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Failure Mode and Effect Analysis

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Failure Mode and Effect Analysis Jackie Harris, Josh Agusti, and Natasha Sommer So now we are going to split into three groups. Each group will conduct an process ... – PowerPoint PPT presentation

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Title: Failure Mode and Effect Analysis


1
Failure Mode and Effect Analysis
  • Jackie Harris, Josh Agusti, and Natasha Sommer

2
Objectives
  • What is FMEA?
  • Why is an FMEA important?
  • History of FMEA
  • Benefits of FMEA
  • Limitations of FMEA
  • How to conduct an FMEA?

3
Who is in Attendance?
  • Anyone conducted an FMEA before?
  • Anyone completed a Risk Analysis Procedure?

4
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

5
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.

6
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.

7
Why do an FMEA?
  • Preventing problems is cheaper and easier than
    cleaning them up.
  • Some things are too risky or costly to incur
    mistakes.

8
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

9
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

10
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

11
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.

12
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.

13
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

14
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

15
Types of FMEA
16
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

17
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

18
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

19
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.

20
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

21
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).

22
Risk Priority Number
23
Procedures for FMEA
Necessity Process Function Problem Failure Mode Effects How bad is it? Severity Causes How Likely? Occurrence Score Steps to Prevent

24
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
25
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
26
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
27
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
28
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
29
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
30
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
31
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
32
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

33
Conclusion
  • What is FMEA?
  • Why is an FMEA important?
  • History of FMEA
  • Benefits of FMEA
  • Limitations of FMEA
  • How to conduct an FMEA?

34
References
  • Lean Six Sigma - http//www.leansixsigma.com/
  • Stunell Technology - http//www.stunell.com/images
    /fmea.jpg
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