Quality Improvement Using FMEA : A Short Review · 2017-06-07 · Handbook in 1984 to promote FMEA. FMEA methodology is now effectively used in a variety of industries including semiconductor,

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 04 Issue: 06 | June -2017 www.irjet.net p-ISSN: 2395-0072

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Quality Improvement Using FMEA : A Short Review

Sourabh Rana1, Dr. R.M.Belokar2

1Production Engineering Department PEC University of Technology, Chandigarh 2Production Engineering Department PEC University of Technology. Chandigarh

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Abstract - - Failure mode and effect analysis (FMEA) is

systematic, proactive method for evaluating the process to

identify were and it might be fail to assist the relevant impact

of different failures in order to identify the part of processes

that are most needed of the change. The FMEA process

associated with step wise process starting from potential

failure causes ,study existing and complete the working of

mechanism , calculate the risk priority number (RPN)of

existing and modified. The presented paper deals with the

review of industrial case study and implementation of FMEA

on them. This work discusses about implementation of Process

Failure mode and effect analysis for improvement in welding

process through better ment in various sub-processes . We

considered various parameters and examined them. The

parameters are discussed along with their rankings. Severity,

Occurrence and Detection are detected to calculate the Risk

Priority Number (RPN). The Risk Priority Number (RPN) can

be obtained by multiplying Occurrence with Severity and

Detection. RPN gives the idea about the most affecting

parameters in the existing welding process. We detected how

failure can occur and suggested the preventive action.

Key Words: Severity, Occurrence, Detection and RPN,

DFMEA, PFMEA, SAW Welding and risk evaluation.

1.INTRODUCTION The purpose of FMEA is to analyze the design

characteristics relative to the planned manufacturing

process to ensure that the resultant product meets

customer needs and expectations. When modes of

failure are identified, improvement can be done by

reducing the chances for occurrence by taking some

correct actions . FMEA provides an organized analysis

of failure modes of the system being defined and

identifies related causes. It uses probabilities of

detection and occurance in addition with a severity

criteria to develop a risk priority number (RPN) for

ranking corrective action considerations. Used in both

the design and manufacturing processes, they

substantially reduce costs by identifying product and

process improvements early in the develop process

when changes are relatively easy and inexpensive to

make. The result obtained found robust ,as the need for

post corrective action and problems are reduced

completely. This project discuses and implementation

of Process Failure mode and effect analysis for

improvement in all sub-processes involved till the

completion of welding process.

2. FMEA Types




2.1 Design FMEA (DFMEA) DFMEA is kind of tool to identify and prevent failure modes of products, that are related to their design, in order to validate the established design parameters for a specific functional performance level, at system, subsystem or component level. It aids in the objective evaluation of design requirements and design alternatives. It provides additional information to aid in the planning of efficient design testing. In order to eliminate or mitigate the effects, DFMEA plays an important role by selecting the optimal design variant and develop a documentary base to support future designs in order to reduce the risks which is associated with the faulty products that reach to the customers.

2.2 Process FMEA (PFMEA)

The purpose of this variant of FMEA is to determine the

potential failure modes of manufacturing/assembly

processes at operation, subsystem or system level and

to eliminate as early as possible the process faults that

could lead to the separation of defective products and

avoid using improper methods as part of the processes.

PFMEA also provides solutions for the development of

future processes and validation programs.

3. Research Methodology

Step 1: First of all collect the functions of

system and make a hierarchical structure. Then

divide the system into several subsystems,

having number of components.

Step 2: Now determine the failure modes of

each component and its effects. Assign the

severity ranking (S) of each failure mode

according to the respective effects on the

system.

Step 3: Determine the causes of failure modes

and estimate the likelihood of each failure that

can occur. Give the rating of ocurrance (O) to

each failure mode according to the likelihood of

its occurrence.

Step 4: Make a list of approaches to detect the

failures and determine the ability of system to

detect the failures prior to the failures

occurring. Hence assign the detection rating

(D) of each failure mode.

Step 5: Calculate the risk priority number

(RPN) and prepare the priorities for attention.

Step 6: Take suitable actions to enrich the

performance of system.

Step 7: Prepare FMEA report in a tabular form.

4. RISK ASSESSMENT FACTORS

Probability of Severity (S): A number from 1 to 10 is

selected, depending on the severity of the potential

failure mode’s effect

• 1 = no effect • 10 = maximum severity




Table -1: Severity Ranking Table

Probability of occurrence (O): A number from 1 to 10 is

selected, depending on the likelihood of the failure

mode’s occurrence

• 1 = very unlikely to occur • 10 = almost certain to occur

Table -2: Occurrence Ranking Table

Probability of detection (D): A number from 1 to 10 is

selected, depending on how unlikely it is that the fault

will be detected by the system responsible (design

control process, quality testing, etc.)

• 1 = nearly certain detention

• 10 = impossible to detect Table -3: Detection Ranking Table

Risk Priority Number (RPN): The failure mode’s risk is

calculated by the formula RPN = S x O x D. RPN =

Severity x Probability of Occurrence x Probability of

Detection. RPN will be a number between 1 (virtually

no risk) and 1000 (extreme risk).

Table -4: Final Table




5. Applications

Used in the design of products and processes (manufacturing line, service procedures, etc.) to anticipate and address potential failure modes early in the process when they are least expensive for correction.

It contributes to the development of effective maintenance procedures. For instance, MSG-3 analysis for aircraft industry.

Identifies the failure modes discovered during testing and update the probabilities of occurrence based on the Reliability Growth testing data.

It is used to evaluate critical plans to modify an existing process.

Used to investigate the credibility of existing systems/processes.

Helps in providing a central location for reliability-related information for the process.

Provides a basic knowledge that helps for the future troubleshooting efforts.

Acts as a learning tool for new engineers. It provides input to other system analyses, for

example Reliability Block Diagram (RBD), Fault Tree, etc.

It can be used to Contribute in the identification of requirements for built-in test equipment (BITE).

It is also included among Probabilistic Risk Assessment (PRA) techniques (such as in nuclear power and other industries).

It is performed to satisfy a customer requirement and/or to comply with Safety and Quality requirements, such as:

o Six Sigma o FDA Good Manufacturing Practices o Process Safety Management Act (PSM

act)

6. Conclusion

In 1950s the attention was paid to the safety to prevent accidents that can be predicted in aerospace industry in advance led to the development of the FMEA methodology. Later, it was introduced as key tool for increasing efficiency and quality in manufacturing processes. In 1970’s automobile company came with FMEA to address the potential problems in the Research and Development (R&D) in the early stage of production and published the

Potential Failure Mode and Effects Analysis Handbook in 1984 to promote FMEA. FMEA methodology is now effectively used in a variety of industries including semiconductor, processing, food service, plastics, software, and healthcare. Several approaches and applications of FMEA have been developed so far. FMEA can be used to optimize the decision making process in new product development in automobile industry .FMEA can be implemented at the design stage once actual failures are observed during test, production and operation. On the basis of results and analysis stated above we are going to implement FMEA on the sub processes involved in welding processes starting from the sheet handling to welding process.

7. Reference

[1] A. A. Nannikar, D. N. Raut, M. Chanmanwar, S. B.

Kamble and D. B. Patil, “FMEA for Manufacturing and

Assembly Process”, International Conference on

Technology and Business Management, pp. 26-28,

March 2012.

[2] Segismundo, Paulo Cauchick Miguel, "Failure mode

and effects analysis (FMEA) in the context of risk

management in new product development: A case

study in an automotive company", International

Journal of Quality & Reliability Management, Volume

25 Issue 9, pp.89 – 912, 2008.

[3] Arabian-Hoseynabadi, H. and Oraee, H. and Tavner,

P. J. “Failure Modes and Effects Analysis (FMEA) ”,

International journal of electrical power and energy

systems, Issue 7, pp. 817-824, 2010.

[4] ArunChauhan, Raj Kamal Malik, Gaurav Sharma,

MukeshVerma, “Performance Evaluation of Casting

Industry by FMEA - A Case Study”, International

Journal of Mechanical Engineering Applications

Research, Volume 2, Issue 2, pp. 113-121, 2011.

[5] Carl S. Carlson, “Understanding and applying the

fundamental of FMEAs”, IEEE, January 2014.




[6] Dr. D.R.Prajapati, “Application of FMEA in Casting

Industries: A case study”, UdyogPragati, vol.35, Issue 4,

pp. 6-14,December 2011.

[7] Ioannis S. Arvanitoyannis and Theodoros H.

Varzakas, “Application of ISO 22000 and failure mode

and effect analysis [FMEA] for industrial processing of

salmon: A case study”, Critical reviews in Food science

and Nutrition, Volume 48, pp. 411-429,2008.

[8] Rakesh.R Bobin Cherian Jos and George Mathew,

“FMEA Analysis for Reducing Breakdowns of a Sub

System in the Life Care Product Manufacturing.

Documents

Quality Improvement Using FMEA : A Short Review · 2017-06-07 · Handbook in 1984 to promote FMEA. FMEA methodology is now effectively used in a variety of industries including semiconductor,