FAKULTI KEJURUTERAAN MEKANIKAL

UNIVERSITI TEKNOLOGI MARA

MEM 678
TOTAL QUALITY MANAGEMENT
FAILURE MODES EFFECTS AND CRITICALITY ANALYSIS (FMECA)
LECTURER:
DR. MOHD FAUZI BIN ISMAIL

NAME

STUDENT I.D

ASHRAF BIN MUSTAZA

2013805316

AHMAD NAJMI BIN AHMAD NAZRI

2013426762

ZUHAILI ASRAF BIN JOHARI

2013247698

SYAHNIZAM BIN ROSELY

2013816498

MUHAMMAD NASRI BIN JAMALUDIN

2013221258

INTRODUCTION

FMEA / FMECA Background and History

FMECA was originally developed in the 1940s by the U.S military. In 1966, NASA released its FMECA
procedure for use on the Apollo program. FMECA also used on many NASA programs such as Galileo,
Magellan, Voyager. The use of FMEA and FMECA are spreading to civil aviation. Ford Motor Company
started to use FMEA in the 1970s after having problems with its Pinto Model. By 1980s, FMEA was widely
used in the automotive industry.

Concept of FMEA / FMECA

Failure Mode and Effects Analysis (FMEA) and Failure Modes, Effects and Criticality Analysis (FMECA)
are created to identify potential failure modes for a product or process and assess the risk associated with
the failure modes. Furthermore, its a method to address issues in terms of importance and identify
corrective actions to solve the most serious problems. Therefore, FMEA /FMECA requires the
identification of:

i.

Items

ii.

Functions

iii.

Effects of Failure

iv.

Cause of Failure

v.

Current Control

vi.

Relevant Action

vii.

Other relevant details

OBJECTIVES
1. To identify the components of products and systems most likely to cause failure.
2. To allows the identification in early in the product development process of potential problems or
safety hazard which are inherent in product design.

PROCEDURE
1. Firstly, the product process function was identified.
2. All possible failure modes of each component were listed.
3. Then, the effects that each mode of failure would have on the function of the product were set
down.
4. All the possible causes of each failure mode were listed.
5. The failure modes were given evaluation from scale 1 to 10.
6. The product of the ratings, C = P x S x D or also known as critically index for each failure mode
was calculated.
7. The corrective action required for each failure was indicated briefly.

TABLE FMECA
PROCESS/
FUNCTION

POSSIBLE
FAILURE MODE

1. PROTECT
FOOT

- Did not protect

from sharp
object

2. COMFORT

3. STABILITY

EFFECT(S)
OF
FAILURE
- Injury

- Didnt protect
from falling
object(heavy)

- Injury

- Didnt protect
from heat

- Injury

- Didnt provide
coziness

- Blistered

POSSIBLE
CAUSE(S) OF
FAILURE
- Nail piercing
the sole

- Shoes dont
provide enough
flexibility

- Heel ache

- Poor ventilation
for foot

- Sweating
foot

Poor sole
gripping of the
sneakers

Injury due
to
slippery

P S D C

CORRECTION
ACTION
-

Change
materials for
the sole

4 8 4 128

Heavy box
fall

3 7 6 126

none

Hot liquid
dropped

3 4 6

72

Change to
waterproof
material

5 2 1

10

Change the
inner
material

To create a
soft insole

Design better
airflow

To design a
grip sole
thread

Inner
material such
as hard
console
Stiff material
(nonflexible)

2 1 3

Poor air flow

design

2 1 4

Poor design
of the sole
thread

3 7 3

63

P = Probability
S = Severity
D = Difficulty
C = Criticallity
C=PxSxD
Probability and Seriousness of Failure and Difficulty of Detection
VALUE 1
P
S
D

10

Low chance of occurrence -----------------------almost certain to occur

Not serious, minor nuisance------------------total failure, safety hazard
easily detected -------------------------------------unlikely to be detected

DISCUSSION

To design a new casual shoes, we have taken three main function/ properties which are protect foot,
comfort and stability. Under the protect foot function, there are three possible failure modes namely, did
not protect from sharp object, did not protect from falling object and did not protect from heat. From these
three factor, the highest criticality value belong to did not protect from sharp object with 128 point. This
mean that this have high priority in this process of designing the shoe. The possible factor of this failure
was mainly because of the nail or sharp object on the walking path and the correction action that we choose
for this failure is to change the material used to make the sole. We will make it much thicker of use material
with high strength value to prevent the piercing by sharp object. The second highest criticality value of this
failure is did not protect from falling object with 126 point. The possible cause for this failure is heavy box
falling when we carry them. This failure may cause an injury to the foot. However there was none action
taken to fix this failure because the probability of falling heavy object is fairly low and should it happened
(box falling), the injury is not very severe. For very heavy object, it might be happened in the workplace,
therefore safety shoe should be worn, not the casual shoe. The least value of criticality belong to did not
protect from the heat with 72 point. The possible cause of this failure is hot liquid dropping. This accident
might occurs at the food court or restaurant. For this failure, we might change the fabric used for the shoe
to be waterproof as the correction action.

For the second function which is comfort, it have three possible failures under the factor which
are, did not provide coziness, do not provide enough flexibility and poor ventilation for foot. The highest
criticality value belong to do not provide coziness with 10 point. This failure might cause blister to the foot
caused by hard inner material. For the correction action, we have choose to change the inner material to the
softer material. The second highest criticality value is poor ventilation for foot with 8 point. This failure
might cause sweating foot and might cause a smelly shoe dues to poor air flow design. For the correction
action, we choose to design a better air flow for the shoe. We might create more air holes to ensure a good
air flow for the shoe. The least criticality value is shoe do not provide enough flexibility with 6 point. This
failure will cause heel ache to the foot due to stiff material. The correction action taken to this failure is to
create a soft insole for the shoe. This may be done using a light material or material with high elasticity
value.

The last function to be taken care of is stability and only one possible failure identified for this
which is poor sole gripping having 63 criticality value. This failure will caused the user to fall due to
slippery floor because of the poor design of the sole thread. For correction action, we will use a grip sole
for the shoe and this will be done by designing a grip sole thread.

CONCLUSION

The main objective in this study which is to identify the components of products and systems most
likely to cause failure has been achieved. The process or function that has been identified was protect foot,
comfort and stability. After comparison and study the higher most likely to cause failure to the user was
protect foot. This mean that protect foot have high priority in this process of designing the shoe. Second
function that most likely causes failure was stability. Stability is important to consider in order to design
the shoe. The stability can cause failure by gripping that can cause injury. Lastly, the comfort. This failure
might cause blister to the foot caused by hard inner material. Therefore, all component and functions that
has been identify was study and compared to make changes and to avoid the failure.
Second objective of this study is to allow the identification in early in the product development
process of potential problems or safety hazard which are inherent in product design. All failure causes that
discuss in previous has been counter with new function or operation materials before product developed.
So, this failure modes effects and critical analysis (FMECA) allows to identify potential problem and safety
hazard in order to create a product. Therefore second objective also successfully achieved.