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FMEA - Failure mode and effects analysis

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Failure mode and effects analysis (FMEA)—also "failure modes", plural, in many publications—was one of the first highly structured, systematic techniques for failure analysis. It was developed by reliability engineers in the late 1950s to study problems that might arise from malfunctions of military systems. An FMEA is often the first step of a system reliability study. It involves reviewing as many components, assemblies, and subsystems as possible to identify failure modes, and their causes and effects. For each component, the failure modes and their resulting effects on the rest of the system are recorded in a specific FMEA worksheet. There are numerous variations of such worksheets. An FMEA can be a qualitative analysis.

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FMEA - Failure mode and effects analysis

  1. 1. FMEA (FAILURE MODE EFFECTS ANALYSIS ) Presented by : Soumyajit Bhuin
  2. 2. WHAT IS FMEA ?  Systematic method of identifying and preventing system.  Focused on preventing problems, enhancing safety, and increasing customer satisfaction.  Ideally, FMEA’s are conducted in the product design or process development stages.
  3. 3. HISTORY OF FMEA First used in the 1960’s in the Aerospace industry during the Apollo missions. In 1974, the Navy developed MIL-STD- 1629 regarding the use of FMEA. In the late 1970’s, the automotive industry was driven by liability costs to use FMEA. Later, the automotive industry saw the advantages of using this tool to reduce risks related to poor quality.
  4. 4. WHY DO A FMEA ?  Preventing problems is cheaper and easier than cleaning them up.  Some things are too risky or costly to incur mistakes.  ISO requirement-Quality Planning  “ensuring the compatibility of the design, the production process, installation, servicing, inspection and test procedures, and the applicable documentation”
  5. 5. TYPES OF FEEA
  6. 6. FMEA INPUTS AND OUTPUTS  C&E Matrix  Process Map  Process History  Procedures  Knowledge  Experience List of actions to prevent causes or detect failure modes History of actions taken FMEA Input Output
  7. 7. RISK ASSESSMENT FACTORS  Severity:  Definition: assessment of the seriousness of the effect(s) of the potential failure mode on the next component, subsystem, or customer if it occurs  Severity applies to effects.  A number from 1 to 5, depending on the severity of the potential failure mode’s effect 1 = no effect 5 = maximum severity
  8. 8. RISK ASSESSMENT FACTORS (COUNT.)  Probability of occurrence (O):  A number from 1 to 5, depending on the likelihood of the failure mode’s occurrence. 1 = very unlikely to occur. 5 = almost certain to occur.  Probability of detection (D):  A number from 1 to 5, 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 5 = impossible to detect
  9. 9. RISK PRIORITY NUMBER (RPN)  RPN is the product of the severity, occurrence, and detection scores. Severity Occurrence Detection RPN RPN will be a number between 1 (virtually no risk) and 125 (extreme risk).
  10. 10. LIMITATIONS  Employee training requirements  Initial impact on product and manufacturing schedules  Financial impact required to upgrade design, manufacturing, and process equipment and tools
  11. 11. Thank You 

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