1. GE 6757 TOTAL QUALITY MANAGEMENT
Faculty
R.Suresh kumar
Assistant Professor(Sr.Gd)
Department of Mechanical Engineering

2. Failure Mode Effect Analysis
FMEA
Failure Mode Effect Analysis

3. FMEA
Failure Mode and Effect Analysis is also known as risk analysis.
It is a preventive measure to systematically display the causes, effects and possible actions regarding observed failures.
Is an engineering technique used to define, identify and eliminate known or potential failures, problem, errors.
It is before-the-event action
Is a never ending process improvement tool.

4. FMEA - OBJECTIVES
Find failures and prevent them.
Priorities failures and attempts to eliminate them.

5. TYPES OF FMEA System FMEA - Design FMEA - Design FMEA Process FMEA -
Service FMEA -
Equipment FMEA Process FMEA
Maintenance FMEA -
Concept FMEA Design FMEA
Environmental FMEA Process FMEA

6. BENEFITS OF FMEA
Improve product/process reliability and quality.
Increase customer satisfaction.
Early identification/elimination of failure modes.
Prioritize product/process deficiencies.
Capture engineering/organisation knowledge
Document and track the action taken to reduce risk
Focus for improved testing and development
Act as catalyst.

7. INPUTS FOR FMEA
People inputs: FMEA is a team work. The team should have assembly engineer, manufacturing engineer, material engineer, quality engineer, service engineer, suppliers and the customer.
2. Data inputs: Product and process specifications, reliability data, customer priority data, process variability data, process descriptions and inspection data.

8. STAGES OF FMEA Stage 1: Specifying Possibilities Functions
ii) Possible failure mode
iii) Root causes
iv) Effects
v) Detection/Prevention.
Stage 2: Quantifying Risks
Probability of cause
ii) Severity of effect
iii) Effectiveness of control to prevent cause
iv) Risk Priority Number (RPN)

9. STAGES OF FMEA
Stage 3: Correcting High Risk Causes
Prioritizing work
Detailing action
Assigning action responsibility
Check points on completion
Stage 4: Re-evaluation of Risk
i) Recalculation of risk priority number

10. FMEA PROCEDURE Describe the product/process and its function
Create a block diagram of the product/process
Complete the header of the FMEA form worksheet
List product/process functions
Identify failure modes
failure mode includes corrosion failure, fatigue, deformation, cracking, electrical short or open etc..
Describe the potential failure effects
defined as the result of a failure mode on the function of the product/process
ex: injury to the user, impaired operation, poor appearance, odour, noise etc..

11. FMEA PROCEDURE
7. Establish a numerical ranking for the Severity(S) of the effect
S is the assessment of the seriousness of the failure effect
standard scale uses 1 for no effect and 10 for very serious effect.
8. The CLASS column is filled
Used to classify any special product characteristics for components that may require additional process controls.
9. Identify the potential causes/mechanisms of failure
10. The probability factor “Occurrence” (O)
It is the chance that one of the specific causes will occur.
Standard scale uses 1 to represent not likely and 10 to indicate inevitable.

12. FMEA PROCEDURE 11. Identify current controls (design or process)
12. Determine the likelihood of detection (D)
It is the assessment of the likelihood that the current controls will detect the cause of failure mode
1 used for certain of detection and 10 for uncertainty of detection.
13. Review Risk Priority Number (RPN)
RPN = S x O x D
14. Determine recommended actions
15. Assign responsibility and target completion date
16. Indicate action taken
After action, re-assess the severity, occurrence and detection and revise the RPN
17. Update the FMEA

14. Thank you