Learn the basics of FMEA. This was presented by me for the Knowledge sharing session at my company.

1. FAILURE MODE
EFFECT ANALYSIS
KSS
ON

2. NEW PRODUCT DEVELOPMENT PHASES

3. WHAT IS FAILURE MODES & EFFECT
ANALYSIS (FMEA)
▸FMEA is the method used in engineering to document and
explore various ways that a product design might fail in real
world usage.
▸Advanced quality improvement tool.
▸Identify, prioritise and eliminate potential failures from the
design before reaching the system.
▸Provides discipline for documenting continuos process
development.

4. WHAT WE CALL A FAILURE?
▸UNSUCCESSFUL: A required function is missing.
▸DETERIORATING: Does not meet a measured value.
▸DEFECTIVE: A part has a physical flaw.
▸DEFICIENT: A material or product is not capable of meeting the
requirements.
▸INCOMPLETE: One or more expected functions are missing.
▸NON-FUNCTIONAL: The component is not responding to the
functions.

5. FAILURES AND FAILURE MODES

6. HISTORY OF FMEA
▸ Developed by US Military in 1949
and refined in the 70’s
▸ Used by reliability engineers
working in the aerospace industry
▸ Ford and GM restructured the
method which found a lot of
importance in the Automotive sector

7. TYPES OF FMEA
▸DESIGN: Analyzes product design before it release to
production. Done in early concept and design stages.
▸PROCESS: Used to analyze manufacturing and assembly
processes after they are implemented.
▸OTHER: Includes system, service, component etc.

8. FMEA TIMELINE
▸DESIGN: Starts early in process. It is complete by the time
preliminary drawings are done but before any tooling is
initiated
▸PROCESS: Starts as soon as the basic manufacturing
methods have been discussed. It is discussed before
releasing for production

9. RESPONSIBILITY AND SCOPE OF
DFMEA
▸DFMEA is a team function
All team members must participate
Input from all engineering fields is desirable
‣ DFMEA is not a one meeting activity
DFMEA will be refined and evolve with the product
Numerous revisions are requires to obtain the full
benefit

10. EFFECTS AND SEVERITY
▸What are the consequences of the failure?
▸How will the failure impact customers?

11. CAUSE AND EFFECTS RELATIONSHIP

12. STEPS TO
CONDUCT
FMEA

14. DFMEA FORM

15. MECHANICAL
CASE STUDY

16. NATARAJ

17. CREATE A BLOCK DIAGRAM

18. ▸Work Column by column
‣ For each mode, brainstorm reasonable effects
select the most severe effect
Multiple effects may have to be entered
‣ After listing all effects, rate the SEVERITY of the effect

19. SEVERITY: IMPORTANCE OF THE EFFECT
ON CUSTOMER REQUIREMENTS.

20. ▸Work Column by column
‣ For each mode, brainstorm reasonable causes
Hide effect and severity columns
‣ After listing all causes, rate the OCCURRENCE

21. OCCURRENCE: FREQUENCY WITH WHICH A GIVEN CAUSE
OCCURS AND CREATES FAILURE MODES.

22. ▸Find ways to prevent the failure in the current design.
‣ Detection includes actions to be taken.

23. PREVENTION & DETECTION: THE ABILITY OF
THE CURRENT CONTROL SCHEME TO DETECT
AND PREVENT A GIVEN CAUSE .

24. RISK PRIORITY NUMBER:
‣ RPN is the product of Severity, Occurrence and Detection
scores

25. ACTIONS TO BE TAKEN

26. WHAT NEXT?
▸REPEAT: Undertake the next revision of the DFMEA.
▸Revise the DFMEA and keep on reducing the RPN.
▸Persistent effort will reduce design risk.
▸Include documentation of your results.
▸FMEA is a continuous flow process.

27. LIMITATIONS OF FMEA:
▸Can be used to identify single failures and not combination
of failures.
▸The study can be time consuming.
▸Can be very complex for multilayered systems.
▸If the designer fails to recognise the failure, then it cannot be
addressed.

29. QUESTIONS ?

30. THANK
YOU!