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    Failure Mode and Effects Analysis: Everything That Can Fail, Shall Fail!

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    Ashok
    The document provides an introduction to Failure Mode and Effects Analysis (FMEA). It defines FMEA as a systematic approach to identify potential failures, determine their causes and assess their effects. The document outlines the objectives, benefits and basic methodology of FMEA. It distinguishes between product/design FMEA and process FMEA and describes the typical FMEA workflow involving failure mode identification, cause analysis, effect assessment, risk evaluation and corrective action determination.

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    Failure Mode and Effects Analysis: Everything That Can Fail, Shall Fail!

    Uploaded by

    Ashok
    109 views38 pages
    The document provides an introduction to Failure Mode and Effects Analysis (FMEA). It defines FMEA as a systematic approach to identify potential failures, determine their causes and assess their effects. The document outlines the objectives, benefits and basic methodology of FMEA. It distinguishes between product/design FMEA and process FMEA and describes the typical FMEA workflow involving failure mode identification, cause analysis, effect assessment, risk evaluation and corrective action determination.

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    Introduction to FMEA

    Original Title

    Fmea Intro

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    The document provides an introduction to Failure Mode and Effects Analysis (FMEA). It defines FMEA as a systematic approach to identify potential failures, determine their causes and assess their effects. The document outlines the objectives, benefits and basic methodology of FMEA. It distinguishes between product/design FMEA and process FMEA and describes the typical FMEA workflow involving failure mode identification, cause analysis, effect assessment, risk evaluation and corrective action determination.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    109 views38 pages

    Failure Mode and Effects Analysis: Everything That Can Fail, Shall Fail!

    Uploaded by

    Ashok
    The document provides an introduction to Failure Mode and Effects Analysis (FMEA). It defines FMEA as a systematic approach to identify potential failures, determine their causes and assess their effects. The document outlines the objectives, benefits and basic methodology of FMEA. It distinguishes between product/design FMEA and process FMEA and describes the typical FMEA workflow involving failure mode identification, cause analysis, effect assessment, risk evaluation and corrective action determination.

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    Everything that can fail, shall fail!

    Failure Mode and Effects Analysis


    FMEA
    Introduction to FMEA

    Failure Mode and Effects Analysis Definition


    A bottoms-up, iterative approach for analyzing a design of a product or process in order to determine what could wrong how badly it might go wrong and what needs to be done to prevent it

    Alternate Definition
    Failure Mode and Effects Analysis (FMEA for short) is a systematic way to recognize and evaluate the potential failures of a product or process. It provides a formal mental discipline for eliminating or reducing the risks of product failure. It also serves as a living document, providing a method of organizing and tracking concerns and changes through product development and launch.

    Yet Another Definition


    Any formal, structured activity which is applied in developing something new to assure that as many potential problems as are reasonably possible to predict have considered, analyzed, and their causes remedied before the item under development reaches the hands of the end user. Applicable to
    product development idea development organization development process development software development

    Failure Mode and Effects Analysis Objective


    to identify early in the product or the manufacturing process design all manner of failures so they can be eliminated or minimized through design correction at the earliest possible time.

    Failure Mode, Effects, and Criticality Analysis (FMECA)


    Whats a FMECA?

    Benefits
    Improved product or process functionality Verify design integrity Provide rationale for change Reduced warranty and replacement costs Reduction in day-to-day manufacturing problems and costs Improved safety of products and processes

    Introduction to FMEA
    Background Basic Concepts Product versus Process Application Overview of Methodology Related Concepts

    Background
    1949 - US military
    Military Procedure MIL-P-1629 (procedures for performing a FMEA used as reliability evaluation technique

    1960s - Used in the by the aerospace industry and NASA during the Apollo program 1988 ISO 9000 business management standards
    required organizations to develop quality systems QS 9000 developed by Chrysler, Ford and GM compliant automotive suppliers shall utilize FMEA 1993 Automotive Industry Action Group (AIAG) and American Society for Quality Control (ASQC)
    Society of Automotive Engineers (SAE) procedure SAE J-1739 Provides general guidelines for performing a FMEA

    Basic Concept
    begin at the lowest level of the system identify potential failure modes assess their effect and causes prioritize based upon effect through redesign
    eliminate the failure or mitigate its effect

    Basic Concept - Example


    component computer monitor part capacitor identify two failure modes
    fail open
    effect are wavy lines appearing on monitor

    fail short
    effect is the monitor going blank

    prioritize short more critical than open determine cause of failure mode
    underrated capacitor

    investigate ways of eliminating failure


    resize capacitor

    More Basic Concepts


    Team effort
    5 to 7 members team lead engineer representation from design, assembly, manufacturing, materials, quality, and suppliers

    Usually done near the end of the product or process design phase Analysis should continue throughout the product development cycle Should be a living document that is updated as design changes and new information becomes available

    Product versus Process


    Product or Design FMEA.
    What could go wrong with a product while in service as a result of a weakness in design. Product design deficiencies

    Process FMEA.
    What could go wrong with a product during manufacture or while in service as a result of noncompliance to specification or design. Manufacturing or assembly deficiencies Focus on process failures and how they cause bad quality products to be produced

    Product (Design) FMEA


    Assumes manufacturing and assembly will produce to design specifications. Does not need to include failure modes resulting from manufacturing and assembly. Does not rely on process controls to overcome design weaknesses. Does consider technical and physical limitations of the manufacturing and assembly process.

    Process FMEA
    Assumes the product meets the intent of the design. Does not need to include failure modes originating from the design.
    assumes a design FMEA covers these failures

    Usually originates from a flow chart of the process

    The FMEA Team


    manufacturing or process engineer quality engineer facilitator

    operations maintenance

    FMEA Team

    product engineer

    Affected Functional Areas


    design materials manufacturing assembly packaging shipping service recycling quality reliability vendors customers.
    downstream engineering functions downstream manufacturing functions end users service functions, recycling or reuse functions

    Methodology
    1. 2. 3. 4. 5. 6. 7. 8. System or Process Definition Determination of Failure Modes Determination of Cause Assessment of Effect Estimation of Probability of Occurrence (O) Estimation of Detecting a Defect (D) Classification of Severity (S) Computation of Criticality (Risk Priority Number)
    RPN = (S) x (O) x (D)

    9. Determination of Corrective Action

    FMEA Flow Diagram


    2. Identify Failure Modes 5. Estimate occurrence 8. Compute RPN Prioritize

    1. Define Process

    3.Establish Cause

    6. Determine Detection

    4. Assess Effect

    7. Assign Severity

    9. Take Corrective Action

    FMEA Worksheet
    Component or Process Failure Mode Failure Cause excessive heat dropping or bumping fatigue, heat heat, brittle insulation Failure Effect picture degraded picture degraded will not conduct shock, damage to unit Correction larger fan improve packaging higher grade wire higher grade wire

    CRT Bad pixels Picture tube CRT Bad pixels Picture tube Cabling to unit Cabling to unit broken or frayed internal short

    Methodology - Example
    Perform a FMEA analysis for the process of installing a roof.

    Task Description

    Failure Mode

    Failure Effect no roof

    Install 90# roll roofing Not installed Gap between Aluminum and roll roofing rippled

    Cause work order missing inexperienced workers poor quality material carelessness, insufficient install time worker inexperience poor quality nails supply error improper size worker inexperience improper size worker oversight poor workmanship inexperienced workers

    Occurrence Detection 2 10

    Severity 10

    RPN 200

    corrective action

    roof leaks water seepage

    6 7

    10 6

    10 7

    600 294

    punctured Nailing shingles nails missing nails bent nails too short nails loose nails misplaced nails too deep Install chimney flashing not installed loose too short

    water seepage roof leaks roof leaks roof leaks roof leaks roof leaks roof leaks roof leaks

    5 7 2 3 6 9 7 1 4 6

    10 10 10 8 7 10 7 2 3 9

    8 10 9 9 10 10 10 10 8 8

    400 700 180 216 420 900 490 20 96 432

    Step 1. Product / Process Definition


    Describe product and its design or the process and its operations Identify the purpose or function of each component or each operation Use functional diagrams, design drawings, flow charts and other graphical techniques Include each significant element that is likely to fail

    Step 2. Determination of Failure Modes


    A failure mode is the manner in which a process could potentially fail to meet the process requirement or the design intent. It is a statement of non-performance or a non-conformance to a design specification. Questions to be answered include:
    how can the process/part fail to meet specs regardless of the specs, what would customer find objectionable?

    Examples of Failure Modes


    ruptures fractures or cracks short or open circuits deformation contamination loss of power buckling

    Step 3. Determination of Cause


    Identify how the failure could occur State in terms of something that can be corrected Attempt to establish an exhaustive list Further analysis may be required to isolate cause (e.g. a design of experiments)

    Example Causes
    improper tolerances or alignment operator error part missing cyclical fatigue poor workmanship defective parts from supplier maintenance induced aging and wear-out excessive environmental conditions

    Failure Mode and Cause


    Failure Mode Category Cause Failure Mechanism Capacitor Short Electrical High Voltage Dielectric Breakdown Metal Contacts Fail Connector Fractures Mechanical Chemical High Humidity & Salt Atmosphere Excessive Vibration Fatigue Corrosion Use of a protective casing Redesign of mountings Possible Corrective Action Derating

    Step 4. Assessment of Effect


    Assess the effect of the failure mode on the customer Customer may be next operation, subsequent operations, the end-user, or the seller Answer the question what might the customer observe or experience.

    Assessment of Effect - examples


    Failure Mechanism produces corrosion manufacturing defect in casing prolonged excessive vibration and fatigue friction and excessive wear contamination (dust and dirt) evaporation prolonged low temperatures drive belt break loss of contact filament breaks brittle seals break in a motor mount loss of engine power and excessive noise shut down of production line circuit board failure light bulb burns out leakage in hydraulic system Failure Mode which causes failure in tank wall seam leaking battery tank rupture flashlight failure to light Failure Effect

    Step 5. Estimation of Probability of Occurrence (O)


    Occurrence refers to how frequently the specific failure mode will be observed. Estimated on a scale from 1 to 10 Statistical analysis may be used if historical data is available Otherwise estimated subjectively

    Step 6. Estimation of Detecting a Defect (D)


    The probability that the current process controls will detect the failure mode before the part or component leaves the process. Assume failure has occurred, and then assess the likelihood that the product will continue to its next stage. Rank on scale of 1 (almost certain to detect) to 10 (no way of detecting failure)

    Step 7. Classification of Severity (S)


    An assessment of the seriousness of the effect of the failure mode on the customer Estimated on a scale of 1 to 10. Assessed against
    safety; i.e. injury or death extent of damage or amount of economic loss

    Step 8. Computation of Criticality


    Risk Priority Number (RPN) Product of Severity (S), Probability of Occurrence (O), and Detecting a Defect (D) RPN = (S) x (O) x (D) Range is 1 to 1000 with the higher the number, the more critical the failure mode. Rank order RPN from highest to lowest

    Step 9. Corrective Action


    Removing the cause of the failure,
    Decreasing the probability of occurrence, or Increase the likelihood of detection, or Reducing the severity of the failure.

    Related Concepts
    Quality Functional Deployment (QFD)
    customer requirements

    Total Quality Management (TQM) Statistical Process Control (SPC)


    detection

    Design of Experiments (DOE)


    root causes

    Six Sigma
    process improvement

    Fault Tree Analysis (FTA) On-going Reliability Testing (ORT)

    Difficulties in Implementation
    Time and resource constraints Lack of understanding of the purpose of FMEA Lack of training Lack of management commitment
    Dale and Shaw, 1990: Failure Mode and Effects Analysis in the Motor Industry, Quality and Reliability Engineering International.

    Failure Mode and Effects Analysis - FMEA


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