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Failure Mode and        Effect Analysis                    FMEA19 September 2012          1
Meaning• It is a preventive measure to  systematically display the  causes, effects and possible  actions regarding observ...
FMEAan engineering technique use todefine, Identify and Eliminateknown and / or potential failures,problems, errors which ...
FMEAis “before-the-event” action and isdone          when         existingsystem/products/processes       arechanged or re...
FMEAis a never-ending-processimprovement tool19 September 2012          5
objective• The objective of FMEA is to anticipate failures and  prevent them from occurring.  FMEA prioritizes failures an...
Types• 1.System FMEA:-• Analyzes components, subsystem  and main system in early stage of  design.• 2.Design FMEA:-• Analy...
Types• 3.Process FMEA:-• Focuses on manufacturing and  assembly processes.• 4.Service FMEA:-• Analyzes services industry p...
5.Environmental FMEA• However, in practice, all the  above types can be broadly  categorized into two types…..• 1.Design F...
2.Process     FMEA       -Manufacturing      process-The Process FMEA is      used primarily to identify areas of      cri...
Benefits• Properly used FMEA provides several  benefits….• Improve product/process reliability and  quality• Increase cust...
.Document and track the actions taken      to reduce risk      .Provide focus for improved testing      and development   ...
Inputs for preparation of FMEA• 1.PEOPLE INPUTS:• The FMEA methodology is a team effort.  The FMEA team should have assemb...
2.    DATA INPUTS: the data inputsneeded to prepare FMEA are productand process specifications, reliabilitydata, customers...
Stages or Methodology• The FMEA methodology has four stages,  They are…• Step 1. SPECIFYING POSSIBILITIES• Functions• Poss...
2.Step . QUANTIFYING RISK           .Probability of cause           .Severity of effect           .Effectiveness of contro...
Step 3. CORRECTING HIGH RISK         CAUSES         .Prioritizing work         .Detailing action         .Assigning action...
Step 4. RE-EVALUATION OF RISKRecalculation of risk prioritynumber19 September 2012                18
Design FMEA FormatItem                                        C                   O                    D                  ...
THANK YOU                     FMEA19 September 2012               20
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FMEA.DR. K. BARANIDHRAN

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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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Transcript of "FMEA.DR. K. BARANIDHRAN"

  1. 1. Failure Mode and Effect Analysis FMEA19 September 2012 1
  2. 2. Meaning• It is a preventive measure to systematically display the causes, effects and possible actions regarding observed failures.19 September 2012 2
  3. 3. FMEAan engineering technique use todefine, Identify and Eliminateknown and / or potential failures,problems, errors which occur inthe system, design, process andservice “before they reach thecustomer”.19 September 2012 3
  4. 4. FMEAis “before-the-event” action and isdone when existingsystem/products/processes arechanged or redesigned19 September 2012 4
  5. 5. FMEAis a never-ending-processimprovement tool19 September 2012 5
  6. 6. objective• The objective of FMEA is to anticipate failures and prevent them from occurring. FMEA prioritizes failures and attempts to eliminate their causes19 September 2012 6
  7. 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.19 September 2012 7
  8. 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,19 September 2012 8
  9. 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.19 September 2012 9
  10. 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 modified19 September 2012 versions of process 10
  11. 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 knowledge19 September 2012 11
  12. 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.19 September 2012 12
  13. 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 customers19 September 2012 13
  14. 14. 2. DATA INPUTS: the data inputsneeded to prepare FMEA are productand process specifications, reliabilitydata, customers priority data, processvariability data, process descriptionsand inspection data19 September 2012 14
  15. 15. Stages or Methodology• The FMEA methodology has four stages, They are…• Step 1. SPECIFYING POSSIBILITIES• Functions• Possible failure modes• Root causes• Effects• Detection/Prevention19 September 2012 15
  16. 16. 2.Step . QUANTIFYING RISK .Probability of cause .Severity of effect .Effectiveness of control to prevent cause .Risk priority number (RPN)19 September 2012 16
  17. 17. Step 3. CORRECTING HIGH RISK CAUSES .Prioritizing work .Detailing action .Assigning action responsibility .Check points on completion19 September 2012 17
  18. 18. Step 4. RE-EVALUATION OF RISKRecalculation of risk prioritynumber19 September 2012 18
  19. 19. Design FMEA FormatItem C O D Action Results Potential Current Response & Potential Potential S l c Design e R Cause(s)/ Recommended Target S O D R Failure Effect(s) of e a c Controls t P Action Mechanism(s) Actions Complete E C E P Mode Failure v s u e N Taken Of Failure Date V C T N s r c Function Prevent Detect 19 September 2012 19
  20. 20. THANK YOU FMEA19 September 2012 20
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