The document discusses Failure Mode and Effects Analysis (FMEA), a systematic method for evaluating potential failures in design, manufacturing, and production processes. It was originally developed in the 1940s for the military and is now commonly used in various industries. An FMEA involves analyzing how and how often a process might fail and classifying the failures by severity, occurrence, and detection. The analysis helps prioritize risks and identify actions needed to prevent failures.

1. FAILURE MODE AND EFFECTS ANALYSIS (FMEA) Non-commercial use only without written permission. Any unauthorized use is prohibited. Author – Jason R Bower

2. Knowledge Base Risk Assessment WHAT IS FMEA? IT’S CRITICAL!!!!! Quality Control Continuous Improvement

4. Definition of controls to prevent failures

6. Utilized in the Apollo space program to minimize failures of expensive prototypes

8. Required elements of PPAP (Production Part Approval Process)

9. Design Element #4

10. Process Element #6

12. Field failure

13. Scrap

14. Prioritizes risk

16. Identifies critical aspects of designs and processes

17. Identifies controls needed

18. Identifies where to focus

19. Essential to Continuous Improvement

21. Process (PFMEA)

23. WHERE IT ALL FITS

24. PRODUCT CYCLE Customer Requirements Design Production Satisfied Customer

25. PRODUCT CYCLE Customer Requirements THE BIG QUESTION What is important and how are we ensuring it’s right? THE BIG ANSWER Critical Characteristics are output from DFMEA and input to PFMEA Design Production Satisfied Customer

27. What’s critical?

28. What do we know?

29. What can go wrong?

30. What happens?Customer Requirements Design Production Satisfied Customer

32. How can we make it better?

33. How can we reduce cost?Design Production Satisfied Customer

35. What’s critical?

36. What do we know?

37. What can go wrong?

38. What happens?Design Production Satisfied Customer

40. How can we make it better?

41. How can we reduce cost?Satisfied Customer

42. FMEA FORM

44. Drill down

46. Be specific

48. Be specific

50. Rating is 1–10 based on standard rules

52. Items critical to function

54. Be specific

57. Good place to reference design / process standards and best practices

60. Severity * Occurrence * Detection

61. Ranks the potential failure modes

65. More knowledge base information