FMEA Rev 4

Failure Modes and Effects Analysis
FMEA
COS 9: Follow Common Problem Solving Techniques
COS 10: Use Six Sigma As The Primary Process Improvement Method
Objectives
 Understand the role of FMEA in an improvement project
 Understand the steps to develop an FMEA
 Reinforce FMEA development with an exercise
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FMEA definition
 Failure Modes and Effects Analysis (FMEA) is a structured approach
to:
− Identify the ways a product or process can fail
− Estimate and prioritize the risk associated with specific failure
causes
− Identify actions needed to reduce or eliminate excessive risk
 FMEA is meant to be a “before – the – event” action, not an “after – the

1
– fact” exercise , however they may be used as a factor filter when the
problem does not have adequate evidence for the FTA approach
1: AIAG “FMEA”, 4th Edition

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Risk
 FMEAs help organize risk assessment and track mitigating actions and results
 FMEA risk levels are numerical assessments of:
1. The severity of the effects of a failure mode on the customer and
2. The likelihood the failure may occur during the life of the product or process and
3. The effectiveness of existing ways to prevent or detect the failure mode before the
customer is affected
 There are many sources of risk; some are shown below
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FMEA overview
How bad is the How well do we
How often prevent or
customer
do we fail2? detect3?
affected1?
Problem Definition Current Process Action
SEV.F
RPN.F
OCC.F
DET.F
C
Potential S l Potential O D R
Process Step Potential Controls Controls Recommended Actions
Requirement: Effect(s) Of E a Cause(s) Of C E P Responsibility
or Function: Failure Mode s (Prevention) (Detection) Action(s) Taken
Failure: V Failure: C T N
s
How is the
What is the input? customer How are
or project Y causes What else can be done and how effective was
affected? avoided3? it after it was implemented?
How are
What can go What causes failures
wrong with the the failure found3?
input? mode?
Is action
needed?
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FMEA types
 Automotive Industry Action Group (AIAG)
FMEA’s help ensure that potential problems
have been considered and addressed during
product and process development and should
be maintained throughout the life of the product
or process. The most common AIAG FMEAs
used at CMI are design - (DFMEA) and process
- (PFMEA) FMEA.
 6S&CI FMEA’s, on the other hand, are short-
lived documents which identify critical X’s early
in a 6S&CI project. These critical X’s then
become the focus of the project’s improvement
efforts.
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Project teams
 FMEA’s depend on a cross-functional group of experts
including someone experienced in leading them
 FMEA teams include the project core team and
project-related experts such as:
− Affected operators, administrators, and supervisors
− Technical experts knowledgeable in the system or
process
− Distribution / service experts
− Supplier quality experts
− Finance / human resources / information
technology (IT) experts
 Contact your local MBB for help and assistance in
FMEA development
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FMEA step 1
Rating Of Importance To 10 6 8 4
Recommended 3rd Quartile: 111 1 2 3 4
Set High Level
Firing Rate
SubTotals:
Accuracy
Collateral
Pressure
Damage
breakpoint Ys ►
Impact
Low Level
Shot
ID:
Processes: Low Level
on C&E Xs ▼
9 1 9 1 172
matrix 38 Score Shot Skilled Scorer
21 Set Catapult Throw Projectile Weight 9 3 3 9 168
Available Force
23 Set Catapult Throw
Adjustment
9 3 3 9 168
CE Process Step
Requirement:
ID: or Function:
Skilled scorer must be able to

Additional
38 Score Shot judge impact point to ±3mm
information
Use actions drop down list (10% of allowable accuracy)
can be
added to the
on C&E matrix to transfer 21
Set Catapult Projectile weight must be requirements
Throw known to ±0.2 grams
inputs (X’s) to FMEA form if needed
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FMEA step 2
Determine failure mode(s)
− Failure modes are ways the function or item could fail to meet the requirement as
experienced by the customer
− One failure mode per line; add lines to capture all relevant failure modes
CE Process Step Potential Failure

Requirement:
ID: or Function: Mode Enter information in all columns for
any FMEA row used. The FMEA will
Skilled scorer must be able to be sorted later, missing information
Shot is scored long
or short will confuse the team.
(10% of allowable accuracy)
Wrong shot is
scored
Set Catapult Projectile weight must be

21 Rock is too light
Throw known to ±0.2 grams
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Linking failure modes to effects
 Teams must consider linkages between failure modes and effects
 Consider the following situations
Failure Mode 1 Effect 1

Effect 2
Failure Mode 1
Failure Mode 2 Effect 2 Effect 1
Failure modes may drive unique effects Single failure modes may drive
multiple effects
Failure Mode 1 Failure Mode 1
Effect 1 AND Effect 1

OR
Failure Mode 2 Failure Mode 2
Multiple failure modes may result in the same Some effects only occur if multiple failure
effect modes are present at the same time
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FMEA step 3
Determine the effect on the customer for each failure mode
− Effects must be stated from the customer’s perspective (warning light illuminated,
reduced power, delay in payment received, etc.)
CE Process Step Potential Failure Potential Effect(s) Of

Requirement:
ID: or Function: Mode Failure:

Shot is scored long Excessive noise in catapult-
or short setting transfer function
Wrong shot is Excessive noise in catapult-
scored setting transfer function
►Rock will overshoot target

Set Catapult Projectile weight must be ►Damage may be too light
21 Rock is too light Rock will overshoot target
Throw known to ±0.2 grams ►Collateral damage may
occur
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FMEA step 4
Identify potential causes of each failure mode
− Possible causes verified to significantly contribute to the problem become the focus
of the project; these are what you’ll fix!
− In many cases, there may be more than one cause for a failure mode
C
S l
CE Process Step Potential Failure Potential Effect(s) Of
Requirement: E a Potential Cause(s) Of Failure:
ID: or Function: Mode Failure: s
V
s

Set Catapult Projectile weight must be ►Damage
Rock will may be too target
overshoot light Rock is made of light material (minions
21 Rock is too light
Throw known to ±0.2 grams ►Collateral damage may prefer moving light rocks)
occur
21 Rock is too light Damage may be too light Nobody assessed the needed rock weight
occur
Collateralmay be toomay
damage light
21 Rock is too light The rock fractured after being quarried
Throw known to ±0.2 grams ►Collateral
occur damage may
occur
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FMEA step 5
List current prevention and detection controls for each cause and failure mode
− Prevention (leading control): these eliminate the cause of the failure or failure mode
and are the preferred ‘control’. (e.g. failsafing, automated control, setup verifications)
− Detection (lagging control): these recognize and flag the failure before the customer
is exposed (e.g. audits, checklists, inspection, testing, training, PMs)
 If an obvious control is available, the team should consider immediate action on it
C
S l O
CE Process Step Potential Failure Potential Effect(s) Of Controls Controls
Requirement: E a Potential Cause(s) Of Failure: C
ID: or Function: Mode Failure: s (Prevention) (Detection)
V C
s

Set Catapult Projectile weight must be ►Damage may be too light Rock is made of light material (minions We don't shoot
21 Rock is too light Rock will overshoot target None
Throw known to ±0.2 grams ►Collateral damage may prefer moving light rocks) sandstone
occur
21 Rock is too light Damage may be toomay
light Nobody assessed the needed rock weight None None
Throw known to ±0.2 grams ►Collateral damage
occur
Collateral may be too
damage maylight Rocks are checked
21 Rock is too light The rock fractured after being quarried None
Throw known to ±0.2 grams ►Collateral
occur damage may before loaded
occur
List only real, current, and in-use controls. Include

documented procedures and instructions where they exist.
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FMEA step 6
Assign 1-10 integer SEV, OCC, and DET ratings to each row
− SEV (1=not severe, 10=severe)
− OCC (1=no occurrences likely, 10=occurrence very likely)
− DET (1=failure is not possible, 10=failure will not be detected)
− These values will be used to calculate the risk priority number (RPN)
C
S l O D
Requirement: E a Potential Cause(s) Of Failure: C E
V C T
s

21 Rock is too light 8 3 None 5
• Each failure mode will have only occur
Set Catapult one SEV
Projectile value
weight must be ►Damage may be too light
21 Rock is too light 8 Nobody assessed the needed rock weight None 10 None 10
• Find the highest SEV for each

occur
Set Catapult Projectile weight must be ►Damage may be too light Rocks are checked
21
Throw failure mode
known to ±0.2 grams andRock
use is toothat
light SEV for
►Collateral damage may
8 The rock fractured after being quarried
before loaded
3 None 4
occur
all entries of that failure mode
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FMEA: scoring
 Many grading scales exist
 Start with a published grading scale
and modify it, if necessary, for your
project needs
 Grading scale examples:
− Worksheet labelled
in FMEA form
− AIAG FMEA, 4th Edition

− CFM-01-01-01-00 → CFM-01-01-01-00
Rev6 PFMEA Template 4th ed.xls →
Printable Criteria Lists (worksheet)
− CORP-01-14-00-00 Integrated Design
Failure Mode and Effects Analysis Example rating scale FMEA form 15 of 25
FMEA step 7
Calculate RPNs and sort the FMEA by RPN:
Use the “calculate RPNs” macro command
− RPN is not absolute; teams scale or bias SEV, OCC, and DET scores.
− Ensure sanity check is performed
C
S l O D R
Requirement: E a Potential Cause(s) Of Failure: C E P
V C T N
s

21 Rock is too light 8 3 None 5 120
occur
21
Set Catapult
Throw
Projectile weight must be
known to ±0.2 grams
RPN = Severity x Occurrence x Detection
Rock is too light
►Damage may be too light
►Collateral damage may
8 Nobody assessed the needed rock weight None 10 None 10 800
occur Effects Likelihood Controls
21 Rock is too light 8 The rock fractured after being quarried 3 None 4 96
Throw known to ±0.2 grams ►Collateral damage may before loaded
occur
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Class
 The classification (class) column provides space to enter symbols used to
classify special - or critical-product or process characteristics
 6S&CI projects rarely use the class field for its intended purpose
 Teams may use the class column to identify their key X’s to help track them
through the project
C
S l O D R
Requirement: E a Potential Cause(s) Of Failure: C E P
V C T N
s
Skilled scorer must be able to Scorer is not trained to properly judge

Shot is scored long Excessive noise in catapult-
or short setting transfer function
6 X2 distance (sees the ball land but loses the None 10 None 9 540
(10% of allowable accuracy) point before it can be measured)
Shot is scored long Excessive noise in catapult- Scorer gets a sight
38 Score Shot judge impact point to ±3mm 6 Target is obscured (can't see the ball land) 5 None 8 240
or short setting transfer function X3 glass
Wrong shot is Excessive noise in catapult- Scorer is distracted or overwhelmed (doesn't FC checks looks at
scored setting transfer function
6
X4 The team now has traceability
watch the shot)
7 None
scorer before shooting
4 168
of these X’s through the rest

Set Catapult Projectile weight must be ►Damage may be too light Rock is madeof the
of light project.
material (minions They can also
We don't shoot
occur back-trace to the Process
21
Set Catapult Projectile weight must be
Rock is too light
►Damage may be too light
8 X1
Flow
Nobody assessed Map
the needed if needed.
rock weight None 10 None 10 800
occur
occur 17 of 25
FMEA step 8
Determine recommended actions to reduce the high RPN risks
− Actions are recommended for only the high RPNs for ‘factor filtering’ FMEA’s
− Actions are derived by the team through brainstorming and other creative
innovation approaches
− Note that AIAG FMEA’s are used for long term control of a product or process and
have separate rules around required actions; see the AIAG guidance for details
C
S l O D R
Requirement: E a Potential Cause(s) Of Failure: C E P Recommended Action(s)
V C T N
s

occur
Set Catapult Projectile weight must be ►Damage may be too light FC needs a way to request and
21 Rock is too light 8 X1 Nobody assessed the needed rock weight None 10 None 10 800
Throw known to ±0.2 grams ►Collateral damage may receive rocks of specific weight
occur
occur
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FMEA step 9
Take appropriate actions and recalculate RPNs – typically towards the end of the
project
− Document your actions and results in the FMEA’s right-hand columns
− Mark actions as prevention (P) or detection (D) to help ascertain their likely
effectiveness
SEV.F
OCC.F
RPN.F
DET.F
R
Actions
P Recommended Action(s) Responsibility
Taken
N
120
FC needs a way to request and

ProcDoc
800 receive rocks of specific weight Glignol 7 5 5 175
updated
(P)
96
Brainstorm solutions and set Demonstrate

accountability improvement 19 of 25
Example FMEA completed on current
process
Problem Definition Current Process
C
Potential S l Potential O D R
Process Step or Potential Failure Controls Controls
CE ID: Requirement: Effect(s) Of E a Cause(s) Of C E P
Function: Mode s (Prevention) (Detection)
Failure: V Failure: C T N
s
How likely will the current controls detect or prevent this

How likely is it that this cause will result in this failure
What is the
failure cause from occurring?

How severe is the effect?
specific
List, one failure
What is the requirement of (Preferred) What (Detection)
mode / row, How will this What specific,
specific process this function, controls are What controls
manners for which failure mode measurable,
function, item, item, interface, or currently in place to are currently in SEV ·
mode?
this function, item, affect the assignable
Concepts interface, or parts part? This not allow the causes place to detect OCC ·
interface, or part function as causes might
from the 5k' should be to exist or to not the failure DET
might fail to meet perceived by the result in the failure
process map or measurable. allow them to result mode should it
the requirement customer? mode?
P diagram? Specifications in the failure mode? occur?
listed in this row.
should be listed if
possible.
The rock
The Scorer must
overshoots the The target is
Good Set (stationary) determine The assessed Illuminate targets
target and 10 obscured (fog, 7 None 6 420
Example catapult throw distance to target distance is too far with fire pots
causes dust, smoke, etc.)
to within 5 feet
collateral
Poor Set Catapult Distance To
Wrong distance Miss target 10 Wrong distance Look for hit 10 10 1000
Example Throw Target
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Example - Updated FMEA following
improvement phase
Current Process Action
SEV.F
OCC.F
RPN.F
DET.F
O D R
Controls Controls Actions Taken and
C E P Recommended Action(s) Responsibility
(Prevention) (Detection) Completion Date
C T N
How likely will the current controls detect or prevent this
Enter the occurence score following completed actions.

Show specific improvement actions
Enter the detection score following completed actions.

How likely is it that this cause will result in this failure
Enter the severity score following completed actions.

for causes with unacceptable RPNs
as determined by the team and
process owner.
failure cause from occurring?

Mark actions as prevention (P) or
(Preferred) What (Detection) detection (D) to help estimate
List the specific
controls are What controls effectiveness.
person and List the specific
currently in place to are currently in SEV · SEV.F ·
mode?
organization actions completed

not allow the causes place to detect OCC · Reduce severity through a product or OCC.F ·
responsible for the and when they were
to exist or to not the failure DET process redesign. Improved control DET.F
recommended actually completed.
allow them to result mode should it cannot reduce severity.
actions.
in the failure mode? occur?
Reduce occurence through redesign
or improved control.
Improve detection through redesign,

controls improvement, and / or
failsafing.
Cosntruction of
Illuminate targets Install field reference markers every 2 Gladwin (king's furrows and towers
7 None 6 420 10 3 6 180
with fire pots furlongs. (P) constructors) completed on the
12th of Samonios.
Look for hit 10 10 1000 training training team this year 3 3 3 27
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Exercise
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Catapult FMEA exercise
 Continue working towards an improvement in catapult accuracy by creating an
FMEA based on the C&E results
 Equipment
− C&E matrix and process maps from previous exercise
− FMEA template
 Instructions
− Transfer the C&E matrix to the FMEA template
− Develop an FMEA for the process
− Work to the recommended actions for the highest ranked RPN’s
 Output/Deliverables
− Show the RPN’s and sorted FMEA
− Show key requirements that will be investigated further
 Duration
− 30 minutes (start presentation at 20 minutes)
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Review results
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Summary
 FMEAs identify high risk failure modes and potential causes
 6S&CI FMEAs, as described here, are used to filter a list of potential
causes to a critical few in support of an improvement effort
 6S&CI FMEAs are typically developed through a process including a
process flow map, 50k and 5k process maps, and C&E matrix
 Ensure you include the needed skilled people on your cross-functional
FMEA team
 MBBs can help you identify and use the various tools and methods
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FMEA Rev 4

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Failure Modes and Effects Analysis

COS 9: Follow Common Problem Solving Techniques

 FMEA is meant to be a “before – the – event” action, not an “after – the

1: AIAG “FMEA”, 4th Edition

Problem Definition Current Process Action

21 Set Catapult Throw Projectile Weight 9 3 3 9 168

Skilled scorer must be able to

CE Process Step Potential Failure

Set Catapult Projectile weight must be

Failure Mode 1 Effect 1

Failure Mode 1 Failure Mode 1

Effect 1 AND Effect 1

CE Process Step Potential Failure Potential Effect(s) Of

Skilled scorer must be able to

►Rock will overshoot target

►Rock will overshoot target

►Rock will overshoot target

List only real, current, and in-use controls. Include

►Rock will overshoot target

• Find the highest SEV for each

− AIAG FMEA, 4th Edition

►Rock will overshoot target

Skilled scorer must be able to Scorer is not trained to properly judge

of these X’s through the rest

►Rock will overshoot target

FC needs a way to request and

Brainstorm solutions and set Demonstrate

How likely will the current controls detect or prevent this

failure cause from occurring?

How likely will the current controls detect or prevent this

Enter the occurence score following completed actions.

Enter the detection score following completed actions.

Enter the severity score following completed actions.

failure cause from occurring?

organization actions completed

Improve detection through redesign,

Look for hit 10 10 1000 training training team this year 3 3 3 27

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