FMEA (Failure Mode Effects Analysis) is a systematic method aimed at identifying and preventing potential problems in product design or process development to enhance safety and customer satisfaction. Originating in the 1960s, it evaluates risks by assessing the severity, probability of occurrence, and probability of detection of failure modes, leading to a Risk Priority Number (RPN) that categorizes the level of risk. Despite its advantages, FMEA also involves limitations such as employee training, initial impacts on schedules, and financial costs for upgrades.

1. FMEA
(FAILURE MODE EFFECTS ANALYSIS )
Presented by :
Soumyajit Bhuin

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. 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. 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. TYPES OF FEEA

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. 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. 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. 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. LIMITATIONS
 Employee training requirements
 Initial impact on product and manufacturing
schedules
 Financial impact required to upgrade design,
manufacturing, and process equipment and tools

11. Thank You 