1. Failure Mode & Effect Analysis
(FMEA)
Tom Hannan & Kevin Kowalis
Eastern Illinois University
School of Technology
Total Quality Systems
INT 5133

2. What is FMEA?
“Is an analytical technique that combines the technology and experience of people in identifying foreseeable failure modes of a product or process and planning for its elimination.” () OR
Before-The-Event action that makes it easier to find flaws in the system

3. Reliability
Is the probability of the product to perform as expected for a certain period of time, under the given operating conditions, and at a given set of product performance characteristics.

4. Reliability Requirements
Based on the definition of the part, assembly, or process under consideration, the reliability of each sub-system and the factors involved in the reliability must be found, and the appropriate relationships for each part, class, or module of the product must be computed.

5. Failure Rate
Periods of failure can conveniently be modeled by an exponential distribution, and the probability of survival of the product or process may be viewed as:
Rt = e ^(-T *F) = e ^ -(T/o)
Rt = the period of operation without failure
T = time specified for operation w/o failure
F = Failure rate
O = the mean time to failure

6. Intent of FMEA An Essential Part of Total Quality Management is FMEA!
Provides Training
Helps communicating similar problems
Tracks the progress of a project
Uncovers oversights, misjudgments, and errors
Calculate the probabilities of failures
Determine if product or process failure effects on other aspects.

7. FMEA Team Supplier Service
FMEA methodology is a team effort where the responsible engineer involves who?
Service
Assembly
Manufacturing
Materials
Quality
Customer
Supplier

8. FMEA Documentation Block Diagram Design or Process Intent
The Customer Needs and Wants
The FMEA Form

9. Divide up into four groups (N,S,E and W)
Class Assignment !!!!!!
Make A Simple Block Diagram
Divide up into four groups (N,S,E and W)
Change Tire
Unicycle
Flashlight
Bicycle

10. Stages of FMEA Re-evaluation of Risk Specifying Possibilities
Quantifying Risk
Correcting High Risk Causes
Re-evaluation of Risk

11. Specifying Possibilities
Functions
Possible Failure Modes
Root Causes
Effects
Detection/Prevention

12. Quantifying Risk Probability of Cause Severity of Effect
Effectiveness of Control to Prevent Cause
Risk Priority Number

13. Correcting High Risk Causes
Prioritizing Work
Detailing Action
Assigning Action Responsibility
Check Points on Completion

14. Re-evaluation of Risk RPN = (S) * (O) * (D) S = SEVERITY
Recalculation of Risk Priority Number
RPN = (S) * (O) * (D)
S = SEVERITY
O = OCCURRENCE
D = DETECTION RAKING 19

15. The Design FMEA Document
FMEA Number
Item
Design Responsibility
Prepared By
Model Number/Year
Key Date
Core Team
FMEA Date

16. The Design FMEA Document
Item/Function
Potential Failure Mode
Potential Effect(s) of Failure
Severity (S)
Classification (CLASS)
Potential Cause(s)/Mechanism(s) of Failure
Occurrence (O)

17. The Design FMEA Document (Con. 1)
Current Design Controls
Detection (D)
Risk Priority Number (RPN)
Recommended Actions
Responsibility and Target Completion Dates
Actions Taken

18. The Process FMEA Document (Con. 2)
Process Function/Requirements
Potential Failure Mode
Potential Effect(s) of Failure
Severity (S)
Classification (CLASS)
Potential Cause(s)/Mechanism(s) of Failure
Occurrence (O)
Current Process Controls

19. Limitations: FMEA document’s do not fix the identified problem
Def. of the action to fix the problem
Will not replace the basic problem-solving process.

20. ?Questions?