This document provides an overview of failure mode and effects analysis (FMEA). It describes FMEA as a tool to identify potential failure modes, estimate the risk associated with failures, and prioritize actions to address high-risk failures. The document outlines the FMEA process, which involves identifying failure modes and their causes and effects, then calculating a risk priority number to prioritize issues. It also discusses design and process FMEAs and when each is used. Finally, it reviews how FMEA relates to and can be used along with other process analysis tools.

1. Engineering Failure Analysis
MEE 3003
Failure Modes Effect Analysis
(FMEA)

2. Learning Objectives
2
 To understand the use of Failure Modes Effect
Analysis (FMEA)
 To learn the steps to developing FMEAs
 To summarize the different types of FMEAs
 To learn how to link the FMEA to other
Process tools

3. Benefits
3
 Allows us to identify areas of our process that
most impact our customers
 Helps us identify how our process is most likely to
fail
 Points to process failures that are most difficult to
detect

4. Application Examples
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 Manufacturing: A manager is responsible for moving a
manufacturing operation to a new facility. He/she
wants to be sure the move goes as smoothly as
possible and that there are no surprises.
 Design: A design engineer wants to think of all the
possible ways a product being designed could fail so
that robustness can be built into the product.
 Software: A software engineer wants to think of
possible problems a software product could fail when
scaled up to large databases. This is a core issue for
the Internet.

5. What Is A Failure Mode?
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 A Failure Mode is:
 The way in which the component, subassembly,
product, input, or process could fail to perform its
intended function
 Failure modes may be the result of upstream
operations or may cause downstream operations
to fail
 Things that could go wrong
What Can Go
Wrong?

6. FMEA
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 Why
 Methodology that facilitates process improvement
 Identifies and eliminates concerns early in the
development of a process or design
 Improve internal and external customer satisfaction
 Focuses on prevention
 FMEA may be a customer requirement (likely
contractual)
 FMEA may be required by an applicable
Quality Management System Standard (possibly
ISO)

7. FMEA
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 A structured approach to:
 Identifying the ways in which a product or process
can fail
 Estimating risk associated with specific causes
 Prioritizing the actions that should be taken to
reduce risk
 Evaluating design validation plan (design FMEA) or
current control plan (process FMEA)

8. When to Conduct an FMEA
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 Early in the process improvement investigation
 When new systems, products, and processes
are being designed
 When existing designs or processes are being
changed
 When carry-over designs are used in new
applications
 After system, product, or process functions are
defined, but before specific hardware is
selected or released to manufacturing

9. History of FMEA
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 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
Examples

10. Types of FMEAs
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 Design
 Analyzes product design before release to
production, with a focus on product function
 Analyzes systems and subsystems in early
concept and design stages
 Process
 Used to analyze manufacturing and assembly
processes after they are implemented
Specialized
Uses

11. FMEA: A Team Tool
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 A team approach is necessary.
 Team should be led by the Process Owner who is
the responsible manufacturing engineer or
technical person, or other similar individual
familiar with FMEA.
 The following should be considered for team
members:
– Design Engineers – Operators
– Process Engineers – Reliability
– Materials Suppliers – Suppliers
– Customers
Team Input
Required

12. FMEA Procedure
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1. For each process input (start with high value inputs),
determine the ways in which the input can go wrong
(failure mode)
2. For each failure mode, determine effects
 Select a severity level for each effect
3. Identify potential causes of each failure mode
 Select an occurrence level for each cause
4. List current controls for each cause
 Select a detection level for each cause
Process Steps

13. FMEA Procedure (Cont.)
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5. Calculate the Risk Priority Number (RPN)
6. Develop recommended actions, assign responsible
persons, and take actions
 Give priority to high RPNs
 MUST look at severities rated a 10
7. Assign the predicted severity, occurrence, and
detection levels and compare RPNs
Process Steps

14. FMEA Inputs and Outputs
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FMEA
Cause & Effect
Matrix
Process Map
Process History
Procedures
Knowledge
Experience
List of actions to
prevent causes or
detect failure
modes
History of actions
taken
Inputs Outputs
Information
Flow

15. Ishikawa’s Cause Effect
Diagram
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16. Severity, Occurrence,
and Detection
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 Severity
 Importance of the effect on customer requirements
 Occurrence
 Frequency with which a given cause occurs and
creates failure modes (obtain from past data if
possible)
 Detection
 The ability of the current control scheme to detect
(then prevent) a given cause (may be difficult to
estimate early in process operations).
Analyzing
Failure &
Effects

17. Rating Scales
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 There are a wide variety of scoring “anchors”,
both quantitative or qualitative
 Two types of scales are 1-5 or 1-10
 The 1-5 scale makes it easier for the teams to
decide on scores
 The 1-10 scale may allow for better precision
in estimates and a wide variation in scores
(most common)
Assigning
Rating
Weights

18. Rating Scales
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 Severity
 1 = Not Severe, 10 = Very Severe
 Occurrence
 1 = Not Likely, 10 = Very Likely
 Detection
 1 = Easy to Detect, 10 = Not easy to Detect
Assigning
Rating
Weights

19. Risk Priority Number (RPN)
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 RPN is the product of the severity, occurrence,
and detection scores.
Severity Occurrence Detection RPN
X X =
Calculating a
Composite
Score

20. The FMEA Form
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Identify failure modes
and their effects
Identify causes of the
failure modes
and controls
Prioritize Determine and
assess actions
A Closer Look

21. Summary
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 An FMEA:
 Identifies the ways in which a product or process
can fail
 Estimates the risk associated with specific causes
 Prioritizes the actions that should be taken to
reduce risk
 FMEA is a team tool
 There are two different types of FMEAs:
 Design
 Process
 Inputs to the FMEA include several other Process
tools such as C&E Matrix and Process Map.
Key Points

22. Armature example case study
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23. Relationships of FMEA with other
Tools
 Fault tree analysis: FTA is a deductive analytical
technique of reliability and safety analysis
 Used for complex dynamic systems
 Provides for objective basis for analysis and
justification for changes and additions
 Developed in 1961 by Bell telephone company.
 It is a model that logically and graphically
represents the various combinations of possible
events, both faulty and normal, occurring in a
system that leads to the top undesired event.
 The tree shows a single failure at the top leading
to the root cause at the bottom. Connected to
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24. Fault Tree Analysis-An example
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25. Benefits of FTA
 Many logic symbols are used for the tree to
describe complex dynamic events
 This helps in visualizing the analysis
 Helps in assembly reliability
 Determines the probability of occurrence for each
of the root causes.
 Provides documented evidence for compliance
with safety.
 Assesses the impact of design changes and
alternatives
 Isolates critical safety behaviour
 Identifies failures that lead to accidents.
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26. Design of Experiments
 Certain independent variables are changed to a
predefined plan and the effects are determined
on the dependent variables.
 DOE is used in reliability testing and can
identifythe primary factors causing an undesired
event.
 DOE is used in FMEA when there is concern
about several independent variables and/or an
interaction effect of casual factors.
 The quality function deployment (QFD) is a
systematic methodology that brings together the
various factions with in the corporation and
focusses them to the voice of the customer.
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27. QFD
 It can help in the identification of weaknesses and
strengths in product development and TQM ( Total
Quality Management).
 This leads to operational and strategic benefits
 Reduced cost, fewer engineering changes, shorter
cycle time and large market share are the advantages
in strategic benefits.
 Is linked to other quality technologies, enhances
communication, identifies conflicting requirements
and preserves information for the future.
 A need analysis of the customer that precedes QFD
will be highly beneficial.
 Ultimately the systems engineer is responsible for
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28. Thank you and Questions
?
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