FMEA (Failure Mode and Effect Analysis)

With the FMEA method, risks can be localized, their probabilities and consequences estimated, and precautions taken to prevent problems from happening.
Different constitutencies:
System-FMEA
Conceptual phase

Design-FMEA
Design phase

Process-FMEA
Realisation Test phase

System- FMEA
Customer Customer service Marketing Process specialists Development team

Design- FMEA
- Customer service - Calculations engineers - Manufacturing specialists - Assembly personnel - Development team

Process- FMEA
- Customer - Inspector/Q - Development team

FMEA: ORGANIZATION OF FUNCTIONS

Step 1: Generating a functional tree
Function 1
Function 1.1 Function 1.2

Function 3
Function 3.1 Function 3.1.1 Function 3.1.2

Function 6

OverallFunction

Function 1.3

Function 2.2 Function 2.1 Function 4.1

Function 2

Function 4

Function 5

EXAMPLE FUNCTION TREE

Provide rotation
Accelerate Rotate d h Brake

activate head
Move head engage suction Seal

Stop

Seal

CD Player

Function 2.2 Function 2.1 Function 4.1

Funktion 2

Function 4

Function 5

Step 2: for each Function identify and localize extreme risks and dangers:

what happens, when ......? which failures can happen ? what are the consequences, when.....?

FMEA ANALYSIS
Step 3: Determining sources, controlling consequences, weighting FMEA FUNCTION:
Effects A B E RPA Action Date responsible A B E RPA* Pot. failure Pot. failure reason

A: Probability of occurance B: Seriousness of consequences E: Probability of detection Values : 1......10 Compare to limit x : RPA > x

Risk Probability Assessment

RPA = A*B*E

Actions, so that RPA* < x

FMEA
Function / component / process step Lists of parts to be analyzed and/or process steps. Indicate how functions are fulfilled. Within the framework of the error analysis, the following steps are executed for every function of the part and/or every process. The results are entered in the corresponding column of the reply form

FMEA
Column 1: Potential failure All conceivable types of failures must be entered for the individual part or process. Check list (incomplete):
Functional performance general Deformation Fatigue Dissolution Misalignment Clamps Corrosion Dirt entry Attrition

FMEA
Column 2: Cause of failure
All conceivable failure causes are assigned to every potential failure. The description of the error causes must guarantee that corresponding correcting-measures can be determined.

Check list (incomplete):

Component failure Defective assembly Defective maintenance False acceptances, specifications False dimensioning Defective construction Defective Material Quality problems in the manufacturing process False heat treatment False operation Defective measurement False instrument

FMEA
Column 3: Effect of failure Starting point is the actual occurrence of the failure. The implications of the failure on the customer and/or user. Check list (incomplete):
Function not accomplished Accident of different severity complicated assembly or disassembly weakening of the component (leading to rupture?) Noise pollution complicated repair Pollution unpleasant appearance

Compute Probabilities
A: Probability of occurance B: Seriousness of consequences E: Probability of detection Values :1......10

Compute Risk Probability Assessment RPA = A*B*E (also called RPN, Risk Probability Number)

Action
Start dealing with the highest RPA functions, and change the designs to mitigate that problem Act on all critical RPAs List person responsible for modification, what action is taken, and date. Once done, re-compute new RPAs

Illustration

FMEA
Useful and systematic approach to failure identification and mitigation. Also Root Cause Analysis and other similar tools exist and are used in industry Many web sites have downloadable software and additional information

Worksheet
Pot. failure Pot. failure reason Effects A B E RPA Action Date responsible A B E RPA*