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1. Design Failure Modes and
Effects Analysis
By
Ammara Aftab
MSC Applied statistics (final)
12th june 2015

2. Design Failure Modes and Effects
Analysis
A structured approach that ensures potential
product failure modes and their associated causes have
been considered and addressed in the product design
–What can go wrong?
 –Where will the variation come from?
 –How can we prevent or control?

3. Failure Modes and Effects Analysis
FAILURE MODE:
How a product can fail to meet design specifications or
functional intent
CAUSE:
• A deficiency that results in a failure mode 􀃎e.g. sources
of variation
EFFECT:
• Impact on customer if the failure mode is not prevented
or corrected

4. FMEA is a part of ISO…

5. Purpose Of Failure Modes and Effects
Analysis

6. Who creates FMEA ????

7. FMEA Flow

8. Ranking system…
A ranking system is used to estimate three factors:
 how Severe the failure would be
 how frequently the failure would Occur,
 how difficult it would be to Detect, and
 These three factors are multiplied and the resulting value is called the
Risk Priority Number (RPN).
 The RPN is used to prioritize the failure modes so that corrective actions
can be taken to reduce the frequency, and severity and/or improve the
detectability of the failure mode.

10. Around 75% percent of toys sold
around the world are made in
China.

11. Lin Jaimin (The founder and General
Manager of Quanzhou Jaimin Toy Co Ltd )

12. Toy company background
Quanzhou Jianmin Toy Co Ltd, located in Quanzhou Scientific and
Technological Development Zone, Fujian province.
The factory, has annual sales of around 2 million yuan,
Employs 3000 workers and produces stuffing dolls, bears, minions,
cars etc.
they usually made as Christmas gifts for children in North America
and Germany.
The busiest season for Jaimin Toy Co Ltd is normally from August to
November.

18. potential
failure
modes
potential effect
of failure
s
e
v
potential
cause of
failure
o
c
c
D
et
RP
N
recommende
d action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
defective
parts of
toys
too big and
some disabled
tyres produced.
9
labor
mistakes he
slept during
working hours
4 4 144
make strict
rule for labor
not to sleep
during
working
hours
Project
Manager
4 3 2 24

19. n
o
potential
failure
modes
potential effect
of failure
s
e
v
potential
cause of
failure
o
c
c
D
e
t
RP
N
recommend
ed action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
3
poor
material
toys are
damages early
I.e broken hand
of a toy
6
using poor
basic organic
material .
8 5 240
provided
basic
organic
material of
good quality.
Material
Engineer
4 4 2 32

20. n
o
potential
failure modes
potential
effect of
failure
s
e
v
potential
cause of
failure
o
cc
D
et
RPN
recommend
ed action
Respons
ibility
and
target
S
E
V
O
C
C
D
E
T
RN
P
4
over
manufactured
toys joint
together
and
products
are waste
5
wrong
assumptio
n
followed
7 6 210
Make correct
assumptions
Process
Engineer
3 4 3 36

21. potential
failure
modes
potential effect
of failure
s
e
v
potential
cause of
failure
o
c
c
D
e
t
RP
N
recommend
ed action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
stretched
toys
a toy is
stretched more
than it specified
9
lake of expert
labor as he
does not set
the
parameters
7 6 378
hire
experienced
and qualified
labor
H.R
Manager
5 3 2 30

22. potential
failure
modes
potential effect
of failure
s
e
v
potential
cause of
failure
o
c
c
D
et
RP
N
recommende
d action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
dead
batteries
company loose
their customers
8 broken wires 6 6 360
repair the
batteries
Technical
Expert
6 3 3 54

23. potential
failure
modes
potential effect of
failure
s
e
v
potential cause
of failure
oc
c
D
et
RP
N
recommended
action
Responsibil
ity and
target
S
E
V
O
C
C
D
E
T
RNP
system
problem in
toys
toys can not
perform well
8
using old
batteries
3 3 72
provide new
batteries
Product
Manager
3 2 2 12

24. System Problem

25. n
o
potential
failure modes
potential effect
of failure
s
e
v
potential
cause of
failure
o
c
c
D
et
RPN
recommen
ded action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
1
variation in
length
same toys have
different length
8
no standard
parameters
settings are
done
6 3 144
Set the
parameters
Test
Engineer
4 5 1 20

26. n
o
potential failure
modes
potential effect
of failure
s
e
v
potential
cause of
failure
o
c
c
D
e
t
R
P
N
recommend
ed action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
2 lack of design
no uniform or
equal parts of
toys
manufactured
I.e their should
be 2eyes but by
mistaken 1 eye
manufactured.
7
No standard
design to
make equal
parts of toys
7 2 98
DOE
process
have to be
improve
Design
Engineer
5 6 1 30

27. potential
failure
modes
potential effect
of failure
s
e
v
potential cause
of failure
o
c
c
D
et
RP
N
recommende
d action
Responsi
bility and
target
S
E
V
O
C
C
D
E
T
RN
P
over
heated
toys are more
melted as
specified
7
Improper heat
treatment
6 5 210
standardized
temperature
Process
Engineer
4 3 4 48
400C

28. THANK
YOU