Importance in NPD process
 Identiy the ways in which a product can ail
 Plan how to prevent those ailure
Denition
• Failure odes and !fects "nalysis (F!") is methodology or analy#ing potential relia$ility pro$lems early in the development cycle where it is easier to ta%e actions to overcome these issues& there$y enhancing relia$ility through design'
• F!" is used to identiy potential ailure modes& determine their efect on the operation o the product& and identiy actions to mitigate the ailures'
• " crucial step is anticipating what might go wrong with a product' hile anticipating every ailure mode is not possi$le& the development team should ormulate as etensive a list o potential ailure modes as possi$le'
 
 
• hen carryover design are used in new system or environments
• For a design F!"& ater product unctions are dened& $ut $eore the design is approved and released to manuacturing
• For the process F!"& when preliminary drawings o the product are availa$le
DF!" timingDF!" timing
When FMEA is complete?
hen the design is released or production the F!" is considered to $e complete'
 Do DF!" once concepts are approved
 
 
Failure mode
 *he manner in which part or process can ail to meet specication
+sually associated with a deect or nonconormance
Cause
" deciency that results in ailure mode
,auses are sources o varia$ility associated with the %ey process input varia$les
Efect
Impact on the customer i ailure mode is not prevented or corrected
CauseCause FailureFailure
(FMEA)(FMEA) EffectEffect
hat is ailure& it-s cause and efect .hat is ailure& it-s cause and efect .
 !fects will lead to loss o customer condence

 
 
 
 
Cause 1Cause 1
Effect 1Effect 1
Effect 2Effect 2
Importance to understand relation $etween cause and efectImportance to understand relation $etween cause and efect
 0 cause can have 1 efects or2
 1 cause can contri$ute or only one
 
 
 *here are our steps to a ris% assessment or F!" session (ollowing the preparation step)3
  0) Identiy ris% items& 1) "naly#e 44 rate and prioriti#e the items& 5) Plan 44 develop an a$atement plan or the highest ris% items 6) Implement the plan and communicate progress with all relevant
parties'
7teps or DF!"7teps or DF!"
 Prepare F8D to show to the whole DF!" team so that they get amiliari#e with the product or design
 *a%e some prototype or similar parts or DF!" session
 Include people rom purchase& 9uality& design and led eperts or the session
 Pro:ect leader should help in maturing o the idea'
 
 
Severity
<ow signicant is the impact o the efect to the customer (internal or eternal)
Occurrence
<ow li%ely is the cause o the ailure mode to occur.
Detection
<ow li%ely will the current system detect the cause or ailure mode i it occurs
RP
" numerical calculation o the relative ris% o a particular ailure mode
=PN > 7ev ?cc Det
 *his num$er is used to place priority on which items need additional 9uality planning'
=PN num$er @ signicance=PN num$er @ signicance
 <igher the =PN num$er higher the ris% o ailure
5
• Percentage of the failure to be addressed
eg !"#$ %"#$ &'# etc
%",1''' -1''' .%"'
/ence the RPN o be targeted 0ould be around 1'''%"'. 2"'
o An RPN *3er 2"' need to ha3e correcti3e action based on the e3erit
and *ccurrence
 
 
• F!" is designed to assist the engineer improve the 9uality and relia$ility o design'
• Increase customer satisaction
• !arly identication and elimination o potential productAprocess ailure modes
• ,apture engineeringAorgani#ation %nowledge
• !mphasi#es pro$lem prevention
• Provide ocus or improved testing and development
• inimi#es late changes and associated cost
• ,atalyst or teamwor% and idea echange $etween unctions 
8enets o F!"8enets o F!"