.

Basic Analysis Procedure for FMEA or FMECA


The basic steps for performing an FMEA/FMECA analysis include:
 Assemble the team.
 Establish the ground rules.
 Gather and review relevant information.
 Identify the item(s) or process(es) to be analyzed.
 Identify the function(s), failure(s), effect(s), cause(s) and control(s) for
each item or process to be analyzed.
 Evaluate the risk associated with the issues identified by the analysis.
 Prioritize and assign corrective actions.
 Perform corrective actions and re-evaluate risk.
 Distribute, review and update the analysis, as appropriate.

Risk Evaluation Methods


A typical FMEA incorporates some method to evaluate the risk associated
with the potential problems identified through the analysis. The two most
common methods, Risk Priority Numbers and Criticality Analysis, are
described next.

Risk Priority Numbers


To use the Risk Priority Number (RPN) method to assess risk, the analysis
team must:
 Rate the severity of each effect of failure.
 Rate the likelihood of occurrence for each cause of failure.
 Rate the likelihood of prior detection for each cause of failure (i.e. the
likelihood of detecting the problem before it reaches the end user or
customer).
 Calculate the RPN by obtaining the product of the three ratings:
RPN = Severity x Occurrence x Detection
The RPN can then be used to compare issues within the analysis and to
prioritize problems for corrective action.

Criticality Analysis
The MIL-STD-1629A document describes two types of criticality analysis:
quantitative and qualitative. To use the quantitative criticality analysis
method, the analysis team must:
 Define the reliability/unreliability for each item, at a given operating time.
 Identify the portion of the items unreliability that can be attributed to each
potential failure mode.
 Rate the probability of loss (or severity) that will result from each failure
mode that may occur.
 Calculate the criticality for each potential failure mode by obtaining the
product of the three factors:
Mode Criticality = Item Unreliability x Mode Ratio of Unreliability x
Probability of Loss
 Calculate the criticality for each item by obtaining the sum of the
criticalities for each failure mode that has been identified for the item.
Item Criticality = SUM of Mode Criticalities
To use the qualitative criticality analysis method to evaluate risk and
prioritize corrective actions, the analysis team must:
 Rate the severity of the potential effects of failure.
 Rate the likelihood of occurrence for each potential failure mode.
 Compare failure modes via a Criticality Matrix, which identifies severity on
the horizontal axis and occurrence on the vertical axis.

Applications and Benefits


The FMEA / FMECA analysis procedure is a tool that has been adapted in
many different ways for many different purposes. It can contribute to
improved designs for products and processes, resulting in higher
reliability, better quality, increased safety, enhanced customer
satisfaction and reduced costs. The tool can also be used to establish and
optimize maintenance plans for repairable systems and/or contribute to
control plans and other quality assurance procedures. It provides a
knowledge base of failure mode and corrective action information that
can be used as a resource in future troubleshooting efforts and as a
training tool for new engineers. In addition, an FMEA or FMECA is often
required to comply with safety and quality requirements, such as ISO
9001, QS 9000, ISO/TS 16949, Six Sigma, FDA Good Manufacturing
Practices (GMPs), Process Safety Management Act (PSM), etc.

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