FMEA

FMEA History

This type of thinking has been around for hundreds of years.

It was first formalized in the aerospace industry during the Apollo
program {NASA } in the 1960.
Initial automotive adoption in the 1970.
Required by QS-9000 & Advanced Product Quality Planning Process
in 1994.
For all automotive suppliers.
Now adopted by many other industries.
What is FMEA ?

1. Identifies Design or process related Failure Modes Before the

happen.
2. Determines the Effect & Severity of these failure modes.
3. Identifies the Causes probability of Occurrence of the Failure
Modes.
4. Identifies the Controls and their Effectiveness.
5. Quantifies and prioritizes the Risks associated with the Failure
Modes.
6. Develops & Documents action plans that will occur to reduce risk.
Four common classes of FMEA

1. System FEMA
- Focuses on how interaction among system might fail.
2. Design FEMA
- Focuses on how product design might fail.
3. Process FEMA
- Focuses on how processes that make the product might fail.
4. Machinery FEMA
- Focuses on how machinery that perform processes might fail.
FMEA Terminology
1- Failure Modes: ( Specific loss of a function ) is a concise description
of how a part , system or manufacturing process may potentially fail to
perform its function.
2- Failure Mode Effect : A description of the consequence or part
failure. A typical failure mode may have several effects depending
on which customer you consider.
3- Severity Rating : (Seriousness of the Effect) it is the numerical rating of
the impact on customers.
4- Failure Mode Causes A description of the design or process
deficiency that results in the failure mode.
5- Occurrence Rating: It an estimate number of frequencies of failure .
6- Failure Mode Controls : what is the methods that can be control
the failure mode.
7- Detection Rating .
8- Risk Priority Number (NPN): it is the product of Severity , Occurrence,
& Detection . RPN = S * O * D
9- Action Planning : In which we reduce the severity no., occurrence
no. & detection no.
The Underlying Message

Dont correct a weak product design by focusing on a super robust

process.
Dont correct a weak process design by focusing on design
changes to the product.
Containment Considerations

Cost of Defects
Risk of Defects
Protecting on time Delivery
Cost of rework.
Cost of Stopping Production
Benefits of Traceability.
 Example- Failure modes and effects analysts for not meeting the stipulated time
for repair of a gearbox
Maintenance
Subtasks/Activities
work/Task/ Failure mode Failure cause Failure effect
Activity
S.no
May be one of the number of
potential causes and cannot be
Diagnosis Not able to identify the item
Repair of a gearbox identified without dismantling
Delay in requisitioning
the required parts
1
Delay in opening the
Dismantling Rusted with use or on account of gearbox
Jammed bolts accumulated muck
Delay due to search for
wrong size tool brought proper tools. Delay in
Tool not suitable for dismantling Improper design or congested accessing the required
Improper access/ lack of space area Proper handling facilities subsystem required to
Improper handling facilities. not installed. mark arrangement for
proper handling.
Delay in opening gear
box. Search for or
Manuals were not supplied procure or manufacture
Lack of maintenance manual Repair Improper manufacture or new spares leading to
Existing spare not fitting in its assembly. Damaged during delay. Not possible to
Repair/Replacement location Extensive damage breakdown repair economically.
 Leakage of lubricant
Damage setting areas or leading to reparing
Assembly Improper fitting improper tolerances and refitting
Improper sequence of Proper sequencing nor Rework causing
operations planned delay
Non- availability of tools
Alignement Lack of proper tools for proper alignment Improper alignment

Lack of knowledge or no Misalignment may

procedure obtained for lead to quick
Improper procedure the manufacture breakdown
Testing Not enough time Production pressure Improper alignment
Poor testing and
may lead to
improper
No proper procedure certification of
Lack of procedure framed fitness for us