Failure Modes Effect Analysis
Failure Modes Effect Analysis
Failure Modes Effect Analysis
A Closer Look
Prioritize
Process Steps
FMEA Procedure
1. For each process input (start with high value inputs), determine the ways in which the input can go wrong (failure mode) 2. For each failure mode, determine effects
Select a severity level for each effect
Process Steps
7. Assign the predicted severity, occurrence, and detection levels and compare RPNs
Information Flow
FMEA
Rating Scales
Severity
1 = Not Severe, 10 = Very Severe
Occurrence
1 = Not Likely, 10 = Very Likely
Detection
1 = Likely to Detect, 10 = Not Likely to Detect
Severity
X Occurrence X
Detection
RPN
Function
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: HVAC (heating, ventilation, and air conditioning) system must defog windows and heat or cool cabin to 70 degrees in all operating conditions (-40 degrees to 100 degrees) within 3 to 5 minutes
Failure Mode
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLES: HVAC system does not heat vehicle or defog windows HVAC system takes more than 5 minutes to heat vehicle HVAC system does not heat cabin to 70 degrees in below zero temperatures HVAC system cools cabin to 50 degrees HVAC system activates rear window defogger
Effect(s) of Failure
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: Cannot see out of front window Air conditioner makes cab too cold Does not get warm enough Takes too long to heat up
Severity
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: Cannot see out of front window severity 9 Air conditioner makes cab too cold severity 5 Does not get warm enough severity 5 Takes too long to heat up severity 4
Cause(s) of Failure
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: Incorrect location of vents Incorrect routing of vent hoses (too close to heat source) Inadequate coolant capacity for application
Occurrence
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: Incorrect location of vents occurrence 3 Incorrect routing of vent hoses (too close to heat source) occurrence 6 Inadequate coolant capacity for application occurrence 2
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: Engineering specifications (P) preventive control Historical data (P) preventive control Functional testing (D) detective control General vehicle durability (D) detective control
Detection
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
Risk Priority Number is a multiplication of the severity, occurrence and detection ratings EXAMPLE: Cannot see out of front window severity 9, incorrect vent location 2, Functional testing detection 3, RPN 54
Recommended Actions
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
All critical or significant characteristics must have recommended actions associated with them
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
All recommended actions must have a person assigned responsibility for completion of the action Responsibility should be a name, not a title Person listed as responsible for an action must also be listed as a team member There must be a completion date accompanying each recommended action
Action Results
Item Potential Failure Mode
Function
S e v
C l a s s
O c c u r
D e t e c
Action Results R P N Recommended Actions Response & Target Complete Date Action Taken S E V O C C D E T R P N
Unless the failure mode has been eliminated, severity should not change Occurrence may or may not be lowered based upon the results of actions Detection may or may not be lowered based upon the results of actions
Fault-tree analysis
A deductive top-down technique. Put the risk or hazard at the root of the tree and identify the system states that could lead to that hazard. Where appropriate, link these with and or or conditions. A goal should be to minimize the number of single causes of system failure.
A coffee shop wants to improve customer satisfaction with the coffee served at their shop
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Step 2: For Each Failure Mode, Identify Effects and Assign Severity
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Step 3: Identify Potential Causes of Each Failure Mode and Assign Score
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Step 4: List Current Controls for Each Cause and Assign Score
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RPNs
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Step 6: Develop Recommended Actions, Assign Responsible Persons, and Take Actions
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Compare RPNs
Step 7: Assign the Predicted Severity, Occurrence, and Detection Levels and Compare RPNs
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or
or
or
Sens or failure
Timer failure
Pu mp s ig nals incorrect
or
or
Beeper fails
Button fails
electronics fail
Power fails
SW fails
IN-CLASS PROBLEM
Most cars have a fuel filter between the fuel tank and the engine. Consider the consequences of a) Anti-function (opposite of filtering) b) Partial function c) Intermittent function d) Excess function
What to Do
Potential Causes of failure should be engineering related such as incorrect material, corrosion, wear and human related such as inexperience, misuse, etc. Current Design Controls are things like inspections, testing, poke yoke, and other design checks that are intended to prevent the problem.