All+Lectures Consolidated

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A SHORT STORY TO
RAISE THE
COURSE CURTAINS…
Copyright © 2019 Advanced Innovation Group Pro Excellence | All Rights Reserved
AIGPE
A SHORT STORY TO RAISE THE COURSE CURTAINS…
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2016
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2016 2007
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We missed using
How can you ensure
FMEA & we’ll use it
there are no glitches
for every event
in future events?
hereafter
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60+ EVENTS
USED FMEA EVERYTIME
EACH EVENT WAS BLIP FREE

& SMOOTH
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THE FAILURE MODE &

EFFECT ANALYSIS (FMEA)
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SECTION INTRODUCTION
WHAT IS A FAILURE
MODE & EFFECT
ANALYSIS (FMEA)?
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FAILURE MODE & EFFECT ANALYSIS (FMEA)
STAGE 01: IDENTIFYING THE FAILURE STAGE 02: SPECIFYING THE STAGE 03: SPECIFYING THE
WHAT IS FMEA?
MODE AND SPECIFYING ITS SEVERITY OCCURRENCE OF FAILURE DETECTABILITY OF FAILURE
SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION
WHAT IS A FAILURE MODE & EFFECT ANALYSIS? WHAT ARE THE 6 DIFFERENT STAGES OF FMEA? WHAT ARE THE POTENTIAL CAUSES? WHAT ARE THE CURRENT PROCESS CONTROLS?
WHY AND WHEN TO USE FMEA? PROCESS FMEA: TOP SECTION WHAT IS THE OCCURRENCE RATING? WHAT IS THE DETECTABILITY RATING?
THE HISTORY OF FMEA WHAT ARE THE COMPONENTS OF STAGE 01? P1 ACTIVITY: STAGE 02 ACTIVITY: STAGE 03
WHAT ARE THE TYPES OF FMEA? WHAT ARE THE COMPONENTS OF STAGE 01? P2 ACTIVITY SOLUTION: STAGE 02 ACTIVITY SOLUTION: STAGE 03
WHAT IS A PROCESS FMEA? WHAT ARE THE COMPONENTS OF STAGE 01? P3 SECTION CONCLUSION SECTION CONCLUSION
ACTIVITY: WHAT IS FMEA? ACTIVITY: STAGE 01
ACTIVITY SOLUTION: WHAT IS FMEA? ACTIVITY SOLUTION: STAGE 01
SECTION CONCLUSION SECTION CONCLUSION
STAGE 04 AND 05: QUANTIFYING RISK STAGE 06: REEVALUATING THE RISK WHAT ARE THE STEPS TO WHAT ARE THE BENEFITS AND
AND CORRECTING HIGH RISK SITUATIONS AND VISUALIZING YOUR FMEA CONSTRUCT AN FMEA? SHORTCOMINGS OF FMEA?
WHAT IS RPN? CALCULATING THE RESULTING RPN WHAT ARE THE STEPS TO CONSTRUCT FMEA? P1 WHAT ARE THE BENEFITS OF FMEA?
WHAT ARE ACTIONS RECOMMENDED? CREATING A SPIDER CHART WHAT ARE THE STEPS TO CONSTRUCT FMEA? P2 WHAT ARE THE SHORTCOMINGS OF FMEA?
WHAT IS RESPONSIBILITY, TARGET

SECTION CONCLUSION
COMPLETION DATES AND ACTIONS TAKEN? Section
SECTION CONCLUSION Lecture
Activity
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IN THIS SECTION, YOU WILL LEARN:
WHAT IS A FAILURE MODE AND EFFECT ANALYSIS?
WHY AND WHEN TO USE FMEA?
THE HISTORY OF FMEA
WHAT ARE THE TYPES OF FMEA?
WHAT IS A PROCESS FMEA?
ACTIVITY & ACTIVITY SOLUTION

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NEXT LECTURE
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WHAT IS A FAILURE
MODE & EFFECT
ANALYSIS (FMEA)?
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WHAT IS FMEA?
METHODICAL AND SYSTEMATIC TECHNIQUE
JOINS THE INNOVATION AND EXPERIENCE OF PEOPLE
HELPS IDENTIFY PREDICTABLE FAILURE MODES OF YOUR PROCESS
YOU CAN THEN PLAN TO EITHER ELIMINATE THESE FAILURE MODES

OR MINIMIZE THEM
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WHAT IS FMEA?
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WHAT IS FMEA?
ANALOGY HOW FMEA WORKS?
SIT IN THE TIME MACHINE  GET INTO A CONFERENCE ROOM
OBSERVE THE ENTIRE EVENT BRAINSTORM ALL POSSIBLE STEPS OF THE EVENT
MAKE NOTES OF ALL THE FAILURE MODES THAT MAKE NOTES OF ALL THE FAILURE MODES THAT
COULD OCCUR IN THE EVENT COULD OCCUR IN THE EVENT
COME BACK TO THE CURRENT DATE | ALSO

PRIORITIZE THE FAILURE MODES
PRIORITIZE THE FAILURE MODES
CREATE ACTION PLANS TO ELIMINATE OR CREATE ACTION PLANS TO ELIMINATE OR

MINIMIZE THOSE FAILURE MODES MINIMIZE THOSE FAILURE MODES
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WHAT IS FMEA?
WHEN IMPLEMENTING FMEA, YOU ARE PERFORMING A SET OF
ACTIONS DESIGNED TO:
PERCEIVE AND ASSESS

RECOGNIZE ACTIVITY THAT DOCUMENT
POTENTIAL FAILURES OF
COULD ELIMINATE YOUR
YOUR PRODUCT OR
POTENTIAL FAILURES PROCESS
SERVICE
FMEA IS A PROACTIVE TOOL
REQUIRES COLLABORATION AMONGST TEAM MEMBERS
HELPS DEPARTMENTS INCORPORATE +VE CHANGES

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WHAT IS FMEA?
FMEA CAN BE EXECUTED IN DESIGN AND OPERATIONS
IN MANUFACTURING AS WELL AS SERVICE INDUSTRY
INVOLVES IDENTIFICATION OF POTENTIAL FAILURE MODES
AND IMPACT OF THOSE ON:
INTERNAL EXTERNAL
CUSTOMERS CUSTOMERS
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WHAT IS FMEA?
HELPS YOU FOCUS ON DETECTING THE POTENTIAL PRODUCT OR
PROCESS RELATED FAILURE MODES
FMEA IS UTILIZED TO:
• ANTICIPATE REASONS FOR FAILURE
• KEEP THEM FROM OCCURRING
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WHAT IS FMEA?
FMEA USES 3 CRITERIA’S TO DEVELOP A RISK PRIORITIZATION #:
SEVERITY OCCURRENCE DETECTION
SEVERITY OF THE FAILURE MODE OCCURRENCE OF THE FAILURE DETECTION PROBABILITY OF THE
MODE FAILURE MODE
RPN HELPS YOU UNDERSTAND WHICH FAILURE MODES ARE

CRITICAL AND ARE TO BE ACTIONED IMMEDIATELY
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WHAT IS FMEA?
TREAT FMEA AS A “LIVING” DOCUMENT
DO NOT CONSIDER FMEA AS A ONE-TIME EXERCISE
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WHY & WHEN TO USE

FMEA?
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WHY FMEA?
HELPS IDENTIFY ALL POSSIBLE HELPS YOU UNDERSTAND HIGHLIGHTS RISK + HELPS YOU EMPOWERS LEARNING +
CAUSES OF FAILURE YOUR BUSINESS PROCESS BUILD COUNTER MEASURES DEVELOPS MULTI-DISCIPLINED
TEAMS
PROCESSES ARE MODE REQUIRES MORE NEEDS FAR MORE PLANNING

USE OF FMEA IS MORE
MUDDLED, INTERTWINED & ORGANIZATION & TO CREATE RELIABLE
SIGNIFICANT TODAY
COMPLICATED PRECAUTION PRODUCTS
CUSTOMERS REQUEST RESULTS HELPS YOU TRACK THOUGHTS HELPS YOU MATCH
CUSTOMERS ARE MORE
OF BEST QUALITY WITH LEAST & ACTIONS TO ENSURE SAFE & CUSTOMERS PRESENT MODE
SPECIFIC THAN EVER BEFORE
PRICE RELIABLE PRODUCTS OF THINKING
HELPS YOU FOLLOW-UP & DOCUMENT FAILURE MODES

LEGAL & JUDICIAL SYSTEM IS
TRACK PROGRESS ON FAILURE IN A THOROUGH, PRECISE &
MORE STRICT THAN EVER
MODES OF YOUR PRODUCTS STRUCTURED MANNER
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WHEN TO USE FMEA?
TO ANALYZE FAILURES OF EXISTING PRODUCTS, PROCESSES OR
SERVICE
WHEN YOU RESTRUCTURE OR UPGRADE YOUR PRODUCTS,

PROCESSES OR SERVICE
WHEN IMPLEMENTING CONTROLS FOR A NEW OR MODIFIED

PROCESSES
WHEN IMPROVEMENT OBJECTIVES ARE BEING SET
DURING THE ENTIRE LIFECYCLE OF PRODUCTS, PROCESSES OR

SERVICE – AT REGULAR INTERVALS OF TIME
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THE HISTORY
OF
FMEA
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THE HISTORY OF FMEA
1940’s 1960’s 1970’s 1990’s Today

Civil Aviation Industry & Ford Motor Company also SAE also published related
Society for Automotive began their use of FMEA standards in 1994
Engineers (SAE) were early
adaptors
FMEA procedures Contractors of NASA used US Environmental the Automotive Industry Extensively used in a
described in US Armed variations of FMEA under a Protection Agency & the Action Group (AIAG) first variety of industries:
Military Procedures variety of names Food Industry began using published an FMEA semiconductor processing,
Document FMEA standard for the food service, plastics,
automotive industry software, healthcare, BPO,
IT and many more
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WHAT ARE THE

DIFFERENT TYPES OF
FMEA?
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WHAT ARE THE DIFFERENT TYPES OF FMEA?
DESIGN PROCESS EQUIPMENT

FMEA FMEA FMEA
MAINTENANCE CONCEPT SERVICE

FMEA FMEA FMEA
SYSTEM ENVIRONMENTAL
FMEA FMEA
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WHAT IS A
PROCESS FMEA?
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IDENTIFIES FAILURE MODES BY RANKING FAILURES
HELPS ESTABLISH PRIORITIES AS PER THE RELATIVE EFFECT ON THE

INTERNAL OR EXTERNAL CUSTOMER
ESTABLISH CONTROLS FOR OCCURRENCE REDUCTION AND

INCREASING DETECTION OF IDENTIFIED FAILURE MODES
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POTENTIAL KEY
FAILURE MODE ACTIONS
ESTABLISH EFFECTIVE
CONTROLS FOR
CALL DROPS
OCCURRENCE REDUCTION
AND EASY DETECTION
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POTENTIAL KEY
FAILURE MODE ACTIONS
A FEW CALL DROPS ARE LOG A TICKET WITH YOUR

OBSERVED SERVICE PROVIDER
MULTIPLE CALL DROPS ARE CALL SERVICE PROVIDER | LOG

OBSERVED A TICKET WITH HIGH SEVERITY
RATING
PROCESS FMEA IS USED FOR BUSINESS AS USUAL ALREADY

ESTABLISHED BUSINESS OPERATIONS
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CONGRATULATIONS
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IN THIS SECTION, YOU LEARNT:
THE HISTORY OF FMEA

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STAGE 01: IDENTIFYING

THE FAILURE MODE &
SPECIFYING ITS
SEVERITY
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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WHAT ARE THE 6 STAGES OF FMEA?
PROCESS FMEA: TOP SECTION
WHAT ARE THE COMPONENTS OF STAGE 01?
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NEXT LECTURE
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WHAT ARE THE 6

DIFFERENT STAGES OF
FMEA?
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1 2 3
IDENTIFYING THE FAILURE AND SPECIFYING THE OCCURRENCE OF SPECIFYING THE DETECTABILITY
SPECIFYING THE SEVERITY OF IT FAILURE OF FAILURE
a. Discuss different steps and activities a. Identify potential causes of each failure a. Identify the current process controls of
b. Brainstorm potential failure modes mode each failure mode
c. Document potential failure effects b. Assign an occurrence ranking b. Assign a Detection rating
d. Assign a severity ranking to each failure
mode
4 5 6
CORRECTING HIGH RISK
QUANTIFYING RISK RE-EVALUATING THE RISK
SITUATIONS
a. Calculate Risk Priority number for each a. Document recommended actions a. After completing the identified actions,
failure mode b. Assign the responsibility and target document the specific actions
date for eliminating or mitigating high b. Revise the severity, occurrence and
risk/high severity failure modes detection ratings
c. Calculate the new RPN number
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PROCESS FMEA:
TOP SECTION
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THE PROJECT TITLE SECTION
UPDATE THE NAME OF THE PROJECT OR THE PROCESS FOR WHICH

THE FMEA IS BEING CREATED
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THE DATE SECTION
ADD THE DATE THE ORIGINAL FMEA WAS COMPILED
THE LATEST REVISION DATE CAN ALSO BE PLACED WHEN YOU REVISE
THE FMEA
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FMEA TEAM SECTION
WRITE NAMES OF THE RESPONSIBLE INDIVIDUALS AND

DEPARTMENTS THAT HAVE AUTHORITY TO PERFORM TASKS
YOU CAN ALSO ADD TEAM MEMBER DEPARTMENT NAMES, PHONE

NUMBERS AND EMAIL ADDRESSES
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PREPARED BY SECTION
ADD THE NAME(S), TELEPHONE NUMBER(S), EMAIL ADDRESS(ES) OF

INDIVIDUALS WHO WILL OR HAVE PREPARED THE FMEA WORKSHEET
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ACTIVITY: CREATE YOUR FMEA
PROJECT TITLE: ADD A SUITABLE TITLE
DATE: ADD TODAY’S DATE
FMEA TEAM: ADD YOUR NAME AND NAME OF INVOLVED MEMBERS
PREPARED BY: ADD YOUR NAME AND NAME OF INDIVIDUALS WHO

WILL PREPARE THIS FMEA WORKSHEET
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NEXT LECTURE
WHAT ARE THE COMPONENTS OF STAGE 01? PART 01
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WHAT ARE THE

COMPONENTS OF
STAGE 01: IDENTIFYING
THE FAILURE &
SPECIFYING OF IT?
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THE 6 STAGES OF FMEA?
1 2 3
mode
4 5 6
SITUATIONS
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COMPONENTS OF STAGE 01
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THE BUSINESS FUNCTION
DOCUMENT THE FUNCTIONAL DEPARTMENT THAT IS BEING

DISCUSSED FOR A FAILURE MODE
YOU WILL NOT ENTER A PRODUCT OR STEP OF THE FAILURE MODE
ENTER A DESCRIPTION OF THE PROCESS THAT IS BEING ANALYZED

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EXAMPLE: THE BUSINESS FUNCTION
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IN YOUR FMEA DOCUMENT, WRITE THE NAME OF YOUR BUSINESS
PROCESS
PAUSE THIS VIDEO, COMPLETE THE ACTIVITY & CONTINUE
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THE PROCESS STEP
DOCUMENT THE STEP OF THE FAILURE MODE
“WHEN CREATING YOUR FMEA, PLEASE KEEP A PROCESS MAP OF

YOUR IN-SCOPE BUSINESS PROCESS HANDY”
USING A PROCESS MAP IS OPTIONAL & NOT MANDATORY

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EXAMPLE: THE PROCESS STEP
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IN YOUR FMEA DOCUMENT, DOCUMENT THE HIGH LEVEL PROCESS
STEPS OF YOUR BUSINESS PROCESS
KEEP THE PROCESS STEPS SIMPLE AND UPTO 3 TO 4 STEPS ONLY
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POTENTIAL FAILURE MODE
IDENTIFY IN WHAT WAYS CAN THE STEP GO WRONG?
DOCUMENT EVERY FAILURE MODE, BUT LIMIT ONE FAILURE MODE

TO EACH ROW OF YOUR FMEA WORKSHEET
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EXAMPLE: POTENTIAL FAILURE MODE
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IN YOUR FMEA DOCUMENT, THINK ABOUT THE FAILURE MODES OF
YOUR BUSINESS PROCESS. DOCUMENT THEM.
LIMIT THE FAILURE MODES TO A MAX. OF 6 TO 7 ONLY FOR THE

PURPOSE OF THIS EXERCISE
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POTENTIAL FAILURE EFFECTS
“WHAT IS THE IMPACT ON THE CUSTOMER IF THE FAILURE MODE IS

NOT PREVENTED OR CORRECTED?”
THE FAILURE EFFECTS SHOULD BE AS PERCEIVED BY THE CUSTOMER
EFFECTS OF MULTIPLE FAILURE MODES COULD COINCIDE

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EXAMPLE: POTENTIAL FAILURE EFFECTS
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IN YOUR FMEA DOCUMENT, DOCUMENT THE POTENTIAL FAILURE
EFFECTS OF THE IDENTIFIED FAILURE MODES OF YOUR BUSINESS
PROCESS
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SEVERITY
ASSESSMENT OF THE SERIOUSNESS OF THE EFFECT OF THE

POTENTIAL FAILURE MODE
SEVERITY APPLIES ONLY TO THE EFFECT OF THE FAILURE
SEVERITY VALUE DOESN’T CHANGE IN FMEA UNLESS SPECIFIC

DESIGN CHANGES ARE MADE IN YOUR BUSINESS PROCESS
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EXAMPLE: SEVERITY RATING
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EXAMPLE: SEVERITY RATING
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IN YOUR FMEA DOCUMENT, IDENTIFY AND DOCUMENT THE
SEVERITY RATING FOR EACH FAILURE MODE
DOWNLOAD AND REVIEW THE RATING SCALE FROM ATTACHED

RESOURCES FOR MANUFACTURING/SERVICE INDUSTRIES
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CONGRATULATIONS
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WHAT ARE THE COMPONENTS OF STAGE 01?
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NEXT SECTION
STAGE 02: SPECIFYING THE OCCURRENCE OF FAILURE
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STAGE 02: SPECIFYING

THE OCCURRENCE OF
FAILURE
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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WHAT ARE POTENTIAL CAUSES?
WHAT IS THE OCCURRENCE RATING?
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NEXT LECTURE
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WHAT ARE THE

POTENTIAL CAUSES?
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WHAT ARE THE POTENTIAL CAUSES?
ASK THE QUESTION, “WHAT CAUSES THE STEP TO GO WRONG?”
EVERY POSSIBLE POTENTIAL CAUSE FOR EACH FAILURE MODE

SHOULD BE LISTED AS COMPLETELY AND CONCISELY AS POSSIBLE
AMBIGUOUS PHRASES SHOULD NOT BE USED

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EXAMPLE: POTENTIAL CAUSES
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IN YOUR FMEA DOCUMENT, LIST DOWN THE POTENTIAL CAUSES OF
EACH FAILURE MODE
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WHAT IS THE
OCCURRENCE RATING?
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OCCURRENCE
OCCURRENCE IS HOW FREQUENTLY THE SPECIFIC FAILURE IS

PROJECTED TO OCCUR
THIS MUST BE DONE FOR EVERY FAILURE LISTED
REDUCTION IN OCCURRENCE RANKING MUST ONLY COME FROM A

DIRECT CHANGE IN THE BUSINESS PROCESS
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EXAMPLE: OCCURRENCE RATING
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EXAMPLE: OCCURRENCE RATING
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IN YOUR FMEA DOCUMENT, IDENTIFY THE OCCURRENCE RATING FOR
EACH FAILURE MODE

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CONGRATULATIONS
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NEXT SECTION
STAGE 03: SPECIFYING THE DETECTABILITY OF FAILURE
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STAGE 03: SPECIFYING

THE DETECTABILITY OF
FAILURE
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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WHAT ARE THE CURRENT PROCESS CONTROLS?
WHAT IS A DETECTABILITY RATING?
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NEXT LECTURE
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WHAT ARE THE

CURRENT PROCESS
CONTROLS?
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DESCRIPTIONS OF CONTROLS THAT EITHER PREVENT THE FAILURE

MODE FROM OCCURRING OR DETECT IT IF IT SHOULD OCCUR
MAY INCLUDE PREVENTION MEASURES, PROCESS VALIDATION AND

VERIFICATION
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THERE ARE THREE TYPES OF PROCESS CONTROLS:
PREVENT THE FAILURE

DETECT THE CAUSE &
MODE FROM OCCURRING / DETECT ONLY THE
LEAD TO CORRECTIVE
REDUCE THE RATE OF FAILURE MODE
ACTIONS
OCCURRENCE
IF FIRST METHOD IS EMPLOYED, THE OCCURRENCE RANKING MAY BE

CHANGED ON THE FOLLOWING VERSION OF THE DOCUMENT
TO IMPROVE THE OCCURRENCE RATING FOR FAILURE MODE, THE

PROCESS CONTROL MUST BE EMPLOYED
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EXAMPLE: CURRENT PROCESS CONTROLS
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IN YOUR FMEA DOCUMENT, LIST DOWN THE CURRENT PROCESS
CONTROLS OF EACH FAILURE MODE THAT YOU HAVE DOCUMENTED
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WHAT IS THE
DETECTABILITY
RATING?
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DETECTABILITY
ASSESSMENT THAT THE PROPOSED PROCESS CONTROL STEP WILL

DETECT A POTENTIAL WEAKNESS OR SUBSEQUENT FAILURE MODE
NEVER ASSUME THAT DETECTION RANKING IS LOW BECAUSE

OCCURRENCE IS LOW
RANKING SYSTEMS SHOULD BE AGREED ON BY THE ENTIRE TEAM

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EXAMPLE: DETECTABILITY RATING
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EXAMPLE: DETECTABILITY RATING
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IN YOUR FMEA DOCUMENT, IDENTIFY THE DETECTABILITY RATING
FOR EACH FAILURE MODE

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CONGRATULATIONS
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WHAT IS A DETECTABILITY RATING?
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STAGE 04 AND 05:

QUANTIFYING THE RISK
AND CORRECTING
HIGH RISK SITUATIONS
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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WHAT IS A RISK PRIORITY NUMBER (RPN)?
WHAT ARE ACTIONS RECOMMENDED?
WHAT IS RESPONSIBILITY, TARGET COMPLETION DATE AND

ACTIONS TAKEN?
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NEXT LECTURE
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WHAT IS A
RISK PRIORITY NUMBER
(RPN)?
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BY DEFINITION THE RISK PRIORITY NUMBER IS:
RPN = (S) X (O) X (D)

WHERE S = SEVERITY, O = OCCURRENCE & D = DETECTION
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RELATIVE MEASURE OF OPERATIONAL RISK
VALUES CAN RANGE FROM 1 TO 1000
THESE VALUES HELP TO RANK ORDER THE FAILURE MODES
FAILURE MODES WITH HIGH RPN SHOULD BE ACTIONED
FAILURE MODES WITH HIGH SEVERITY SHOULD ALSO BE ACTIONED
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EXAMPLE: RISK PRIORITY NUMBER (RPN)
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IN YOUR FMEA DOCUMENT, IT IS NOW TIME TO USE THE FORMULA
AND CALCULATE THE RPN NUMBER
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WHAT ARE THE

ACTIONS
RECOMMENDED?
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WHAT ARE THE ACTIONS RECOMMENDED?
AFTER ADDING A RISK PRIORITY NUMBER, DISCUSS THE CORRECTIVE
ACTIONS FOR FAILURE MODES
BEGIN WITH THE FAILURE MODE WITH THE GREATEST RPN AND
WORKING IN DESCENDING ORDER TO RPN
FAILURE MODES WITH HIGH SEVERITY CRITERIA SHOULD BE

EXAMINED WITH THE LEAD GROUP OF FAILURE MODES
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THE PURPOSE OF THE RECOMMENDED ACTIONS IS TO REDUCE
FAILURE MODES THAT HAVE HIGH RISK PRIORITY NUMBERS:
REDESIGNING THE
INCREASE IN PROCESS A PROCESS LEVEL REVISION
PROCESS HELPS MITIGATE
VALIDATION ACTIONS CAN BRING ABOUT A
POTENTIAL CAUSES &
RESULTS IN REDUCTION OF REDUCTION IN THE
REDUCES THE
DETECTION RANKING SEVERITY RANKING
OCCURRENCE RANKING
ENTER “NONE” IF THERE ARE NO RECOMMENDED ACTIONS

AVAILABLE TO REDUCE ANY OF THE RANKING CRITERIA
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EXAMPLE: ACTIONS RECOMMENDED
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CREATE SUITABLE ACTIONS THAT WILL HELP IN REDUCING THE
OCCURRENCE, INCREASING THE DETECTABILITY
THERE MAY BE CERTAIN ACTIONS THAT MAY HAVE IMPACT ON

SEVERITY AS WELL. BUT IN MY EXPERIENCE THOSE WILL BE RARE
GO AHEAD AND HAVE THESE ACTIONS DOCUMENTED IN YOUR FMEA

TEMPLATE
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WHAT ARE
RESPONSIBILITY,
TARGET COMPLETION
DATES AND ACTIONS
TAKEN?
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RESPONSIBILITY & TARGET COMPLETION DATES
THE INDIVIDUAL OR GROUP RESPONSIBLE FOR THE RECOMMENDED

ACTIONS AND THE TARGET COMPLETION DATE SHOULD BE ENTERED
AS REFERENCE FOR FUTURE DOCUMENT USERS
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ACTIONS TAKEN
AFTER AN ACTION HAS BEEN IMPLEMENTED, A BRIEF DESCRIPTION

OF THE ACTUAL ACTION AND ITS EFFECTIVE DATE SHOULD BE
ENTERED
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FOR YOUR FMEA, DOCUMENT THE RESPONSIBILITY, TARGET
COMPLETION DATES AND ACTIONS TAKEN
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CONGRATULATIONS
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WHAT ARE ACTIONS RECOMMENDED?
WHAT IS RESPONSIBILITY, TARGET COMPLETION DATE AND

ACTIONS TAKEN?
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STAGE 06:
REEVALUATING THE
RISK AND VISUALIZING
YOUR FMEA
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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CALCULATING THE RESULTING RPN
CREATING A SPIDER CHART
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NEXT LECTURE
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CALCULATING THE
RESULTING RPN
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AFTER THE CORRECTIVE ACTIONS HAVE BEEN EXECUTED, THE

RESULTING SOD RANKINGS SHOULD BE RE-ESTIMATED
THEN THE RESULTING RPN SHOULD BE RE-CALCULATED AND

RECORDED
IF NO ACTIONS ARE TAKEN, THIS SECTION SHOULD BE LEFT BLANK
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AFTER THE SECTION IS COMPLETED, THE RESULTING RPN’S SHOULD
BE EVALUATED, AND IF FURTHER ACTION IS DEEMED NECESSARY,
STEPS FROM THE RECOMMENDED ACTIONS SECTIONS SHOULD BE
REPEATED
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FOR YOUR FMEA, YOU CAN WAIT UNTIL ALL ACTIONS GET
IMPLEMENTED
ONCE IMPLEMENTED, YOU CAN RE-ESTIMATE THE RESULTING SOD

RANKING & RECALCULATE THE RPN
RE-VISIT YOUR FMEA REGULARLY TO IDENTIFY AND DOCUMENT ANY

ADDITIONAL FAILURE MODES
FMEA SHOULD BE A LIVING DOCUMENT AND THUS, MUST BE

UPDATED REGULARLY
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CONGRATULATIONS
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WHAT ARE THE STEPS

TO CONSTRUCT A
FAILURE MODE AND
EFFECT ANALYSIS?
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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WHAT ARE THE STEPS

TO CONSTRUCT A
FAILURE MODE AND
EFFECT ANALYSIS?
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STEPS TO CONSTRUCT FMEA
FILL IN THE IDENTIFYING IDENTIFY THE FUNCTIONS
ASSEMBLE A CROSS- IDENTIFY THE SCOPE OF
1 2 3 INFORMATION AT THE 4 OF YOUR SCOPE &
FUNCTIONAL TEAM FMEA
TOP OF YOUR FMEA FORM PROCESS STEPS
FOR EACH FUNCTION, FOR EACH FAILURE MODE, FOR EACH FAILURE MODE,
DETERMINE HOW SERIOUS
5 IDENTIFY THE POTENTIAL 6 IDENTIFY THE POTENTIAL 7 8 DETERMINE ALL THE
EACH EFFECT IS
FAILURE MODES FAILURE EFFECTS POTENTIAL ROOT CAUSES
FOR EACH CAUSE, FOR EACH CAUSE, FOR EACH CONTROL,

1 1 1 CALCULATE THE RISK
9 DETERMINE THE IDENTIFY CURRENT DETERMINE THE
0 1 2 PRIORITY NUMBER (RPN)
OCCURRENCE RATING PROCESS CONTROLS DETECTION RATING
CONTINUE TO RE-
1 IDENTIFY RECOMMENDED 1 EVALUATE THE RISKS AND
3 ACTIONS 4 FAILURES IN YOUR
BUSINESS PROCESS
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1. ASSEMBLE A CROSS-FUNCTIONAL TEAM
ASSEMBLE A CROSS-FUNCTIONAL TEAM OF PEOPLE WITH DIVERSE
KNOWLEDGE
MANUFACTURING FUNCTIONS OFTEN INCLUDED ARE:

DESIGN MANUFACTURING QUALITY TESTING RELIABILITY
PURCHASING CUSTOMER
MAINTENANCE SALES MARKETING
(& SUPPLIERS) SERVICE
SERVICE INDUSTRY FUNCTIONS INCLUDED ARE:

OPERATIONS TRAINING FINANCE MIS QUALITY
CUSTOMER
TRANSITION
SUPPORT
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2. IDENTIFY THE SCOPE OF FMEA
IS IT FOR CONCEPT, SYSTEM, DESIGN, PROCESS, OR SERVICE?
WHAT ARE THE BOUNDARIES?
HOW DETAILED SHOULD WE BE?
USE FLOWCHARTS TO IDENTIFY THE SCOPE AND TO MAKE SURE

EVERY TEAM MEMBER UNDERSTANDS IT IN DETAIL
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3. FILL IDENTIFYING INFORMATION
FILL IN THE:
• PROJECT TITLE
• DATE WHEN THE FMEA WAS CREATED
• FMEA TEAM MEMBER NAMES AND
• THE NAMES OF INDIVIDUALS INVOLVED IN CREATING FMEA
WORKSHEET
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4. IDENTIFY THE FUNCTIONS OF YOUR SCOPE
IDENTIFY WHICH FUNCTIONAL DEPARTMENTS WOULD YOU BE
CREATING YOUR FMEA
YOU CAN ALSO DOCUMENT THE PROCESS STEPS
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5. IDENTIFY THE POTENTIAL FAILURE MODES
BRAINSTORM THE POTENTIAL FAILURE MODES OF EACH STEP OR
EACH FUNCTIONAL DEPARTMENT
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6. IDENTIFY THE POTENTIAL FAILURE EFFECTS
IDENTIFY THE POTENTIAL FAILURE EFFECTS ON:
SYSTEM RELATED SYSTEMS PROCESS RELATED PROCESSES
PRODUCT SERVICE CUSTOMER REGULATIONS
"WHAT DOES THE CUSTOMER EXPERIENCE BECAUSE OF THIS

FAILURE?”
“WHAT HAPPENS WHEN THIS FAILURE OCCURS?"
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7. DETERMINE HOW SERIOUS EACH EFFECT IS
THIS IS THE SEVERITY RATING
SEVERITY IS USUALLY RATED ON A SCALE FROM 1 TO 10, WHERE 1 IS

INSIGNIFICANT AND 10 IS CATASTROPHIC
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8. DETERMINE ALL THE POTENTIAL ROOT CAUSES
USE TOOLS CLASSIFIED AS ROOT CAUSE ANALYSIS TOOLS, AS WELL
AS THE BEST KNOWLEDGE AND EXPERIENCE OF THE TEAM
LIST ALL POSSIBLE CAUSES FOR EACH FAILURE MODE ON THE FMEA
FORM
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9. DETERMINE THE OCCURRENCE RATING
THIS RATING ESTIMATES THE PROBABILITY OF FAILURE OCCURRING
FOR THAT REASON DURING THE LIFETIME OF YOUR SCOPE
OCCURRENCE IS USUALLY RATED ON A SCALE FROM 1 TO 10, WHERE

1 IS EXTREMELY UNLIKELY AND 10 IS INEVITABLE
ON THE FMEA TABLE, LIST THE OCCURRENCE RATING FOR EACH

CAUSE
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10. IDENTIFY CURRENT PROCESS CONTROLS
THESE ARE TESTS, PROCEDURES OR MECHANISMS THAT YOU NOW
HAVE IN PLACE TO KEEP FAILURES FROM REACHING THE CUSTOMER
THESE CONTROLS MIGHT PREVENT THE CAUSE FROM HAPPENING,

REDUCE THE LIKELIHOOD THAT IT WILL HAPPEN OR DETECT FAILURE
AFTER THE CAUSE HAS ALREADY HAPPENED BUT BEFORE THE
CUSTOMER IS AFFECTED
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11. DETERMINE THE DETECTION RATING
THIS RATING ESTIMATES HOW WELL THE CONTROLS CAN DETECT ITS
FAILURE MODE AFTER THEY HAVE HAPPENED
DETECTION IS USUALLY RATED ON A SCALE FROM 1 TO 10
1 MEANS THE CONTROL IS ABSOLUTELY CERTAIN TO DETECT THE

PROBLEM
10 MEANS THE CONTROL IS CERTAIN NOT TO DETECT THE PROBLEM

(OR NO CONTROL EXISTS)
ON THE FMEA TABLE, LIST THE DETECTION RATING FOR EACH CAUSE
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12. CALCULATE THE RISK PRIORITY NUMBER
RPN = S X O X D
RPN PROVIDES GUIDANCE FOR RANKING POTENTIAL FAILURES IN

THE ORDER THEY SHOULD BE ADDRESSED
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13. IDENTIFY RECOMMENDED ACTIONS
THESE ACTIONS MAY BE DESIGN OR PROCESS CHANGES TO LOWER
OCCURRENCE
THEY MAY BE ADDITIONAL CONTROLS TO IMPROVE DETECTION
ALSO NOTE WHO IS RESPONSIBLE FOR THE ACTIONS AND TARGET

COMPLETION DATES
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14. CONTINUE TO RE-EVALUATE
AS ACTIONS ARE COMPLETED, NOTE RESULTS AND THE DATE ON THE
FMEA FORM
ALSO, NOTE NEW S, O, OR D RATINGS AND NEW RPNS
CONTINUE TO RE-EVALUATE THE RISKS AND FAILURES IN YOUR

BUSINESS PROCESS
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WHAT ARE THE

BENEFITS AND
SHORTCOMINGS OF
USING FMEA?
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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BENEFITS OF FMEA
DETERMINES THE PROCESS

CONDUCTS A SYSTEMATIC CALCULATES THE
DETERMINES THE IMPACT STEPS WHOSE FAILURE
1 REVIEW OF 2 3 4 PROBABILITIES OF
OF THE FAILURE MODE WILL HAVE CRITICAL
FAILURE MODES FAILURES
EFFECTS
HELPS ESTABLISH TEST DETERMINES WHICH ARE

HELPS IN SETTING UP TEST HELPS COLLECT INPUT
PROGRAM REQUIREMENTS THE COMPONENTS THAT
5 PROGRAM REQUIREMENTS 6 7 DATA TO UNDERSTAND 8
TO CONFIRM EXACT HAVE A HIGH FAILURE
TO DECIDE FAILURE MODE THE IMPACT OF CHANGES
FORECASTS OF RELIABILITY RATE
HELPS REVEAL
HELPS ELIMINATE HELPS TO REDUCE THE
OVERSIGHTS,
ADVERSE IMPACT THAT A 1 1 TIME TAKEN TO DEVELOP
9 MISINTERPRETATIONS,
BUSINESS OPERATIONS 0 1 AND IMPLEMENT BAU
ERRORS OR EVEN
COULD CREATE OPERATIONS
BLUNDERS
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WHAT ARE THE

SHORTCOMINGS OF
USING FMEA?
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SHORTCOMINGS OF FMEA
ISSUES BEYOND TEAM IF THE TEAM DOESN’T

IF THE TEAM FORGETS TO
FMEA IS ONLY AS GOOD MEMBER KNOWLEDGE FOCUS ON DETAILS, MANY
1 2 3 LIST FAILURE MODES, 4
AS THE TEAM BEHIND IT AREN’T LIKELY TO BE FAILURE MODES WILL BE
THEY’LL BE IGNORED
DETECTED OR RESOLVED MISSED
TOO MANY DETAILS MAY FMEA IS GENERALLY

5 MAKE THE ANALYSIS SEEM 6 TREATED AS A STATIC
A DAUNTING TASK DOCUMENT
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COURSE SUMMARY &

CONCLUSION
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
AIGPE
SECTION: WHAT IS FMEA?
THE HISTORY OF FMEA
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1 2 3
mode
4 5 6
SITUATIONS
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SECTION: STAGE 01 OF FMEA
TOP SECTION OF FMEA:
DIFFERENT COMPONENTS OF STAGE 01:
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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WHAT ARE THE POTENTIAL CAUSES?
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
AIGPE
WHAT IS THE DETECTION RATING?
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
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SECTION: STAGE 04 & 05 OF FMEA
WHAT IS A RISK PRIORITY NUMBER?
WHAT IS THE RESPONSIBILITY, TARGET COMPLETION DATES AND

ACTIONS TAKEN?
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WHAT IS FMEA?

SECTION CONCLUSION
Activity
AIGPE
AIGPE
WHAT IS FMEA?

SECTION CONCLUSION
Activity
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SECTION: 14 STEPS TO CONSTRUCT FMEA
FILL IN THE IDENTIFYING IDENTIFY THE FUNCTIONS
ASSEMBLE A CROSS- IDENTIFY THE SCOPE OF
1 2 3 INFORMATION AT THE 4 OF YOUR SCOPE &
FUNCTIONAL TEAM FMEA
TOP OF YOUR FMEA FORM PROCESS STEPS
FOR EACH FUNCTION, FOR EACH FAILURE MODE, FOR EACH FAILURE MODE,
DETERMINE HOW SERIOUS
5 IDENTIFY THE POTENTIAL 6 IDENTIFY THE POTENTIAL 7 8 DETERMINE ALL THE
EACH EFFECT IS
FAILURE MODES FAILURE EFFECTS POTENTIAL ROOT CAUSES
FOR EACH CAUSE, FOR EACH CAUSE, FOR EACH CONTROL,

1 1 1 CALCULATE THE RISK
9 DETERMINE THE IDENTIFY CURRENT DETERMINE THE
0 1 2 PRIORITY NUMBER (RPN)
OCCURRENCE RATING PROCESS CONTROLS DETECTION RATING
CONTINUE TO RE-
EVALUATE THE RISKS AND
1 IDENTIFY RECOMMENDED 1
FAILURES IN YOUR
3 ACTIONS 4
BUSINESS PROCESS. FMEA
IS A LIVING DOCUMENT
AIGPE
WHAT IS FMEA?

SECTION CONCLUSION
Activity
AIGPE
KEEP LEARNING & KEEP GROWING

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AIGPE

USED FMEA EVERYTIME

EACH EVENT WAS BLIP FREE

THE FAILURE MODE &

SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION

ACTIVITY: WHAT IS FMEA? ACTIVITY: STAGE 01

ACTIVITY SOLUTION: WHAT IS FMEA? ACTIVITY SOLUTION: STAGE 01

SECTION CONCLUSION SECTION CONCLUSION

SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION

WHAT IS RESPONSIBILITY, TARGET

WHY AND WHEN TO USE FMEA?

THE HISTORY OF FMEA

WHAT ARE THE TYPES OF FMEA?

WHAT IS A PROCESS FMEA?

ACTIVITY & ACTIVITY SOLUTION

METHODICAL AND SYSTEMATIC TECHNIQUE

JOINS THE INNOVATION AND EXPERIENCE OF PEOPLE

HELPS IDENTIFY PREDICTABLE FAILURE MODES OF YOUR PROCESS

YOU CAN THEN PLAN TO EITHER ELIMINATE THESE FAILURE MODES

SIT IN THE TIME MACHINE  GET INTO A CONFERENCE ROOM

COME BACK TO THE CURRENT DATE | ALSO

CREATE ACTION PLANS TO ELIMINATE OR CREATE ACTION PLANS TO ELIMINATE OR

PERCEIVE AND ASSESS

FMEA IS A PROACTIVE TOOL

REQUIRES COLLABORATION AMONGST TEAM MEMBERS

HELPS DEPARTMENTS INCORPORATE +VE CHANGES

IN MANUFACTURING AS WELL AS SERVICE INDUSTRY

INVOLVES IDENTIFICATION OF POTENTIAL FAILURE MODES

AND IMPACT OF THOSE ON:

FMEA IS UTILIZED TO:

• ANTICIPATE REASONS FOR FAILURE

• KEEP THEM FROM OCCURRING

SEVERITY OCCURRENCE DETECTION

RPN HELPS YOU UNDERSTAND WHICH FAILURE MODES ARE

DO NOT CONSIDER FMEA AS A ONE-TIME EXERCISE

WHY & WHEN TO USE

PROCESSES ARE MODE REQUIRES MORE NEEDS FAR MORE PLANNING

HELPS YOU FOLLOW-UP & DOCUMENT FAILURE MODES

WHEN YOU RESTRUCTURE OR UPGRADE YOUR PRODUCTS,

WHEN IMPLEMENTING CONTROLS FOR A NEW OR MODIFIED

WHEN IMPROVEMENT OBJECTIVES ARE BEING SET

DURING THE ENTIRE LIFECYCLE OF PRODUCTS, PROCESSES OR

1940’s 1960’s 1970’s 1990’s Today

WHAT ARE THE

DESIGN PROCESS EQUIPMENT

MAINTENANCE CONCEPT SERVICE

IDENTIFIES FAILURE MODES BY RANKING FAILURES

HELPS ESTABLISH PRIORITIES AS PER THE RELATIVE EFFECT ON THE

ESTABLISH CONTROLS FOR OCCURRENCE REDUCTION AND

A FEW CALL DROPS ARE LOG A TICKET WITH YOUR

MULTIPLE CALL DROPS ARE CALL SERVICE PROVIDER | LOG

PROCESS FMEA IS USED FOR BUSINESS AS USUAL ALREADY

WHY AND WHEN TO USE FMEA?

THE HISTORY OF FMEA

WHAT ARE THE TYPES OF FMEA?

WHAT IS A PROCESS FMEA?

ACTIVITY & ACTIVITY SOLUTION

STAGE 01: IDENTIFYING

SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION

ACTIVITY: WHAT IS FMEA? ACTIVITY: STAGE 01

ACTIVITY SOLUTION: WHAT IS FMEA? ACTIVITY SOLUTION: STAGE 01

SECTION CONCLUSION SECTION CONCLUSION

SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION SECTION INTRODUCTION

WHAT IS RESPONSIBILITY, TARGET