FMEA.DR. K. BARANIDHRAN

April 7, 2023 1

Failure Mode

and Effect

Analysis

April 7, 2023 2

Meaning

• It is a preventive measure to systematically display the causes, effects and possible actions regarding observed failures.

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FMEAan engineering technique use to define, Identify and Eliminate known and / or potential failures, problems, errors which occur in the system, design, process and service “before they reach the customer”.

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FMEAis “before-the-event” action and is done when existing system/products/processes are changed or redesigned

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FMEAis a never-ending-process improvement tool

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objective

• The objective of FMEA is to anticipate failures and

prevent them from occurring. FMEA prioritizes failures and attempts to eliminate their causes

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• 1.System FMEA:-• Analyzes components,

subsystem and main system in early stage of design.

• 2.Design FMEA:-• Analyzes the products/parts

before they are released to manufacturing.

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Types• 3.Process FMEA:-• Focuses on manufacturing

and assembly processes.• 4.Service FMEA:-• Analyzes services industry

process before they are released to impact the customer. And Equipment, Maintenance, Concept FMEA,

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5.Environmental FMEA• However, in practice, all the

above types can be broadly categorized into two types…..• 1.Design FMEA involves the

analysis of the potential failures of product or service due to component or subsystem unreliability.

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2.Process FMEA -Manufacturing process-The Process

FMEA is used primarily to identify areas of critically of control and to emphasize the design and more reliable process – It may be noted the equipment, service, and

environmental FMEA are

slightly modified versions of process FMEA

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Benefits • Properly used FMEA provides several

benefits….• Improve product/process reliability and

quality• Increase customer satisfaction• Early identification and elimination of

potential product/process failure modes• Prioritize product/process deficiencies• Capture engineering/organization knowledge

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.Document and track the actions taken to reduce risk.Provide focus for improved testing and development.Minimize late changes and associate cost..Act as catalyst for team work and idea exchange betweens.

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Inputs for preparation of FMEA

• 1.PEOPLE INPUTS:• The FMEA methodology is a team

effort. The FMEA team should have assembly engineer, manufacturing engineer, materials engineer, quality engineer, service engineer, suppliers and the customers

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2. DATA INPUTS: the data inputs needed to prepare FMEA are product and process specifications, reliability data, customers priority data, process variability data, process descriptions and inspection data

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Stages or Methodology

• The FMEA methodology has four stages, They are…

• Step 1. SPECIFYING POSSIBILITIES• Functions• Possible failure modes• Root causes• Effects • Detection/Prevention

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2.Step . QUANTIFYING RISK.Probability of cause.Severity of effect.Effectiveness of control to prevent cause.Risk priority number (RPN)

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Step 3. CORRECTING HIGH RISK CAUSES.Prioritizing work.Detailing action.Assigning action responsibility.Check points on completion

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Step 4. RE-EVALUATION OF RISKRecalculation of risk priority number

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Design FMEA Format

DetectPrevent

ActionTaken

Action ResultsResponse &

TargetComplete

RecommendedActions

CurrentDesign

Controls

PotentialCause(s)/

Mechanism(s)Of Failure

PotentialEffect(s) of

Failure

Potential FailureMode

DetectPrevent

ActionTaken

Action ResultsResponse &

TargetComplete

RecommendedActions

Current

Controls

PotentialCause(s)/

Mechanism(s)Of Failure

PotentialEffect(s) of

Failure

Potential FailureMode

Function

April 7, 2023 20

THANK YOU

FMEA.DR. K. BARANIDHRAN

Education

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