Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. “Failure modes” means the ways, or modes, in which something might fail. Failures are any errors or defects, especially ones that affect the customer, and can be potential or actual. “Effects analysis” refers to studying the consequences of those failures.

1. GE 6757 TOTAL QUALITY
MANAGEMENT
FACULTY
F.JUSTIN DHIRAVIAM
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
1

2. FMEA
FAILURE MODE EFFECT ANALYSIS

3. FMEA
• FAILURE MODE AND EFFECT ANALYSIS IS ALSO KNOWN AS RISK ANALYSIS.
• IT IS A PREVENTIVE MEASURE TO SYSTEMATICALLY DISPLAY THE CAUSES,
EFFECTS AND POSSIBLE ACTIONS REGARDING OBSERVED FAILURES.
• IS AN ENGINEERING TECHNIQUE USED TO DEFINE, IDENTIFYAND ELIMINATE
KNOWN OR POTENTIAL FAILURES, PROBLEM, ERRORS.
• IT IS BEFORE-THE-EVENT ACTION
• IS A NEVER ENDING PROCESS IMPROVEMENT TOOL.

4. FMEA - OBJECTIVES
1. FIND FAILURES AND PREVENT THEM.
2. PRIORITIES FAILURES AND ATTEMPTS TO ELIMINATE THEM.

5. TYPES OF FMEA
1. SYSTEM FMEA -
2. DESIGN FMEA - DESIGN FMEA
3. PROCESS FMEA -
4. SERVICE FMEA -
5. EQUIPMENT FMEA - PROCESS FMEA
6. MAINTENANCE FMEA -
7. CONCEPT FMEA - DESIGN FMEA
8. ENVIRONMENTAL FMEA - PROCESS FMEA

6. BENEFITS OF FMEA
1. IMPROVE PRODUCT/PROCESS RELIABILITY AND QUALITY.
2. INCREASE CUSTOMER SATISFACTION.
3. EARLY IDENTIFICATION/ELIMINATION OF FAILURE MODES.
4. PRIORITIZE PRODUCT/PROCESS DEFICIENCIES.
5. CAPTURE ENGINEERING/ORGANISATION KNOWLEDGE
6. DOCUMENT AND TRACK THE ACTION TAKEN TO REDUCE
RISK
7. FOCUS FOR IMPROVED TESTING AND DEVELOPMENT
8. ACT AS CATALYST.

7. INPUTS FOR FMEA
1. PEOPLE INPUTS: FMEA IS A TEAM WORK. THE TEAM SHOULD
HAVE ASSEMBLY ENGINEER, MANUFACTURING ENGINEER,
MATERIAL ENGINEER, QUALITY ENGINEER, SERVICE
ENGINEER, SUPPLIERS AND THE CUSTOMER.
• 2. DATA INPUTS: PRODUCT AND PROCESS SPECIFICATIONS,
RELIABILITY DATA, CUSTOMER PRIORITY DATA, PROCESS
VARIABILITY DATA, PROCESS DESCRIPTIONS AND
INSPECTION DATA.

8. STAGES OF FMEA• STAGE 1: SPECIFYING POSSIBILITIES
i) FUNCTIONS
ii) II) POSSIBLE FAILURE MODE
iii) III) ROOT CAUSES
• IV) EFFECTS
• V) DETECTION/PREVENTION.
• STAGE 2: QUANTIFYING RISKS
i) PROBABILITY OF CAUSE
ii) II) SEVERITY OF EFFECT
• III) EFFECTIVENESS OF CONTROL TO PREVENT CAUSE
• IV) RISK PRIORITY NUMBER (RPN)

9. STAGES OF FMEA
• STAGE 3: CORRECTING HIGH RISK CAUSES
i) PRIORITIZING WORK
ii) DETAILING ACTION
iii) ASSIGNING ACTION RESPONSIBILITY
iv) CHECK POINTS ON COMPLETION
• STAGE 4: RE-EVALUATION OF RISK
• I) RECALCULATION OF RISK PRIORITY NUMBER

10. FMEA PROCEDURE
1. DESCRIBE THE PRODUCT/PROCESS AND ITS FUNCTION
2. CREATE A BLOCK DIAGRAM OF THE PRODUCT/PROCESS
3. COMPLETE THE HEADER OF THE FMEA FORM WORKSHEET
4. LIST PRODUCT/PROCESS FUNCTIONS
5. IDENTIFY FAILURE MODES
• FAILURE MODE INCLUDES CORROSION FAILURE, FATIGUE,
DEFORMATION, CRACKING, ELECTRICAL SHORT OR OPEN ETC..
6. DESCRIBE THE POTENTIAL FAILURE EFFECTS
• DEFINED AS THE RESULT OF A FAILURE MODE ON THE FUNCTION OF THE
PRODUCT/PROCESS
• EX: INJURY TO THE USER, IMPAIRED OPERATION, POOR APPEARANCE,
ODOUR, NOISE ETC..

11. FMEA PROCEDURE
• 7. ESTABLISH A NUMERICAL RANKING FOR THE SEVERITY(S) OF THE EFFECT
• S IS THE ASSESSMENT OF THE SERIOUSNESS OF THE FAILURE EFFECT
• STANDARD SCALE USES 1 FOR NO EFFECT AND 10 FOR VERY SERIOUS EFFECT.
• 8. THE CLASS COLUMN IS FILLED
• USED TO CLASSIFYANY SPECIAL PRODUCT CHARACTERISTICS FOR COMPONENTS
THAT MAY REQUIRE ADDITIONAL PROCESS CONTROLS.
• 9. IDENTIFY THE POTENTIAL CAUSES/MECHANISMS OF FAILURE
• 10. THE PROBABILITY FACTOR “OCCURRENCE” (O)
• IT IS THE CHANCE THAT ONE OF THE SPECIFIC CAUSES WILL OCCUR.
• STANDARD SCALE USES 1 TO REPRESENT NOT LIKELYAND 10 TO INDICATE
INEVITABLE.

12. FMEA PROCEDURE
• 11. IDENTIFY CURRENT CONTROLS (DESIGN OR PROCESS)
• 12. DETERMINE THE LIKELIHOOD OF DETECTION (D)
• IT IS THE ASSESSMENT OF THE LIKELIHOOD THAT THE CURRENT CONTROLS WILL DETECT
THE CAUSE OF FAILURE MODE
• 1 USED FOR CERTAIN OF DETECTION AND 10 FOR UNCERTAINTY OF DETECTION.
• 13. REVIEW RISK PRIORITY NUMBER (RPN)
• RPN = S X O X D
• 14. DETERMINE RECOMMENDED ACTIONS
• 15. ASSIGN RESPONSIBILITY AND TARGET COMPLETION DATE
• 16. INDICATE ACTION TAKEN
• AFTER ACTION, RE-ASSESS THE SEVERITY, OCCURRENCE AND DETECTION AND REVISE THE
RPN
• 17. UPDATE THE FMEA

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