Beer Brewing Pfmea

FMEA Process
Type/Model/Fabrication/Load: Beer making (based on Indian Pale Ale) FMEA/Process Step: Complete beer brewing process
Item Code: 5% IPA Revision State: Item Code: Revision State:
Effects S C Failure Mode Causes Process Element: Sterilisation Function: Sterilise all of the equipment and then rinse with clean water and allow to dry [5% Indian Pale 8 Equipment is [Instructions] Ale Beer] 40 not sterilised Ambiguous pints of beer is methodoloscapped [5% Indian Pale 9 gy Ale Beer] Beer makes the party goers unwell [5% Indian Pale 7 Ale Beer] Beer taste has a bitterness to it [5% Indian Pale 9 [Instructions] Ale Beer] Beer is too Metric / imperial gaseous (bad) [5% Indian Pale 9 weights and Ale Beer] volumes Beer aroma is not specified poor (e.g. (including vinegary) U.S. imperial) [5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party
[5% Indian Pale Ale Beer] Beer is cloudy/hazy
[Brewer] Fails to sterilise container used to carry water
[Brewer] Does not wash hands beforehand [Instructions] Insufficient detail about alternative ingredients (does & don'ts)
[Steriliser] insufficent concentration / ratios
[Home] Poor air quality (micro organisms present) [Brewer] Washes out sterilising fluid too early
[Water] Domestic supply quality
is contaminated (micro organisms present)
[5% Indian Pale 8 Ale Beer] Beer tastes of detergent [5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 8 Ale Beer] 40 pints of beer is scapped
Steriliser not [Brewer] fully rinsed from Does not rinse equipequipment ment properly
[Brewer] Forgets to rinse equipment properly
Process Element: Preparing the Wort Characteristics: Place Malt & Hops container into warm water for a time of >= 5 mins +5 [5% Indian Pale 6 Malt & Hops [Instructions] Ale Beer] Brewing process not warmed Ambiguous takes methodololonger than sufficiently gy required [5% Indian Pale 7 Ale Beer] Beer is watery
[5% Indian Pale Ale Beer] Alcohol content is not as per product description
[Kettle]
Thermostat failure [Brewer] Impatientience / carelessness or inexperience
Characteristics: Add boiling water to the fermentation bucket = 5 litres +1 [5% Indian Pale 6 Excessive [Instructions] Ale Beer] boilBrewing process ing water Metric / imperial takes longer than added weights and required volumes not specified (including U.S. imperial)
[Fermentation Bucket & lid] Volume measurements are illegible [5% Indian Pale 6 Ale Beer] Brewing process takes longer than required Insufficient boiling water added [Instructions] Metric / imperial weights and volumes not specified (including U.S. imperial)
[Fermentation Bucket & lid] Volume measurements are illegible [Brewer] Impatientience / carelessness or inexperience
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale Ale Beer] Beer is cloudy/hazy
Water added
[Brewer]
is not at boil- Impatientience / careing point lessness or inexperience
[5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party
[5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Brewer] Omits a stage
Characteristics: Add the ingredients to the fermentation bucket = 1 kg beer enhancer (sugar) 1.8kg Malt & Hops [5% Indian Pale 5 Excessive [Scales] Ale Beer] Beer is too quantity of Batteries are flat gaseous sug[5% Indian Pale 7 ar Ale Beer] Beer tastes yeasty
[5% Indian Pale 7 Ale Beer] Beer is cloudy/hazy [5% Indian Pale 6 Ale Beer] Alcohol content is not as per product description [5% Indian Pale 4 Ale Beer] Beer is too sweet [5% Indian Pale 6 Ale Beer] Party goers are inebriated to early in the night [Instructions] Ambiguous methodology
[Brewer] Adds more sugar than required
[Instructions] Insufficient detail about alternative ingredients (does & don'ts)
[Brewer] Incorrect type of sugar used (e.g. brown sugar / Muscovado)
[Scales] Out of calibration
[Instructions] Metric / imperial weights and volumes not specified (including U.S. imperial)
[Brewer] Impatientience / carelessness or inexperience
[5% Indian Pale Ale Beer] Beer tastes caramelly/ malty [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer is too gaseous
Incorrect [Brewer] ingredients added Incorrect type of sugar used (e.g. brown sugar / Muscovado)
[5% Indian Pale 6 Ale Beer] Alcohol content is not as per product description [5% Indian Pale 4 Ale Beer] Beer is too sweet [5% Indian Pale 6 Ale Beer] Brewing process takes longer than required [5% Indian Pale 8 Ale Beer] 40 pints of beer is scapped [5% Indian Pale 8 Ale Beer] Beer is not ready for
[Brewer] Impatientience / care-
Gavin's 40th birthday party
lessness or inexperience
[Brewer] Experimentation with process (Brewer has a 'good' idea!)
[5% Indian Pale Ale Beer] Alcohol content is not as per product description [5% Indian Pale Ale Beer] Beer is watery
Insufficient quantity of Malt & Hops
[Instructions] Ambiguous methodology
[Brewer] Fails to rinse out Malt & Hops container
[5% Indian Pale Ale Beer] Beer is flat [5% Indian Pale Ale Beer] Beer is watery [5% Indian Pale Ale Beer] Insufficient alcoholic beverages for the party goers
Insufficient quantity of sugar
[Scales] Batteries are flat
[Brewer] Incorrect type of sugar used (e.g. brown sugar / Muscovado)
[5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party
Sugar omitted
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Beer aroma is poor (e.g.
Wort is contamination
[Brewer] Fails to cover the wort
vinegary) [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Fermentation Bucket & lid] Bacterial contamination present
[Malt & Hops] Bacterial contamination present
[Scales] Bacterial contamination present [Brewer] Does not wash hands beforehand [Home] Poor air quality (micro
organisms present) [Sugar] Bacterial contamination present
[Brewer] Washes out sterilising fluid too early
[Spoon] Bacterial contamination present [Malt & Hops] Poor quality product / batch
Function: Mix contents until ingredients are dissolved
[5% Indian Pale Ale Beer] Beer is flat
Ingredients mixing not mixed to a soluble state
[5% Indian Pale 6 Ale Beer] Brewing process takes longer than required [5% Indian Pale 7 Ale Beer] Beer is watery
[Spoon] Insufficient length
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer is not ready for
[Brewer] Does not wash hands beforehand
Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Home] Poor air quality (micro organisms present) [Spoon]
Bacterial contamination present
Characteristics: Fill the fermentation bucket to the correct volume = 40 pints [5% Indian Pale 6 Insufficient [Brewer] Ale Beer] Insufficient water added Experimentation alcoholic bevwith erages for the process (Brewer party goers has a [5% Indian Pale 5 'good' idea!) Ale Beer] Beer is too gaseous
[5% Indian Pale 6 Ale Beer] Party goers are inebriated to early in the night [5% Indian Pale 4 Ale Beer] Beer is too sweet [5% Indian Pale Ale Beer] Beer tastes caramelly/ malty
[Fermentation Bucket & lid] Volume measurements are illegible [Instructions] Metric / imperial weights and volumes not specified (including U.S. imperial)
[Fermentation Bucket & lid] Insufficient capacity
[5% Indian Pale Ale Beer]
Wort is contami-
[Instructions]
7
Beer taste has a bitterness to it [5% Indian Pale 9 Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale 7 Ale Beer] Beer is cloudy/hazy [5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped nation Ambiguous methodology
[Brewer] Fails to sterilise container used to carry water
[Brewer] Does not wash hands beforehand [Home]
Poor air quality (micro organisms present) [Water] Domestic supply quality is contaminated (micro organisms present)
Function: Cover fermentation bucket and insert airlock whilst temperature settles [5% Indian Pale 7 Wort is [Fermentation Ale Beer] contamiBucket & Beer taste has a nation lid] bitterness to it Bacterial contamination [5% Indian Pale 9 present Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale 7 [Airlock] Ale Beer] Beer is Airlock or fluid cloudy/hazy content is [5% Indian Pale 8 contaminated Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 9 [Brewer] Ale Beer] Beer makes the Impatientience / party caregoers unwell lessness or inexperience [5% Indian Pale 9 Ale Beer] Beer is too gaseous (bad)
[5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Fermentation Bucket & lid] Plastic fatigue (cracks / orange peel) [Brewer] Omits a stage
[Thermometer] Bacterial contamination present
Process Element: Add yeast Characteristics: Mix the yeast into the wort at a specified temperature = 22 Centigrade 5C [5% Indian Pale 8 Yeast omitted [Brewer] Ale Beer] Beer is not ready Impatientience / for careGavin's 40th lessness or birthday party inexperience [5% Indian Pale 6 Ale Beer] Brewing process takes longer than required
[5% Indian Pale Ale Beer] Beer is watery [5% Indian Pale Ale Beer] Beer is flat
Yeast added
[Instructions]
when wort is Ambiguous methodolotoo hot gy
[5% Indian Pale 6 Ale Beer] Brewing process takes longer than required [5% Indian Pale 6 Ale Beer] Alcohol content is not as per product description [5% Indian Pale 8 Ale Beer] 40 pints of beer is scapped [5% Indian Pale 8 Ale Beer] Airlock does not bubble during the fermentation [5% Indian Pale 8 Ale Beer] yeast is killed
[Thermometer] Out of calibration [5% Indian Pale 6 Ale Beer] Brewing process takes longer than required Yeat not mixed to a soluble state [Instructions] Ambiguous methodology
[5% Indian Pale Ale Beer]
Yeast added
[Brewer]
6
Brewing process takes longer than required when wort is Impatientience / caretoo cold lessness or inexperience
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Spoon] Bacterial contamination present
[Home] Poor air quality (micro organisms present)
[Thermometer] Bacterial contamination present
Function: Cover fermentation bucket and insert airlock [5% Indian Pale 7 Airlock is not [Brewer] Ale Beer] Beer taste has a inserted into Impatientience / bitterness lid careto it lessness or inexperience [5% Indian Pale 9 Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale 7 Ale Beer] Beer is cloudy/hazy 8
[5% Indian Pale Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[5% Indian Pale 8 Ale Beer] Airlock does not bubble during the fermentation [5% Indian Pale Ale Beer] Beer taste has a bitterness to it
Beer is contaminated
[Airlock] Airlock or fluid content is contaminated
[5% Indian Pale Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Fermentation Bucket & lid] Bacterial contamination present
[5% Indian Pale 8 Ale Beer] Airlock does not bubble during the fermentation
Lid is not fully sealed /
[Brewer]
Impatientience / carepushed home lessness or inexperience
Process Element: Primary Fermentation Characteristics: Beer is allowed to ferment for = 6 days 2
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped [5% Indian Pale Ale Beer] Insufficient alcoholic beverages for the party goers [5% Indian Pale Ale Beer] 40 pints of beer is scapped
Beer is contaminated
[Fermentation Bucket & lid] Plastic fatigue (cracks / orange peel)
[Airlock] Airlock or fluid content is contaminated
Beer leakage [Fermentation Bucket & lid] Plastic fatigue (cracks / orange peel)
[Home] Shelf strength in airing
[5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] 40 pints of beer is scapped
cupboard is inadequate Fermentation [Brewer] does not Uses only boiling water occur (no bub-when preparing the wort bles exit airlock)
[Water] Domestic supply quality is contaminated (micro organisms present)
[Water] Domestic supply quality is contaminated (chlorine content)
[Home] Ambient temperature is too low / incorrect proximity to heat source
[Home] Ambient temperature is too high / incorrect proximity to heat source
[Yeast] Past best before date
[5% Indian Pale Ale Beer] Alcohol content is not as per product description [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] Beer tastes caramelly/ malty
Fermentation [Instructions] process stopped too Ambiguous methodology
early
[5% Indian Pale 7 Ale Beer] Beer tastes yeasty [5% Indian Pale 4 Ale Beer] Beer is too sweet
[5% Indian Pale Ale Beer] Beer is too gaseous
Characteristics: Beer is allowed to ferment in constistent temperature of = 20-25C [5% Indian Pale 6 Temperature [Home] Ale Beer] Beer is flat fluctuations Location is close to [5% Indian Pale 4 draughts / UV Ale Beer] light source Beer is too sweet
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Alcohol content is not as per product description [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[5% Indian Pale 8 Ale Beer] Beer is not ready for
Gavin's 40th birthday party [5% Indian Pale 8 Ale Beer] yeast is killed [5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 8 Ale Beer] 40 pints of beer is scapped [5% Indian Pale Ale Beer] yeast is killed
Temperature is too high
[5% Indian Pale 6 Ale Beer] Brewing process takes longer than required [5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 8 Ale Beer] Airlock does not bubble
Temperature is too low
[Home] Ambient temperature is too low / incorrect proximity to heat source
during the fermentation
Process Element: Keg Fermentation Function: Syphon the fermenting beer into a keg avoiding the sediment [5% Indian Pale 7 Beer is [Syphon] Ale Beer] contamiBeer taste has a nated Bacterial bitterness contamination to it present [5% Indian Pale 9 Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale 7 [Home] Ale Beer] Beer is Poor air quality cloudy/hazy (micro [5% Indian Pale 8 organisms Ale Beer] present) Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 9 [Brewer] Ale Beer] Beer makes the Does not wash party hands goers unwell beforehand [5% Indian Pale 9 Ale Beer] Beer is too gaseous (bad) [5% Indian Pale 8 [Keg] Ale Beer] 40 pints of beer Plastic fatigue is scapped (cracks /
orange peel) [Keg] Bacterial contamination present [5% Indian Pale Ale Beer] Insufficient alcoholic beverages for the party goers [5% Indian Pale Ale Beer] 40 pints of beer is scapped
Beer spillage [Brewer] Impatientience / carelessness or inexperience
[Syphon] Insufficient length
[Syphon] Multi-section product [Keg] Insufficient capacity
[5% Indian Pale Ale Beer] Beer is cloudy/hazy
Excess sediment decanted
[5% Indian Pale 4 Ale Beer] Party goers have 'wind' the next day
Characteristics: Add additional ingredients = 150 g 30g [5% Indian Pale 7 Beer is [Keg] Ale Beer] contamiBeer taste has a nated Bacterial bitterness contamination to it present 9 [5% Indian Pale Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale 7 [Scales] Ale Beer] Beer is Bacterial cloudy/hazy contamination [5% Indian Pale 8 present Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 9 [Sugar] Ale Beer] Beer makes the Bacterial party contamination goers unwell present [5% Indian Pale 9 Ale Beer]
9
Beer is too gaseous (bad) [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Spoon] Bacterial contamination present [Brewer] Does not wash hands beforehand [Instructions] Metric / imperial weights and volumes not specified (including U.S. imperial)
[5% Indian Pale 5 Ale Beer] Beer is too gaseous [5% Indian Pale 6 Ale Beer] Alcohol content is not as per product description [5% Indian Pale 4 Ale Beer] Beer is too sweet [5% Indian Pale 6 Ale Beer] Party goers are inebriated to early in the night [5% Indian Pale 7 Ale Beer] Beer is cloudy/hazy [5% Indian Pale 6 Ale Beer] Brewing process takes longer than required
Excessive quantity of sugar
[Brewer] Adds more sugar than required
[Scales] Batteries are flat
[5% Indian Pale 5 Ale Beer] Beer is too gaseous [5% Indian Pale 6 Ale Beer] Alcohol content is not as per product description [5% Indian Pale 4 Ale Beer] Beer is too sweet
Incorrect [Brewer] ingredients added Incorrect type of sugar used (e.g. brown sugar / Muscovado)
[5% Indian Pale 6 Ale Beer] Beer tastes caramelly/ malty [5% Indian Pale 6 Ale Beer] Party goers are inebriated to early in the night [5% Indian Pale 6 Ale Beer] Beer is flat [5% Indian Pale Ale Beer] Alcohol content is not as per product description [5% Indian Pale Ale Beer] Beer is watery
Insufficient quantity of sugar
[Brewer] Experimentation with process (Brewer has a 'good' idea!)
[5% Indian Pale Ale Beer] Beer is flat [5% Indian Pale Ale Beer] Beer is watery [5% Indian Pale Ale Beer] Alcohol content is not as
Sugar omitted
per product description
Characteristics: Beer is allowed to ferment for = 7 days +6 [5% Indian Pale 7 Beer is [Keg] Ale Beer] contamiBeer taste has a nated Bacterial bitterness contamination to it present [5% Indian Pale 9 Ale Beer] Beer aroma is poor (e.g. vinegary) [5% Indian Pale 7 Ale Beer] Beer is cloudy/hazy [5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 9 Ale Beer] Beer makes the party goers unwell [5% Indian Pale 9 Ale Beer] Beer is too gaseous (bad) [5% Indian Pale 8 Ale Beer] 40 pints of beer is scapped
[5% Indian Pale Ale Beer] Insufficient alcoholic beverages for the party goers
Beer leakage [Keg] Plastic fatigue (cracks / orange peel)
Beer leakage
[5% Indian Pale Ale Beer] 40 pints of beer is scapped
[Keg] Insufficient capacity
[5% Indian Pale 7 Ale Beer] Beer is cloudy/hazy [5% Indian Pale 6 Ale Beer] Alcohol content is not as per product description [5% Indian Pale 4 Ale Beer] Beer is too sweet
Fermentation [Brewer] process stopped too early Impatientience / carelessness or inexperience
[5% Indian Pale 7 Ale Beer] Beer tastes yeasty [5% Indian Pale 4 Ale Beer] Party goers have 'wind' the next day [Instructions] Ambiguous methodology
[Brewer] Experimentation with process (Brewer has a
'good' idea!)
[Yeast] Insufficient resistance to high alcohol content
Characteristics: Beer is allowed to ferment in constistent temperature of = 20-25C [5% Indian Pale 7 Temperature [Home] Ale Beer] is Beer is too low Ambient cloudy/hazy temperature is [5% Indian Pale 6 too low / Ale Beer] incorrect proxAlcohol content imity to heat is not as source per product description [5% Indian Pale 4 Ale Beer] Beer is too sweet
[5% Indian Pale 7 Ale Beer] Beer tastes yeasty [5% Indian Pale 4 Ale Beer] Party goers have 'wind' the next day
[5% Indian Pale 4 Ale Beer] Beer is too sweet [5% Indian Pale Ale Beer] Alcohol content is not as per product description [5% Indian Pale Ale Beer] 40 pints of beer is scapped [5% Indian Pale Ale Beer] Beer is cloudy/hazy [5% Indian Pale Ale Beer] yeast is killed
Temperature is too high
[5% Indian Pale Ale Beer] Beer is flat [5% Indian Pale Ale Beer]
Temperature fluctuations
4
Beer is too sweet
[5% Indian Pale Ale Beer] Beer taste has a bitterness to it [5% Indian Pale Ale Beer] Alcohol content is not as per product description [5% Indian Pale Ale Beer] 40 pints of beer is scapped
[5% Indian Pale 8 Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale 8 Ale Beer] yeast is killed
[Home] Excessive variations in the ambient temperature
FMEA Process
Number: Pag
Responsible: Company: Responsible: Company: Preventive Action O Detection Action D RPN
Created: 13/03/20
Created: 13/03/20
Modified: 13/03/20
en rinse with clean water and allow to dry Initial State: 13/03/2013
Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013
2 Instructions are read thoroughly before commencing brewing
54
Use of good quality brew kit ingredients Shop owner / supplier advice
2 Directions are read and re-read at each stage of the brewing process
36
Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013
Instructions clearly express that all equipment needs to be sterilised Initial State: 13/03/2013 Common sense / hygiene Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Quantity is specified in the instructions Instructions specify imperial and metric weights and volumes Initial State: 13/03/2013 Controlled environment Initial State: 13/03/2013 Instructions clearly express that all equipment needs to be sterilised Initial State: 13/03/2013 Water quality is assured by
3 none
10 270
3 none
10 270
90
3 Sterilising solution has a strong smell
108
3 none
10 270
54
2 none
10 180
2 none water board Revision State: 20/03/2013 2 Beer clarity and smell are checked during the seconadary fermentation stage Initial State: 13/03/2013
10 180
8 {144}
Instructions clearly express that all equipment needs to be sterilised Initial State: 13/03/2013 Instructions clearly express that all equipment needs to be sterilised Past experiences with similar brew kits that are being drank with gusto!
48
32
nto warm water for a time of >= 5 mins +5 Initial State: 13/03/2013
42
TPM on all devices Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
2 Visual inspection 3 none
14
10 210
3 Regular referal to the instructions
5 {105}
entation bucket = 5 litres +1 Initial State: 13/03/2013
Use of good quality brew kit ingredients Shop owner / supplier advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013
24
Products recently purchased (JIT) Initial State: 13/03/2013
1 Visual inspection
12
24
24
Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013
Products recently purchased (JIT) Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
1 Visual inspection
12
3 none
10 180
3 Regular referal to the instructions Initial State: 13/03/2013
{90}
Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
3 none
10 270
5 {135}
Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! 3 subsequent stages will be affected (detection post process) 7 189
mentation bucket = 1 kg beer enhancer (sugar)
Initial State: 13/03/2013
Alternative scales available
4 Scales clearly display a battery level symbol
28
Use of good quality brew kit ingredients
2 Instructions are read thoroughly before commenc-
42
Shop owner / supplier advice Initial State: 13/03/2013
ing brewing
Ingredients and quantities are specified in the instruc-
5 Electronic scales within accurate to
35
5 tions Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Ingredients and quantities are specified in the instructions Past experiences with similar brew kits that are being drank with gusto! Shop owner / supplier advice Initial State: 13/03/2013 TPM on all devices 0.25g
35
70
2 Sugar packaging is clearly labelled
14
3 1 standard bag of white cane sugar should weigh approx. 1kg (Gold sample)
63
Digital scales used Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with
28
3 none
10 210
3 none
10 210
each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 5 {105}
Ingredients and quantities are specified in the instructions Past experiences with similar brew kits that are being drank with gusto! Shop owner / supplier advice
16
80
Shop owner / supplier advice Initial State: 13/03/2013 Past experiences with simi-
ing brewing
3 none
10 240
3 none lar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 5 Smell & clarity checks - small glass poured before 6 days into final fermentation process Initial State: 13/03/2013
10 240
5 {120}
5 none
10 400
6 {240}
Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Instructions include special care points
42
2 Visual inspection
28
Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
3 none
10 210
5 {105}
Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Alternative scales available
42
4 Scales clearly display a battery level symbol
28
Initial State: 13/03/2013 Ingredients and quantities are specified in the instructions Past experiences with similar brew kits that are being drank with gusto! Shop owner / supplier advice Initial State: 13/03/2013 TPM on all devices
14
3 1 standard bag of white cane sugar
63
TPM on all devices
3 should weigh approx. 1kg (Gold sample)
63
Digital scales used Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
28
3 none
10 210
5 {105}
Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013
3 subsequent stages will be affected (detection post process)
168
Common sense / hygiene
3 none
10 270
3 none
10 270
54
Shop owner / supplier advice Initial State: 13/03/2013
ing brewing
Instructions include special care points Initial State: 13/03/2013 Shop owner / supplier advice Use of good quality brew kit ingredients Basic hygiene practice Mixed with boiling water to ensure sterility Initial State: 13/03/2013 Instructions include special care points Initial State: 13/03/2013 Common sense / hygiene Initial State: 13/03/2013
2 none
10 180
2 none
10 180
2 none
10 180
3 none
10 270
Controlled environment Initial State: 13/03/2013 Shop owner / supplier advice Use of good quality brew kit ingredients Mixed with boiling water to ensure sterility Basic hygiene practice Initial State: 13/03/2013 Instructions clearly express that all equipment needs to be sterilised Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
3 none 2 none
10 270 10 180
54
3 none
10 270
3 Regular referal to the instructions Initial State: 13/03/2013 Instructions include special care points Initial State: 13/03/2013 Shop owner / supplier advice Use of good quality brew kit ingredients Past experiences with similar brew kits that are being drank with gusto! 2 none
5 {135}
10 180
2 none
10 180
ssolved
3 none
10 210
3 Regular referal to the instructions Initial State: 13/03/2013 Shop owner / supplier advice Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013
5 {105}
1 Cannot complete and move on to next operation 3 subsequent stages will be affected (detection post process)
147
3 none
10 270
2 Instructions are read thoroughly
54
54
before commencShop owner / supplier advice Initial State: 13/03/2013 ing brewing
Controlled environment Initial State: 13/03/2013
3 none
10 270
Instructions include special care points o the correct volume = 40 pints Initial State: 13/03/2013
2 none
10 180
5 none
10 300
5 Smell & clarity checks - small glass poured before 6 days into
6 {180}
6 {180}
final fermentation process Initial State: 13/03/2013
Products recently purchased (JIT) Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
1 Visual inspection
12
24
3 none
10 180
3 Regular referal to the instructions Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Shop owner / supplier advice Initial State: 13/03/2013 2 Visual inspection
{90}
12
54
Instructions clearly express that all equipment needs to be sterilised Initial State: 13/03/2013
3 none
10 270
Common sense / hygiene Initial State: 13/03/2013
3 none
10 270
Controlled environment Initial State: 13/03/2013 Water quality is assured by water board Revision State: 20/03/2013
3 none 2 none
10 270 10 180
2 Beer clarity and smell are checked during the seconadary fermenta-
8 {144}
8 {144}
tion stage Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions 5 {135}
3 none
10 270
rt airlock whilst temperature settles Initial State: 13/03/2013
Instructions include special care points Initial State: 13/03/2013
2 none
10 180
Instructions include special care points
2 Visual inspection
90
Past experiences with similar brew kits that are being
3 none
10 270
3 none
10 270
drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 5 {135}
Products recently purchased (JIT) Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013 Instructions include special care points
1 Visual inspection
45
189
2 none
10 180
a specified temperature = 22 Centigrade 5C Initial State: 13/03/2013
Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet
3 none
10 240
Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013 5 {120}
168
48
32
Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013 Past experiences with simi-
3 none
10 240
3 none lar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 Mechanical thermometer used Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 2 Instructions are read thoroughly before commencing brewing
10 240
5 {120}
2 Visual inspection
48
36
3 subsequent stages will be affected (detection post process) 3 none
126
10 180
{90}
3 none
10 180
{90}
2 none
10 180
Controlled environment
3 none
10 270
2 none
10 180
3 none
10 270
rt airlock
3 none
10 270
5 {135}
Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013
189
2 Visual inspection
90
2 none
10 180
3 none
10 270
Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions 5 {120} 3 none 10 240
= 6 days 2
1 Visual inspection
45
2 Visual inspection
90
1 Visual inspection
40
Office floor used instead Initial State: 13/03/2013
1 none
Cost and time limitations
1 Primary fermentation will be impeded / airlock does not bubble
56
Initial State: 13/03/2013 Water quality is assured by water board Revision State: 20/03/2013
2 none
10 160
2 Beer clarity and smell are checked during the seconadary fermentation stage Initial State: 13/03/2013
8 {128}
Water quality is assured by water board
2 Water Chlorination can be smelt from the tap (US tap=faucet) 2 Climate supervisor (wife) Lack of hot domestic water supply (discovered when
32
Initial State: 13/03/2013 Home is in a temperate climate and centrally heated Past experiences with similar brew kits that are being drank with gusto!
48
Home is in the UK, which is unlikely to lead to excessively high temperatures Initial State: 13/03/2013 Home is in a temperate climate and centrally heated Past experiences with similar brew kits that are being drank with gusto! Warm floor space in office has been assigned (location where the cat usually sleeps!) Initial State: 13/03/2013 Use of good quality brew kit ingredients Past experiences with similar brew kits that are being drank with gusto! Revision State: 20/03/2013
teenage son want to shower)
2 Climate supervisor (wife) Lack of hot domestic water supply (discovered when teenage son want to shower)
48
2 none
10 160
2 Visual inspection Audible sounds of bubbles exiting the airlock expected within 24 hours Initial State: 13/03/2013
32
42
3 none
10 210
5 {105}
constistent temperature of = 20-25C Initial State: 13/03/2013
Home is double glazed
1 Climate supervisor (wife)
24
fermentation bucket is covered
2 Instructions are read thoroughly
48
48
before commencShop owner / supplier advice Initial State: 13/03/2013 ing brewing
Home is in a temperate climate and centrally heated Past experiences with similar brew kits that are being drank with gusto! Warm floor space in office has been assigned (location where the cat usually sleeps!) Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013
48
48
Home is in a temperate climate and centrally heated
48
Past experiences with similar brew kits that are being
Lack of hot domestic water supply (dis-
drank with gusto! Home is in the UK, which is unlikely to lead to excessively high temperatures Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice
covered when teenage son want to shower)
48
eg avoiding the sediment Initial State: 13/03/2013
2 none
10 180
3 none
10 270
3 none
10 270
Products recently purchased (JIT) Initial State: 13/03/2013 Instructions include special care points Initial State: 13/03/2013
1 Visual inspection
45
2 none
10 180
3 none
10 240
3 Regular referal to the instructions Initial State: 13/03/2013 Shop owner / supplier advice Initial State: 13/03/2013 Compression fit at joint Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Shop owner / supplier advice Initial State: 13/03/2013
5 {120}
1 Cannot complete and move on to next operation 3 Visual inspection 2 Visual inspection
2 1
48 16
3 none
10 210
3 Regular referal to the instructions Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013
5 {105}
42
150 g 30g
2 none
10 180
2 none
10 180
Shop owner / supplier
2 none
10 180
2 none advice Use of good quality brew kit ingredients Mixed with boiling water to ensure sterility Basic hygiene practice Initial State: 13/03/2013 Instructions include special care points Initial State: 13/03/2013 Common sense / hygiene Initial State: 13/03/2013 2 none
10 180
10 180
3 none
10 270
2 Directions are read and re-read at each stage of the
28
Shop owner / supplier advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013
brewing process
Past experiences with similar brew kits that are being drank with gusto!
3 none
10 210
3 none
10 210
Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions Initial State: 13/03/2013 Ingredients and quantities are specified in the instructions Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 TPM on all devices 5 Electronic scales within accurate to 0.25g 2 Instructions are read thoroughly before commencing brewing 1 35 5 {105}
42
3 1 standard bag of white cane sugar should weigh approx. 1kg (Gold sample) 4 Scales clearly display a battery level symbol
63
Digital scales used Initial State: 13/03/2013 Alternative scales available
28
Ingredients and quantities are specified in the instructions Past experiences with similar brew kits that are being
12
drank with gusto! Shop owner / supplier advice
5 none
10 350
5 Smell & clarity checks - small glass poured before 6 days into final fermentation process Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier 2 Directions are read and re-read at each stage of the
6 {210}
147
28
28
advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
brewing process
3 none
10 210
3 Regular referal to the instructions Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 2 Instructions are read thoroughly before commencing brewing
5 {105}
70
42
Past experiences with similar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be
3 none
10 210
downbloaded from the internet Revision State: 20/03/2013 3 Regular referal to the instructions
= 7 days +6
5 {105}
2 none
10 180
Products recently purchased (JIT) Initial State: 13/03/2013 Past experiences with similar brew kits that are being drank with gusto! Shop owner / supplier advice Initial State: 13/03/2013
1 Visual inspection
40
2 Visual inspection
16
3 none
10 210
3 Regular referal to the instructions Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013 Past experiences with similar brew kits that are being
5 {105}
42
5 none
10 350
5 none
10 350
drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013 5 Smell & clarity checks - small glass poured before 6 days into final fermentation process Initial State: 13/03/2013 Shop owner / supplier advice 6 {210}
3 none
10 210
Use of good quality brew kit ingredients Past experiences with similar brew kits that are being drank with gusto! constistent temperature of = 20-25C Initial State: 13/03/2013
Home is in a temperate climate and centrally heated
42
Past experiences with similar brew kits that are being drank with gusto! Home is in the UK, which is unlikely to lead to excessively high temperatures
Lack of hot domestic water supply (discovered when teenage son want to shower)
2 Directions are read and re-read at each stage of the
32
Shop owner / supplier advice Measuring devices at Gavin's home display both imperial & metric units Initial State: 13/03/2013 Home is in a temperate climate and centrally heated Past experiences with similar brew kits that are being drank with gusto! Warm floor space in office has been assigned (location where the cat usually sleeps!) Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice Initial State: 13/03/2013
brewing process
48
48
Past experiences with simi-
3 none
10 240
3 none lar brew kits that are being drank with gusto! Instructions supplied with each brewing kit & can be downbloaded from the internet Revision State: 20/03/2013
10 240
5 {120}
Initial State: 13/03/2013 Home is in a temperate climate and centrally heated 2 Climate supervisor (wife) Lack of hot domestic water supply (discovered when teenage son want to shower) Initial State: 13/03/2013 Use of good quality brew kit ingredients Shop owner / supplier advice 2 Instructions are read thoroughly before commencing brewing 3 48 3 48
Number: 1.1 Page:
Created: 13/03/2013
Created: 13/03/2013 Modified: 13/03/2013 R/D
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer 3/22/2013 in revision
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer
4/3/2013 in revision
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer 3/15/2013 completed

Beer Brewing Pfmea

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Beer Brewing Pfmea

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FMEA Process

Item Code: 5% IPA Revision State: Item Code: Revision State:

[5% Indian Pale Ale Beer] Beer is cloudy/hazy

[Brewer] Fails to sterilise container used to carry water

[Steriliser] insufficent concentration / ratios

[Water] Domestic supply quality

is contaminated (micro organisms present)

[Brewer] Forgets to rinse equipment properly

Thermostat failure [Brewer] Impatientience / carelessness or inexperience

is not at boil- Impatientience / careing point lessness or inexperience

[Brewer] Omits a stage

[Brewer] Adds more sugar than required

[Instructions] Insufficient detail about alternative ingredients (does & don'ts)

[Brewer] Incorrect type of sugar used (e.g. brown sugar / Muscovado)

[Scales] Out of calibration

[Brewer] Impatientience / carelessness or inexperience

[Instructions] Insufficient detail about alternative ingredients (does & don'ts)

[Brewer] Impatientience / care-

Gavin's 40th birthday party

[Brewer] Experimentation with process (Brewer has a 'good' idea!)

Insufficient quantity of Malt & Hops

[Instructions] Ambiguous methodology

[Brewer] Fails to rinse out Malt & Hops container

[Brewer] Impatientience / carelessness or inexperience

Insufficient quantity of sugar

[Instructions] Ambiguous methodology

[Scales] Batteries are flat

[Brewer] Incorrect type of sugar used (e.g. brown sugar / Muscovado)

[Scales] Out of calibration

[Brewer] Impatientience / carelessness or inexperience

[Brewer] Omits a stage

[Brewer] Fails to cover the wort

[Instructions] Ambiguous methodology

[Fermentation Bucket & lid] Bacterial contamination present

[Malt & Hops] Bacterial contamination present

organisms present) [Sugar] Bacterial contamination present

[Brewer] Washes out sterilising fluid too early

[Brewer] Impatientience / carelessness or inexperience

Function: Mix contents until ingredients are dissolved

[5% Indian Pale Ale Beer] Beer is flat

Ingredients mixing not mixed to a soluble state

[Brewer] Impatientience / carelessness or inexperience

[Spoon] Insufficient length

[Brewer] Omits a stage

[Brewer] Does not wash hands beforehand

[Instructions] Ambiguous methodology

[Home] Poor air quality (micro organisms present) [Spoon]

Bacterial contamination present

[Brewer] Impatientience / carelessness or inexperience

[Fermentation Bucket & lid] Insufficient capacity

[5% Indian Pale Ale Beer]

[Brewer] Fails to sterilise container used to carry water

[Brewer] Does not wash hands beforehand [Home]

[Brewer] Impatientience / carelessness or inexperience

[5% Indian Pale Ale Beer] 40 pints of beer is scapped

[Thermometer] Bacterial contamination present

[Brewer] Omits a stage

when wort is Ambiguous methodolotoo hot gy

[Brewer] Impatientience / care-

[Brewer] Omits a stage

[Brewer] Impatientience / carelessness or inexperience

[5% Indian Pale Ale Beer]

[Spoon] Bacterial contamination present

[Home] Poor air quality (micro organisms present)