1. Failure Mode & Effect Analysis (FMEA)
October 25, 2016
Failure Mode & Effect Analysis (FMEA)

2. Content
This session will provide a basic understanding of the Process FMEA quality tool.
After a brief description of the tool we will use the tool on an example
FMEA overview 4
Steps in performing FMEA 7
Do’s and Don’ts 9
Example – practice the FMEA 11

3. “If you don’t have time to do it right you must have time to do it over.”
Anonymous

4. Failure Modes & Effects Analysis (FMEA) overview
FMEA is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service.
“Failure modes” = the ways, or modes, in which something might fail. Failures are any errors or defects, especially ones that affect the customer, and can be potential or actual.
“Effects analysis” = studying the consequences of those failures.
Failures are prioritized according to:
how serious their consequences are,
how frequently they occur,
how easily they can be detected.
The purpose of the FMEA is to take actions to eliminate or reduce failures, starting with the highest-priority ones.

5. FMEA – an example from the service industry

6. When to use FMEA
When a process, product or service is being designed or redesigned, after quality function deployment.
When an existing process, product or service is being applied in a new way.
Before developing control plans for a new or modified process.
When improvement goals are planned for an existing process, product or service.
When analyzing failures of an existing process, product or service.
Periodically throughout the life of the process, product or service
FMEA is used during design to prevent failures.
Later it’s used for control, before and during ongoing operation of the process.
Ideally, FMEA begins during the earliest conceptual stages of design and continues throughout the life of the product or service..

7. Steps in performing FMEA
Assemble a cross-functional team of people with diverse knowledge about the process, product or service and customer needs. Functions often included are: design, manufacturing, quality, testing, reliability, maintenance, purchasing (and suppliers), sales, marketing (and customers) and customer service.
Identify the scope of the FMEA. Is it for concept, system, design, process or service? What are the boundaries? How detailed should we be?
Review the design/process; identify list of Process Steps (INPUT to meeting)
Brainstorm potential failure modes
For each failure mode, identify all potential effects of failure
Assign severity rating (S)
For each failure effect, identify all potential causes
Assign occurrence rating (O)
For each failure cause, identify all controls that could detect the cause
Assign detection rating (D)
Calculate Risk Priority Number (RPN) = S x O x D

8. Steps in performing FMEA
Develop action plan * : tasks to improve the current controls or reduce O. To reduce S a redesign of product or service may be required.
Take action: this is the step where many FMEAs fall apart due to lack of management support, conflicting priorities, lack of resources and lack of team leadership. The actions have to be implemented and results should be validated.
Recalculate the RPN: bring the team back and recalculate RPN. Use objective evidence.
Periodically review and update
* Once the initial RPN scores are tabulated, the team may decide on a cutoff score (if not standardized in the organization). Not too low (spend time/resources on too many risks) nor too high (not address important risks). Suggest cutoff = 250
The whole meeting should last no more than 4 hours.

9. Do’s Provide FMEA training to involved team Always use the approach
Ask for SME if required
Talk to your customer about how they intend to use the product/service
Brainstorm all possible failure modes if they can happen occasionally
When two risks have the same overall score, the risk with the higher Severity rating is escalated
Complete the action and reassess the risk as a team
Update the FMEA with new learned risks.

10. Don’ts
Don’t fight over ratings of small difference. Analyze the impact thoroughly if the team is divided by two or three rating points (e.g. 4 and 7)
Don’t get hung up on a number game; the objective is t create a reduced-risk product and/or service
Don’t perform FMEA to comply with procedures or standards. FMEA is a business risk management tool. It has to be used with commitment to make it work.

11. Example – practice the FMEA
Case study: self-checkout product
What to do:
Fill in the FMEA template
Don’t overthink it; the purpose is to learn the tool
Complete a few lines; pretend you implemented the recommended actions and recalculate RPN

12. Contact Stefano Paoli Cell: (506) 292-6482
siemens.ca/answers