Failure Mode and

Effects Analysis
 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 in the 1960’s.
 Initial automotive adoption in the 1970’s.
 Potential serious & frequent safety issues.

 Required by QS-9000 & Advanced Product Quality Planning Process

in 1994.
 For all automotive suppliers.

 Now adopted by many other industries.

 Potential serious & frequent safety issues or loyalty issues.
 FMEA -- An Introduction

• Why Do FMEAs?
Da y • Definition, Purpose,
1 Types, Benefits
• FMEA Working Model
Introduction
• Generating / Managing
• Team Approach
 FMEA -- Definition
Structured group of activities which ...
• Recognize and evaluate the potential
failure of a product or process and its
effects
• Identify actions which could eliminate or
reduce the chance of the potential
failure occurring
• Document the process

2-2
 FMEA Purposes

Origin of Elimination of
Failures Failures
Failures

FMEA

JOB 1 Time
 FMEA -- Purposes

FMEAs are intended to ...

• Identify potential failure modes and rate severity
of effects
• Identify critical and significant characteristics
• Help engineers prioritize and focus on eliminating
product and process concerns and helps prevent
problems from occurring
• Test adequacy of controls from DCP process

2-2
 FMEA -- Types
System
Design
Design
Concept
Concept FMEA
FMEA Sub-System
FMEA
FMEA Component
System
Assembly Sub-System
Process
Process Component
FMEA
FMEA
System
Manufacturing Sub-System
Component

2-4
 Benefits -- Concept FMEAs

Design • Helps select optimum concept

Concept
Concept • Identifies potential failure modes
Process • Considers potential effects
• Helps generate occurrence ratings
• Identifies testing requirements
• Helps determine if hardware system
redundancy is required

2-5
 Benefits -- Design FMEAs
• Aids in evaluating requirements and
Design
Design alternatives
Concept
• Aids in initial design for DFM
Process
• Increases probability of detecting failure
modes and their effects
• Provides additional information for
testing requirements
• Helps identify critical and significant
characteristics
• Helps validate DVPs and SDSs
2-5
 Benefits -- Process FMEAs
• Identifies potential product related failure
Design
modes
Concept • Assesses effects on all customers
Process
Process • Identifies potential Manufacturing and
Assembly causes to focus controls on
reducing occurrence and/or increasing
detection
• Establishes a priority system for
considering corrective actions
• Identifies confirmed critical and significant
characteristics
2-6
 Generating FMEAs

Who initiates? Who prepares? Who updates?

When to Failure
Failure
Who is FMEA
discard? customer?
Mode
Mode
FMEAsand
and
How is FMEA Effects
Effects When started
documented? Analysis
Analysis and updated?

When is FMEA Relationship

complete? to FPDS?

2-9
 FMEA Working Model
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 Managing FMEAs

FMEAs are living documents, and are updated

when ...

• Modification to a component, process or

system is planned
• Component is to be used in new
environment
• Customer concern arises: Global 8D
 FMEAs and Systems Engineering
Customer Customer Focus Customer
Musts / Wants Customer Experience & Feedback Satisfaction

CFMEA
Vehicle Level Inputs
• Purchaser / owner / operator Customer Purchase, Operate
& Maintain Disposal
• Regulatory (FMVSS, EPA, ...) Requirements
• Corporate (WCR, ABS, Manuf, ...)

Requirements Feasibility
Cascade Feedback

Vehicle Level Requirements

• Vehicle Attributes DVM / DVP Vehicle Production
• Vehicle System Specification - VDS Verification

Requirements Feasibility

DFMEA
Cascade Feedback

PFMEA
System / Subsystem Level
• System & DVM / DVP System
• Subsystem Design Specifications - Verification
SDS

Requirements Feasibility
Cascade Feedback

Part /
Part/ Component Fabrication /
Component Design Verification
• Component Design Specification - CDS

2-13 KO SI SC PA PR J1
 Team Approach -- FMEA

Core
Team

Support
Team
3-5
Design FMEA -- An Introduction

 Identify FMEA Team

Da y  Establish Scope
1
 Describe Function
Design FMEA
» Brainstorming
Introduction
» Function Trees
 Practice Exercise 1
 Design FMEA
Potential
Failure Mode and Effects Analysis

Scope
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component

Team
Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 Design FMEA -- Team

Facilitator or Application Engineer

Technical Affairs
Representatives
Support from:
Team • Customer
Service
Design Engineer
CORE • Suppliers
Manufacturing / Team • Global Test
Process Engineer
Operations
• Corporate
3-5 Quality
 Design FMEA -- Scope

Once core team is established...

• Create a block diagram
• Identify the boundary for analysis
• Confirm composition of the support team

3-8
 Constructing Block Diagrams

Service Assembly

Part Screw Component/ Weld Part

X Assembly Y

User
Other Adhesive Part
Systems Z
3-10
Block Diagram -- Example

Headlamp Assembly
Block Diagram -- Example

Vertical Trimmer Assembly

 Block Diagram -- Example

Hood Adjuster User

(Clearance) Socket

Lateral
Location Clips
Vehicle Body Screw Vertical 2
Upper Cross Trimmer Reflector
Member Assembly
 Determine Function
Potential
Failure Mode and Effects Analysis

Scope
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:

Team
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 What is Function ?
• Design intent or engineering requirement
• Must be measurable or set at an
actionable level
• Representation of all wants, needs and
requirements, both spoken and unspoken

5-6
 Describe Function

Verb
Verb Noun
Noun
Indicates action, Indicates what the
occurrence, being action relates to

Generate Light
Speed
Control Fuel
Dispense Seat Track
5-7 Rust
Prevent
 Describe Function
Thought Starters ...
• Satisfy user
• Attract user
• Assure convenience
• Assure dependability
• Governmental requirements
• Safety requirements
 Brainstorming

Exercise in creative thinking

Method to generate ideas
Brainstorming -- Guidelines

• Warm up
• Suspend judgment
• Anything goes
• Quantity counts
• Springboard
• Persevere
• Warm down
 Brainstorming -- Pitfalls
• Low team trust
• Broad task definition
• Criticism, competition, defensiveness
• Silliness, lack of focus
• Questions and explanations
• Organizing ideas during creative stage
Brainstorming -- Agreement

• Everyone explains view(s)

• Identify needs of individuals
• If you can’t meet a need, say so
• Check out feelings -- yours / others
• Don’t compromise, average,
or ‘split the difference’
 Function Trees
• Provide an organized approach to identify
the essential features of a product (or
process sometimes)
• Help ensure that ‘unspoken’ and ‘spoken’
requirements are defined
• Provide a graphical representation of
functions to ensure clear, total team
understanding
Constructing Function Trees

HOW ? WHY ?
Secondary
Level
Primary Tertiary
Level Level
 Vertical Trimmer Function Tree

HOW ? WHY ?
Permit / Maintain Adjust Light Beam X° Both Directions
Horizontal
Adjustment Locate Headlamp Laterally 10 Years,
150,000 Miles
Retain Setting 10
Adjust Years, 150,000 Miles

Headlamp Permit / Maintain

Adjust Light Beam X° Both Directions

Vertical Adjustment Locate Headlamp Vertically 10 Years,

150,000 Miles

Retain Setting 10
Years, 150,000 Miles
 Guidelines
• Brainstorm all functions (VERB - NOUN)
• Document individual functions by asking
“HOW is function achieved?”
• Repeat left to right, until actionable level
• Use worksheet to check that actionable level is
measurable
• Work right to left and check structure by asking
“WHY is function included?”
 Practice Exercise 1

Block diagram
Brainstorming
Function Tree
Presentation -- Practice 1

Technical
Technical Team
Debrief
Debrief Debrief
 Design FMEA Functions
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Function
1

Function
2

Function
3 Sub- Sub-Sub-
Function Function
Function
n
Function Sub- Sub-Sub-
Function Function

Sub- Sub-Sub-
Function Function
 Design FMEA Path 1

 Failure Modes
Day
1  Effects -- Severity
 Recommended Actions
DFMEA -- Path  Potential Special
1
Characteristics
 Practice Exercise 2
 Design FMEA -- Path 1

Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 Potential Failure Modes
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Function
1

Function
2

Function
3
Potential Failure Modes:
Function
• No function
4
• Partial function
Function
n
• Intermittent function
5-8 • Unintended function
 Potential Failure Modes

Failure Mode Type Potential Failure Mode

No function Not operational
Partial function Not all of function operating
Intermittent function Occasionally does not
function
Unintended function Unexpected function occurs

3-21
Failure Modes -- Vertical Trimmer

Failure Mode: Adjust Light Beam X° in Both Directions

Failure Mode Type Potential Failure Mode

No function No adjustment
Partial function Adjustment in one direction
Intermittent function Adjustment sometimes and
not at others
Unintended function Trimmer itself produces light
 Effects of Failure Modes
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

5-10
 Effects of Failure Modes
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
Failure
Mode 1
Function
1
Failure
Mode n

Potential Effects of Failure Modes:

Function
2 • Part / Sub-component
• Assembly
• System
Function
n
• Vehicle
• Government Regulations
5-11 • Customer (Internal and End User)
 Design FMEA -- Effects Table

Vertical Trimmer

Failure
Part / SC Assbly System Vehicle Gov’t Custmr
Mode Trimmer Headlamp Lt System (-) Regs Driver
May Be Cannot be Misaligned Impaired Road Impaired
Doesn’t Stripped By Adjusted Lightbeam Night/Fog Vehicle Night/Fog
Adjustment Perforsmanc Light Regs Vision
Retain e ‘89
Attempt
Setting F/CMVSS
Non-
Compliance
 Design FMEA -- Severity
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

5-13
Suggested Severity Evaluation Criteria
Effect Criteria: Severity of Effect Ranking
Hazardous ... affects safe vehicle operation and/or
Without government regulation without warning 10
Warning

Hazardous ... affects safe vehicle operation and/or

With Warning government regulation with warning 9

… operable at reduced level of

Low performance. Customer experience some 5
dissatisfaction

None No Effect
1
 DFMEA Severity Rating Example

Item S
Potential Potential
Failure Effects of Failure E
Function Mode V
Part: May be stripped during
Does not
Vertical
maintain
adjustment (7) 10
Trimmer/ Assembly: Headlamp
adjustment cannot be adjusted (6)
Retains System: Misaligned lightbeam (8)
Setting Vehicle: Impaired night/fog
performance (7)
Govt Regs: Non-compliance (10)
Customer: Impaired night/ fog (7)
 DFMEA -- Recommended Actions

Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

5-32
 Select and Manage Actions

To Reduce: Consider This Action: To Accomplish This:

Severity Change the design ... Eliminate failure

mode(s) ...

3-37
 Identify Potential Special Characteristics

Design FMEA

S=9
S=10

YC

7-11
 Practice Exercise 2

Failure Modes
Effects
Severity
Recommended
Actions

Classifications
Break
Break
 Managing FMEAs

FMEAplus
Presentation -- Practice 2

Technical
Technical Team
Debrief
Debrief Debrief
 Section Summary

 Failure Modes
Day
1  Effects -- Severity
 Recommended Actions
DFMEA -- Path  Potential Special
1
Characteristics
 Practice Exercise 2
 Warm-Down -- Day 1

Place Self Others Team

Purpose Agenda
 Course Purpose

These three days are designed to ...

help you function effectively
as an FMEA team member,
but not to leave as an FMEA
team leader or an FMEA expert
 Day 1

Failure Mode and Effects Analysis