Beer Brewing Pfmea Aiag-Format

Item:Beer making (based on Indian Pale Ale - IPA)
Model Year(s)/Vehicle(s):Complete brewing process

Team:
Function
Potential Failure Mode Potential Effect(s) of
Failure
Process Element: Sterilisation
Sterilise
Equipment is
all of
not sterilised
the
equipment
and
then
rinse
with
clean
water
and
allow to
dry
[5% Indian Pale Ale

Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale
Beer]
Beer taste has a bitterness to it
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
Steriliser not fully rinsed from

equipment
[5% Indian Pale Ale

Beer]
Beer tastes of detergent
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Process Element: Preparing the Wort
Place
Malt & Hops
Malt &
not warmed sufHops
ficiently
container into
warm
water
for a
time of
>= 5
mins +5
Add boiling
water to
the fermentation
bucket
= 5 litres
+1
Excessive boiling water

added
[5% Indian Pale Ale

Beer]
Brewing process takes
longer than required
[5% Indian Pale Ale

Beer]
Beer is watery
[5% Indian Pale Ale
Beer]
Alcohol content is not
as per product description
[5% Indian Pale Ale

Beer]
Insufficient boiling water

added
[5% Indian Pale Ale

Beer]
Water added
is not at boiling
point
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
Add the
ingredients to
the fermentation
bucket
= 1 kg
beer
enhanc
er (sugar)
1.8kg
Malt &
Hops
Excessive quantity of sugar
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Beer is too gaseous
[5% Indian Pale Ale
Beer]
Beer tastes yeasty
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
Party goers are inebriated to early in the night
Incorrect ingredients added
[5% Indian Pale Ale

Beer]
Beer tastes caramelly/
malty
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
Beer is too gaseous
[5% Indian Pale Ale
Beer]

[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
party
Insufficient
quantity of
Malt & Hops
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is watery
Insufficient
quantity of sugar
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
Beer is watery
[5% Indian Pale Ale
Beer]
Insufficient alcoholic
beverages for the party goers
Sugar omitted
Wort is contamination
[5% Indian Pale Ale

Beer]
party
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Mix contents
until
ingredients are
Ingredients mixing not mixed

to a soluble
state
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale
dissolved
Beer]
[5% Indian Pale Ale
Beer]
Beer is watery
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]

party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Fill the
fermentation
bucket
to the
correct
volume
40
pints
Insufficient
water added
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale

Beer]
Beer is too gaseous
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
malty
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale

Beer]
40 pints of beer is
scapped
Cover
fermentation
bucket
and
insert air-
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
lock
whilst
tempera-
Beer]
g. vinegary)
ture settles
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Process Element: Add yeast
Mix the
Yeast omitted
yeast
into the
wort at
a specified temperature =
22 Centi-
[5% Indian Pale Ale

Beer]
party
[5% Indian Pale Ale
Beer]
grade
5C
Yeast added
when wort is
too hot
[5% Indian Pale Ale

Beer]
Beer is watery
[5% Indian Pale Ale
Beer]
Beer is flat
[5% Indian Pale Ale
Beer]

[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Airlock does not bubble during the fermentation
[5% Indian Pale Ale
Beer]
yeast is killed
Yeat not
mixed to a soluble state
[5% Indian Pale Ale

Beer]
Cover
fermen-
Yeast added
when wort is
too cold
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Airlock is not
inserted into lid
tation
bucket
and
insert air-

[5% Indian Pale Ale
Beer]
lock

g. vinegary)
Beer is contaminated
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
Lid is not fully

sealed /
pushed home
Process Element: Primary Fermentation

Beer is
Beer is contamiallowed
nated
to ferment for
6
days 2
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
Beer leakage
Fermentation
does not occur
(no bubbles
exit airlock)
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Fermentation
process
stopped too
early
Beer is
allowed
to ferment in
constistent temperature of
Temperature
fluctuations
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
malty
[5% Indian Pale Ale
Beer]
Beer tastes yeasty
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
Beer is too gaseous
[5% Indian Pale Ale
Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
= 2025C
Temperature is
too high
Temperature is
too low

[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
yeast is killed
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
yeast is killed
[5% Indian Pale Ale

Beer]

[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
Process Element: Keg Fermentation

Syphon
Beer is contamithe fernated
menting
beer
into a
keg
avoiding the
sediment
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer spillage
Excess sediment decanted
Beer is too gaseous

(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
Party goers have
'wind' the next day
Add
additional ingredients =
150 g
30g
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Excessive quantity of sugar
[5% Indian Pale Ale

Beer]
Beer is too gaseous
[5% Indian Pale Ale
Beer]
as per product descrip-
tion
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale

Beer]
Incorrect ingredients added
[5% Indian Pale Ale

Beer]
Beer is too gaseous
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Insufficient
quantity of sugar
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
malty
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
Beer is flat
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is watery
Sugar omitted
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
Beer is watery
Beer is
allowed
to ferment for
7
days +6
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
Beer leakage
Fermentation
process
stopped too
early
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
tion
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
Beer tastes yeasty
[5% Indian Pale Ale
Beer]
Party goers have
'wind' the next day
Beer is
allowed
to ferment in
constistent tempera-
Temperature is
too low
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
ture of
= 2025C
Temperature is
too high
tion
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
Beer tastes yeasty
[5% Indian Pale Ale
Beer]
Party goers have
'wind' the next day
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
yeast is killed
Temperature
fluctuations
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
yeast is killed
FMEA
Process
Process Responsibility:Robbins, Gavin, Penkridge, FMEA Facilitator / Traine

Key date:
S C Potential Cause(s) of
Failure
Preventive Actions
Use of good quality

brew kit ingredients
[Instructions]
Ambiguous methodology
Shop owner / supplier advice
[Instructions]
Metric / imperial
weights and volumes
not specified (including
U.S. imperial)
[Brewer]
Fails to sterilise container
used to carry water
[Brewer]
Does not wash hands
Use of good quality

Measuring devices
at Gavin's home display both imperial
& metric units
Instructions clearly
express that all
equipment needs to
be sterilised
Common sense /
hygiene
3
beforehand
[Instructions]
Insufficient detail about
alternative ingredients
(does & don'ts)
[Steriliser]
insufficent concentration / ratios
[Home]
Poor air quality (micro
organisms present)
[Brewer]
Washes out sterilising fluid too early
[Water]
Domestic supply quality
is contaminated (micro
organisms present)
[Brewer]
Does not rinse equipment properly
[Brewer]
Forgets to rinse equipment properly
Use of good quality

Quantity is specified
in the instructions
Instructions specify
imperial and metric
weights and volumes
Controlled environment
express that all
equipment needs to
be sterilised
Water quality is
assured by water
board
express that all
equipment needs to
be sterilised
express that all
equipment needs to
be sterilised
Past experiences
with similar brew kits
that are being
drank with gusto!
[Instructions]
Use of good quality


[Kettle]
Thermostat failure
TPM on all devices
[Brewer]
Impatientience / carelessness or inexperience
Past experiences
that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be downbloaded from the
internet
Use of good quality
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
[Fermentation Bucket &

lid]

Measuring devices
& metric units
Products recently pur- 1
chased (JIT)
Volume measurements
are illegible
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)

lid]
Volume measurements
are illegible
[Brewer]
[Brewer]
[Brewer]
Omits a stage
Use of good quality


Measuring devices
& metric units
chased (JIT)
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
[Scales]
Batteries are flat
Alternative scales
available
[Instructions]
Use of good quality

[Brewer]
Adds more sugar than
required
Ingredients and
quantities are specified in the
instructions
[Instructions]
(does & don'ts)
Use of good quality

[Brewer]
Incorrect type of sugar
used (e.g. brown sugar /
Muscovado)

Ingredients and
instructions
Past experiences
that are being
drank with gusto!
[Scales]
Out of calibration
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
[Brewer]
[Brewer]
Muscovado)
Digital scales used

Use of good quality
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Ingredients and
instructions
Past experiences
that are being
drank with gusto!

TPM on all devices
[Instructions]
Use of good quality

(does & don'ts)

4

[Brewer]
[Brewer]
Experimentation with
process (Brewer has a
'good' idea!)
[Instructions]
7
[Brewer]
Fails to rinse out Malt &
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality

Instructions include
special care points
7
2
Hops container
[Brewer]
[Instructions]
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality

[Scales]
Batteries are flat
Alternative scales
available
[Brewer]
Muscovado)
Ingredients and
instructions
Past experiences
that are being
drank with gusto!
TPM on all devices
[Scales]
Out of calibration
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
Digital scales used

Use of good quality
Measuring devices
[Brewer]

& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
[Brewer]
Omits a stage
[Brewer]
Fails to cover the wort
Common sense /
hygiene
[Instructions]
Use of good quality


lid]
Bacterial contamination
present
special care points
[Malt & Hops]

present
Use of good quality

[Scales]
present
[Brewer]
Does not wash hands
beforehand
[Home]
organisms present)
[Sugar]
present
[Brewer]
Washes out sterilising fluid too early
[Brewer]
[Spoon]
Basic hygiene practice

Mixed with boiling
water to ensure
sterility
special care points
Common sense /
hygiene

Use of good quality
Mixed with boiling
water to ensure
sterility
express that all
equipment needs to
be sterilised
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points
2
present
[Malt & Hops]
Poor quality product /
batch
[Brewer]

Use of good quality
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
with each brewing
[Spoon]
Insufficient length
[Brewer]
Omits a stage
[Brewer]
Does not wash hands
beforehand
[Instructions]

internet
Past experiences
that are being
drank with gusto!
Common sense /
hygiene
Use of good quality


[Home]
3
organisms present)
[Spoon]
present
special care points
[Brewer]
'good' idea!)
Past experiences
that are being
drank with gusto!

lid]
Volume measurements
are illegible
[Instructions]
Metric / imperial
weights and volumes
with each brewing
internet
chased (JIT)
Use of good quality

Shop owner / suppli-
6
U.S. imperial)
[Brewer]

lid]
Insufficient capacity
[Instructions]
er advice
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
Use of good quality
[Brewer]
Fails to sterilise container
used to carry water
[Brewer]
Does not wash hands
beforehand
[Home]
organisms present)
express that all
equipment needs to
be sterilised
Common sense /
hygiene
[Water]
organisms present)
Water quality is
assured by water
board
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points

lid]
present
[Airlock]
Airlock or fluid content is

contaminated
special care points
[Brewer]
Past experiences
that are being
drank with gusto!

lid]
Plastic fatigue (cracks /
orange peel)
[Brewer]
Omits a stage
[Thermometer]
present
[Brewer]
[Instructions]
Past experiences
that are being
drank with gusto!
special care points
Past experiences
that are being
drank with gusto!
with each brewing
[Brewer]
Omits a stage
with each brewing

internet
chased (JIT)
internet
Past experiences
that are being
drank with gusto!
Use of good quality

[Instructions]
Metric / imperial
Use of good quality

2
weights and volumes
U.S. imperial)
[Brewer]
[Thermometer]
Out of calibration
[Instructions]
[Brewer]
Omits a stage
[Brewer]
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Mechanical thermometer used
Use of good quality
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
with each brewing
2
2
internet
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points
[Brewer]
[Spoon]
present
[Home]
organisms present)
[Thermometer]
present
[Brewer]
Does not wash hands
beforehand
special care points
Common sense /
hygiene
[Brewer]
Impatientience / care-
Past experiences
3
lessness or inexperience
[Brewer]
Omits a stage
that are being

drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
[Airlock]
contaminated
special care points

lid]
special care points
present
[Brewer]
Does not wash hands
beforehand
Common sense /
hygiene
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet

lid]
orange peel)

chased (JIT)
[Airlock]
contaminated
special care points

lid]
orange peel)

chased (JIT)
[Home]
Shelf strength in airing
cupboard is inadequate
Office floor used

instead
[Brewer]
Uses only boiling water
when preparing the wort
Cost and time limitations
[Water]
organisms present)
Water quality is
assured by water
board
[Water]
is contaminated (chlorine content)
[Home]
Ambient temperature is
too low / incorrect proximity to heat source
[Home]
too high / incorrect proximity to heat source
[Yeast]
Past best before date
Water quality is
assured by water
board
Home is in a temperate climate and centrally heated

Past experiences
that are being
drank with gusto!
Home is in the UK,
which is unlikely to
lead to excessively
high temperatures
Past experiences
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
where the cat usually sleeps!)
Use of good quality
Past experiences

that are being
drank with gusto!
[Instructions]
Use of good quality


[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet
[Home]
Location is close to
draughts / UV light source
Home is double
glazed
fermentation bucket
is covered
[Instructions]
Use of good quality

[Home]
[Instructions]
[Home]
Past experiences
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
Use of good quality
Home is in a temperate climate and cen-
2
trally heated
Past experiences
that are being
drank with gusto!
Home is in the UK,

lead to excessively
high temperatures
Use of good quality
[Instructions]

7
[Syphon]
present
special care points
[Home]
organisms present)
[Brewer]
Does not wash hands
Common sense /
hygiene
beforehand
[Keg]
orange peel)

chased (JIT)
[Keg]
present
special care points
[Brewer]
[Syphon]
Insufficient length
[Syphon]
Multi-section product
[Keg]
[Brewer]
[Instructions]
Past experiences
that are being
drank with gusto!
with each brewing
internet
Compression fit at
joint
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality
3
2

special care points
[Keg]
present
[Scales]
present
special care points
[Sugar]
present
Use of good quality

Mixed with boiling

water to ensure
sterility
[Spoon]
present
[Brewer]
Does not wash hands
beforehand
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
special care points
Common sense /
hygiene
Use of good quality

[Brewer]
[Brewer]
Adds more sugar than
required
[Instructions]
[Scales]
Out of calibration
[Scales]
Batteries are flat
5
[Brewer]
Muscovado)
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Ingredients and
instructions
Use of good quality
TPM on all devices
Digital scales used

Alternative scales
available
Ingredients and
instructions
Past experiences
that are being
drank with gusto!
4
er advice
6
[Brewer]
'good' idea!)
[Brewer]
Omits a stage
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
Use of good quality
Measuring devices
& metric units
[Brewer]
[Instructions]
(does & don'ts)
[Instructions]
[Brewer]
[Keg]
present
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality
Use of good quality
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points
[Keg]
orange peel)

chased (JIT)
[Keg]
[Brewer]
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
with each brewing
[Instructions]

[Brewer]
'good' idea!)
[Yeast]
Insufficient resistance to
high alcohol content
internet
Use of good quality
[Home]
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
Home is in the UK,

lead to excessively
high temperatures
[Instructions]
Metric / imperial
weights and volumes
Use of good quality


U.S. imperial)
[Home]
[Instructions]
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
Use of good quality
[Brewer]
[Home]
Excessive variations in
the ambient temperature
er advice
Past experiences
that are being
drank with gusto!
with each brewing
internet
[Instructions]
Use of good quality

FMEA
Process
dge, FMEA Facilitator / Trainer
Detection Actions
D RPN Recommended Actions
Cause
Failure Mode
Instructions are
read thoroughly
before commencing brewing
54
Directions are read

and re-read at
each stage of the
brewing process
36
none
10 270
none
10 270
none
10 270
Instructions are
read thoroughly
90
Sterilising solution
has a strong smell
108
none
has a strong smell
none
10 270
54
10 180 D: Beer
clarity
and
smell
are
checke
d during the
seconadary
fermentation
stage
has a strong smell
48
has a strong smell
32
32
Instructions are
read thoroughly
42
Visual inspection
14
none
10 210 D: Regular referal to the

instructions
Directions are read

and re-read at
each stage of the
brewing process
24
Visual inspection
12
Visual inspection
12
Directions are read

and re-read at
each stage of the
brewing process
24
Visual inspection
12
none

instructions
none

instructions
subsequent stages
will be affected
(detection post
process)
189
Scales clearly display a battery level symbol

Instructions are
read thoroughly
28
42
Electronic scales
within accurate to
0.25g
35
Instructions are
read thoroughly
70
Sugar packaging
is clearly labelled
14
1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
Directions are read
and re-read at
each stage of the
brewing process
none
63
28

instructions
Sugar packaging
is clearly labelled
16
Instructions are
read thoroughly
before commenc-
80
80
ing brewing
none

instructions
none
10 400 D: Smell
& clarity
checks small
glass
poured
before 6
days
into
final fermentation
process
Instructions are
read thoroughly
42
Visual inspection
28
Visual inspection
none
28

instructions
Instructions are
read thoroughly
42

Sugar packaging
is clearly labelled
28
14
1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
Directions are read
and re-read at
each stage of the
brewing process
63
28
none
subsequent stages
will be affected
(detection post
process)
none
Instructions are
read thoroughly

instructions
168
10 270
54
none
10 180
none
10 180
none
10 180
none
10 270
none
10 270
none
10 180
has a strong smell
54
none

instructions
none
10 180
none
10 180
none
10 180
none

instructions
Cannot complete
and move on to
next operation
subsequent stages
will be affected
(detection post
process)
none
Instructions are
read thoroughly
none
147
10 270
54
10 270
none
10 270
none
10 180
none
10 300 D: Smell
& clarity
checks small
glass
poured
before 6
days
into
final fermentation
process
Visual inspection
12
Directions are read

and re-read at
each stage of the
brewing process
24
none
24

instructions
Visual inspection
12
Instructions are
read thoroughly
54
none
10 270
none
10 270
none
10 270
none
10 270
none
10 180 D: Beer
clarity
and
smell
are
checke
d during the
seconadary
fermentation
stage
none

instructions
none
10 180
Visual inspection
none
90

instructions
Visual inspection
45
subsequent stages
will be affected
(detection post
process)
none
189
none
10 180

instructions
subsequent stages
will be affected
(detection post
process)
Instructions are
read thoroughly
168
48
Directions are read

and re-read at
32
32
each stage of the

brewing process
none

instructions
Visual inspection
48
Instructions are
read thoroughly
36
subsequent stages
will be affected
(detection post
process)
none
126

instructions
none

instructions
none
10 180
none
10 270
none
10 180
none
10 270
none
10 270 D: Regular refer-
none
10 270
al to the
instructions
subsequent stages
will be affected
(detection post
process)
189
Visual inspection
90
none
10 180
none
10 180
none
10 270
none

instructions
Visual inspection
45
Visual inspection
90
Visual inspection
90
Visual inspection
40
none
Primary fermentation will be impeded / airlock does

not bubble
56
none
10 160 D: Beer
clarity
and
smell
are
checke
d during the
seconadary
fermentation
stage
Water Chlorination
can be smelt from
the tap (US
tap=faucet)
Climate supervisor
(wife)
32
48
48
Lack of hot domestic water supply (discovered when

teenage son want
to shower)
Climate supervisor
(wife)
teenage son want
to shower)
none
10 160
Instructions are
read thoroughly
none
Climate supervisor
(wife)
42

instructions
24
Instructions are
read thoroughly
48
Climate supervisor
(wife)
48
Instructions are
read thoroughly
48
Climate supervisor
(wife)
48

teenage son want
to shower)
48
48

teenage son want
to shower)
Instructions are
read thoroughly
none
10 180
none
10 270
none
10 270
Visual inspection
none
45
10 180
none

instructions
Cannot complete
and move on to
next operation
Visual inspection
48
Visual inspection
16
none
Instructions are
read thoroughly
before commenc-

instructions
42
42
ing brewing
none
10 180
none
10 180
none
10 180
none
10 180
none
10 270
Directions are read

and re-read at
each stage of the
brewing process
28
none

instructions
Electronic scales
within accurate to
0.25g
Instructions are
read thoroughly
35
42
1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
Sugar packaging
is clearly labelled
63
28
12
none
subsequent stages
will be affected
(detection post
process)
Directions are read
and re-read at
each stage of the
brewing process
10 350 D: Smell
& clarity
checks small
glass
poured
before 6
days
into
final fermentation
process
147
28
none

instructions
Instructions are
read thoroughly
70
Instructions are
read thoroughly
42
none

instructions
none
10 180
Visual inspection
40
Visual inspection
16
none

instructions
Instructions are
read thoroughly
42
none
10 350 D: Smell
& clarity
checks small
glass
poured
before 6
days
into
final fermentation
process
none
10 210
Climate supervisor
(wife)
teenage son want
42
to shower)
Directions are read

and re-read at
each stage of the
32
48
48
brewing process
Climate supervisor
(wife)
teenage son want
to shower)
Instructions are
read thoroughly
none
Climate supervisor
(wife)

teenage son want
to shower)
Instructions are
read thoroughly
48

instructions
48
48
Number:1.1
Page:
Prepared By:
Created:13/03/2013
Responsibility & Target Completion
Date
Modified:20/03/2013
Action Results
Actions Taken
S O D RPN
Robbins, Gavin, Penkridge, FMEA

Facilitator / Trainer
3/22/2013
in revision
9 2 8 {144
}

4/3/2013
in revision
7 3 5 {105
}

6 3 5 {90}
4/3/2013
in revision

4/3/2013
in revision
9 3 5 {135
}

4/3/2013
in revision
7 3 5 {105
}

8 3 5 {120
}
4/3/2013
in revision

3/27/2013
in revision
8 5 6 {240
}

4/3/2013
in revision
7 3 5 {105
}

4/3/2013
in revision
7 3 5 {105
}

4/3/2013
in revision
9 3 5 {135
}

4/3/2013
in revision
7 3 5 {105
}

3/27/2013
in revision
6 5 6 {180
}

4/3/2013
in revision
6 3 5 {90}

9 2 8 {144
}
3/22/2013
in revision
9 3 5 {135
}
4/3/2013
in revision

4/3/2013
9 3 5 {135
}
in revision

4/3/2013
in revision
8 3 5 {120
}

8 3 5 {120
}
4/3/2013
in revision

4/3/2013
in revision
6 3 5 {90}

6 3 5 {90}
4/3/2013
in revision

9 3 5 {135
}

4/3/2013
in revision
9 3 5 {135
}

4/3/2013
in revision
8 3 5 {120
}

8 2 8 {128
}
3/22/2013
in revision

3/15/2013
D: Visual
inspection
D: Audi-
8 2 2
32
completed

4/3/2013
in revision
ble
sounds
of bubbles exiting the
airlock
expected within 24
hours
7 3 5 {105
}

8 3 5 {120
}
4/3/2013
in revision

4/3/2013
in revision
7 3 5 {105
}

4/3/2013
in revision
7 3 5 {105
}

3/27/2013
in revision
7 5 6 {210
}

7 3 5 {105
}
4/3/2013
in revision

4/3/2013
in revision
7 3 5 {105
}

4/3/2013
in revision
7 3 5 {105
}

3/27/2013
in revision
7 5 6 {210
}

4/3/2013
in revision
8 3 5 {120
}

Beer Brewing Pfmea Aiag-Format

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Beer Brewing Pfmea Aiag-Format

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Item:Beer making (based on Indian Pale Ale - IPA)

Model Year(s)/Vehicle(s):Complete brewing process

[5% Indian Pale Ale

Steriliser not fully rinsed from

[5% Indian Pale Ale

Excessive boiling water

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Insufficient boiling water

[5% Indian Pale Ale

[5% Indian Pale Ale

Excessive quantity of sugar

Incorrect ingredients added

[5% Indian Pale Ale

as per product description

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Ingredients mixing not mixed

[5% Indian Pale Ale

[5% Indian Pale Ale

Beer is not ready for

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Brewing process takes

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Beer taste has a bitterness to it

Beer aroma is poor (e.

[5% Indian Pale Ale

Lid is not fully

Process Element: Primary Fermentation

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Beer taste has a bitterness to it

[5% Indian Pale Ale

Brewing process takes

Process Element: Keg Fermentation

[5% Indian Pale Ale

Excess sediment decanted

Beer is too gaseous

[5% Indian Pale Ale

[5% Indian Pale Ale

Excessive quantity of sugar

[5% Indian Pale Ale

[5% Indian Pale Ale

Incorrect ingredients added

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale