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tOTAL QUALITY MANAGEMENT - FMEA, FINAL YEAR B.E.CS- PRESENTED BY DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGEMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNOLOGY (sit) CHENNAI
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April 7, 2023 1
Failure Mode
and Effect
Analysis
FMEA
April 7, 2023 2
Meaning
• It is a preventive measure to systematically display the causes, effects and possible actions regarding observed failures.
April 7, 2023 3
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”.
April 7, 2023 4
FMEAis “before-the-event” action and is done when existing system/products/processes are changed or redesigned
April 7, 2023 5
FMEAis a never-ending-process improvement tool
April 7, 2023 6
objective
• The objective of FMEA is to anticipate failures and
prevent them from occurring. FMEA prioritizes failures and attempts to eliminate their causes
April 7, 2023 7
Types
• 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.
April 7, 2023 8
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,
April 7, 2023 9
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.
April 7, 2023 10
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
April 7, 2023 11
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
April 7, 2023 12
.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.
April 7, 2023 13
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
April 7, 2023 14
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
April 7, 2023 15
Stages or Methodology
• The FMEA methodology has four stages, They are…
• Step 1. SPECIFYING POSSIBILITIES• Functions• Possible failure modes• Root causes• Effects • Detection/Prevention
April 7, 2023 16
2.Step . QUANTIFYING RISK.Probability of cause.Severity of effect.Effectiveness of control to prevent cause.Risk priority number (RPN)
April 7, 2023 17
Step 3. CORRECTING HIGH RISK CAUSES.Prioritizing work.Detailing action.Assigning action responsibility.Check points on completion
April 7, 2023 18
Step 4. RE-EVALUATION OF RISKRecalculation of risk priority number
April 7, 2023 19
Design FMEA Format
DetectPrevent
RPN
DET
OCC
SEV
ActionTaken
Action ResultsResponse &
TargetComplete
Date
RecommendedActions
RPN
Detec
CurrentDesign
Controls
Occur
PotentialCause(s)/
Mechanism(s)Of Failure
Class
Sev
PotentialEffect(s) of
Failure
Potential FailureMode
Item
DetectPrevent
RPN
DET
OCC
SEV
ActionTaken
Action ResultsResponse &
TargetComplete
Date
RecommendedActions
RPN
Detec
Current
Controls
Occur
PotentialCause(s)/
Mechanism(s)Of Failure
Class
Sev
PotentialEffect(s) of
Failure
Potential FailureMode
Function
April 7, 2023 20
THANK YOU
FMEA