FMEA - Failure Mode Effects Analysis

A B C D
Process PROCESS EQUIPMENT or Link in SUB ASSEMBLY, List all potential FAILURE MODES,
Step Description process component or process focus on failure result rather than
root cause

1.0
Store Ingredient Pipework Seals/Couplings Leaks
1.0
Store Ingredient Pipework Structure Rupture/Leaks
1.0
Store Ingredient Tank Structure Rupture/Leaks
1.1 Transfer
Ingredient Ball Valve Valve seal/seats Wear
1.1 Transfer
Ingredient Ball Valve Valve seal/seats Damage
1.1 Transfer
Ingredient Ball Valve Valve ball Does not fully open/close
1.1 Transfer
Ingredient Ball Valve Valve stem Wear
1.1 Transfer
Ingredient Ball Valve Valve ball Does not rotate open
1.1 Transfer
Ingredient Ball Valve Valve ball Does not rotate closed
1.1 Transfer
Ingredient Ball Valve Body/Housing Cracks
1.1 Transfer
Ingredient Ball Valve Fastenings loose assembly
1.2
Pump Ingredient Motor Bearing insufficient lubrication
1.2
Pump Ingredient Pump Bearing insufficient lubrication
1.2
Pump Ingredient Pump Impellor Misaligned
1.2
Pump Ingredient Motor Terminal Box Loose terminal connections
1.2
Pump Ingredient Motor Windings Overheat/ Temperature damage
1.2
Pump Ingredient Motor Fan Dirt/Build Up
1.2
Pump Ingredient Motor Windings Damage to insulation
1.2
Pump Ingredient Motor Bearing excessive lubrication
1.2
Pump Ingredient Pump Bearing Misaligned
1.2
Pump Ingredient Pump Bearing excessive lubrication
1.2 Key way damage
Pump Ingredient Motor Fan Fan no longer turns with motor
1.2
Pump Ingredient Pump Bearing Corrosion
1.2
Pump Ingredient Motor Bearing induced vibration
1.2
Pump Ingredient Pump Bearing induced vibration
1.2
Pump Ingredient Pump Impellor Erosion, wear
1.2
Pump Ingredient Pump Mechanical Seal Sealing face cracked/fractured
1.2
Pump Ingredient Motor Bearing Misaligned
1.2
Pump Ingredient Pump Mechanical Seal Internal O-rings perish
1.2
Pump Ingredient Motor Windings Internal Corrosion
1.3
Filter Ingredient Filter Filter cartridge completely blocked
1.3
Filter Ingredient Filter Filter cartridge partially blocked, build up of sediment
1.3
Filter Ingredient Filter Filter cartridge fails to seal
1.3
Filter Ingredient Filter Filter housing Rupture/Leaks
1.4
Spray Ingredient Spray ball Spray ball blocked
2.0
Mix Ingredients Motor (Agitator) Bearing insufficient lubrication
2.0
Mix Ingredients Coupling (Agitator) Bearing insufficient lubrication
2.0
Mix Ingredients Motor (Agitator) Terminal Box Loose terminal connections
2.0
Mix Ingredients Motor (Agitator) Windings Overheat/ Temperature damage
2.0
Mix Ingredients Motor (Agitator) Fan Dirt/Build Up
2.0
Mix Ingredients Motor (Agitator) Windings Damage to insulation
2.0
Mix Ingredients Motor (Agitator) Bearing excessive lubrication
2.0
Mix Ingredients Coupling (Agitator) Bearing excessive lubrication
2.0 Key way damage
Mix Ingredients Motor (Agitator) Fan Fan no longer turns with motor
2.0
Mix Ingredients Motor (Agitator) Bearing induced vibration
2.0
Mix Ingredients Coupling (Agitator) Bearing induced vibration
2.0
Mix Ingredients Coupling (Agitator) Mechanical Seal Sealing face cracked/fractured
2.0
Mix Ingredients Motor (Agitator) Bearing Misaligned
2.0
Mix Ingredients Coupling (Agitator) Bearing Misaligned
2.0
Mix Ingredients Coupling (Agitator) Mechanical Seal Internal O-rings perish
2.0
Mix Ingredients Impellor (Agitator) Shaft and Blades Misaligned, imbalances
2.0
Mix Ingredients Motor (Agitator) Windings Internal Corrosion
3.0
Transfer Product Ball Valve Valve seal/seats Wear
3.0
Transfer Product Ball Valve Valve seal/seats Damage
3.0
Transfer Product Ball Valve Valve ball Does not fully open/close
3.0
Transfer Product Ball Valve Valve stem Wear
3.0
Transfer Product Ball Valve Valve ball Does not rotate open
3.0
Transfer Product Ball Valve Valve ball Does not rotate closed
3.0
Transfer Product Ball Valve Body/Housing Cracks
3.0
Transfer Product Ball Valve Fastenings loose assembly
3.1
Pump Product Motor Bearing insufficient lubrication
3.1
Pump Product Pump Bearing insufficient lubrication
3.1
Pump Product Pump Impellor Misaligned
3.1
Pump Product Motor Terminal Box Loose terminal connections
3.1
Pump Product Motor Windings Overheat/ Temperature damage
3.1
Pump Product Motor Fan Dirt/Build Up
3.1
Pump Product Motor Windings Damage to insulation
3.1
Pump Product Motor Bearing excessive lubrication
3.1
Pump Product Pump Bearing Misaligned
3.1
Pump Product Pump Bearing excessive lubrication
3.1 Key way damage
Pump Product Motor Fan Fan no longer turns with motor
3.1
Pump Product Pump Bearing Corrosion
3.1
Pump Product Motor Bearing induced vibration
3.1
Pump Product Pump Bearing induced vibration
3.1
Pump Product Pump Impellor Erosion, wear
3.1
Pump Product Pump Mechanical Seal Sealing face cracked/fractured
3.1
Pump Product Motor Bearing Misaligned
3.1
Pump Product Pump Mechanical Seal Internal O-rings perish
3.1
Pump Product Motor Windings Internal Corrosion
ts Analysis
1. Map out the selected process or functions of the system or plant (A)
2. For each process step itemise the major components and sub-components (B, C)
3. For component or sub-component list the fialure modes and effects (D, E)
4. Using the scoring matrix populate: Severity (F), Probability (G) and Detection (H)

E F G H I J
Potential EFFECT on SEVERITY of PROBABILITY of DETECTION of Risk Priority Rank
process plant or product effect failure effect failure Number RPN
(Sum of D)

loss of product, 6 3 3 54 63
contamination
loss of product, 9 2 2 36 71
contamination
loss of product, 9 2 1 18 72
contamination
loss of product, slow to 4 6 5 120 34
transfer, inefficiencies,
loss of product, slow to 4 5 5 100 39
transfer, inefficiencies,
loss of product, slow to 6 5 3 90 47
transfer, inefficiencies,
Valve Leaks 4 4 5 80 49
Valve fails to seal
9 2 3 54 63
no liquid can pass
unable to prevent liquid 9 2 3 54 63
passing
loss of product, 6 1 3 18 72
contamination
loss of product, 6 1 3 18 72
contamination
Bearing lifespan reduced 6 5 7 210 3
Bearing fails
Bearing lifespan reduced 6 5 7 210 3
Bearing fails
Rapid reduction in lifespan of 6 5 7 210 3
impellor
Motor Faults 9 3 7 189 11
Unable to operate
Motor trips on High Temp, 7 3 8 168 14
Intermittent operation
Motor trips on High Temp, 7 6 4 168 14
Intermittent operation
Motor Faults 10 2 8 160 20
Unable to operate
Bearing lifespan reduced 5 5 6 150 23
Bearing fails
Excessive and rapid wear 6 5 5 150 23
Bearing fails
Bearing lifespan reduced 5 5 6 150 23
Bearing fails
Motor trips on High Temp, 7 5 4 140 31
Intermittent operation
Bearing lifespan reduced 4 4 7 112 36
Bearing fails
Neglected will result in 5 5 4 100 39
further damage
Neglected will result in 5 5 4 100 39
further damage
efficiencies loss, cannot 3 3 8 72 51
maintain pressure
loss of product, 4 4 4 64 56
contamination
Excessive and rapid wear 6 2 5 60 59
Bearing fails
loss of product, 4 3 4 48 66
contamination
Motor Faults 7 3 2 42 69
Unable to operate
9 6 8 432 1
no flow
6 6 6 216 2
pressure drop, reduced flow
filter passes and does not 7 3 5 105 38
filter
loss of product, 7 1 2 14 77
contamination
liquid not dispersed evenly, 6 3 4 72 51
inadequate coverage
Bearing lifespan reduced 6 5 7 210 3
Bearing fails
Bearing lifespan reduced 6 5 7 210 3
Bearing fails
Motor Faults 9 3 7 189 11
Unable to operate
Motor trips on High Temp, 7 3 8 168 14
Intermittent operation
Motor trips on High Temp, 7 6 4 168 14
Intermittent operation
Motor Faults 10 2 8 160 20
Unable to operate
Bearing lifespan reduced 5 5 6 150 23
Bearing fails
Bearing lifespan reduced 5 5 6 150 23
Bearing fails
Motor trips on High Temp, 7 5 4 140 31
Intermittent operation
Neglected will result in 5 5 4 100 39
further damage
Neglected will result in 5 5 4 100 39
further damage
loss of product, 4 4 4 64 56
contamination
Excessive and rapid wear 6 2 5 60 59
Bearing fails
Excessive and rapid wear 6 2 5 60 59
Bearing fails
loss of product, 4 3 4 48 66
contamination
5 3 3 45 68
excessive vibration
Motor Faults 7 3 2 42 69
Unable to operate
loss of product, slow to 4 6 5 120 34
transfer, inefficiencies,
loss of product, slow to 4 5 5 100 39
transfer, inefficiencies,
loss of product, slow to 6 5 3 90 47
transfer, inefficiencies,
Valve Leaks 4 4 5 80 49
Valve fails to seal
6 4 3 72 51
no liquid can pass
unable to prevent liquid 6 4 3 72 51
passing
loss of product, 6 1 3 18 72
contamination
loss of product, 6 1 3 18 72
contamination
Bearing lifespan reduced 6 5 7 210 3
Bearing fails
Bearing lifespan reduced 6 5 7 210 3
Bearing fails
Rapid reduction in lifespan of 6 5 7 210 3
impellor
Motor Faults 9 3 7 189 11
Unable to operate
Motor trips on High Temp, 7 3 8 168 14
Intermittent operation
Motor trips on High Temp, 7 6 4 168 14
Intermittent operation
Motor Faults 10 2 8 160 20
Unable to operate
Bearing lifespan reduced 5 5 6 150 23
Bearing fails
Excessive and rapid wear 6 5 5 150 23
Bearing fails
Bearing lifespan reduced 5 5 6 150 23
Bearing fails
Motor trips on High Temp, 7 5 4 140 31
Intermittent operation
Bearing lifespan reduced 4 4 7 112 36
Bearing fails
Neglected will result in 5 5 4 100 39
further damage
Neglected will result in 5 5 4 100 39
further damage
efficiencies loss, cannot 3 3 8 72 51
maintain pressure
loss of product, 4 4 4 64 56
contamination
Excessive and rapid wear 6 2 5 60 59
Bearing fails
loss of product, 4 3 4 48 66
contamination
Motor Faults 7 3 2 42 69
Unable to operate
 FMEA Scoring Matrix
Severity Occurrence Detection
No effect on customer/process 1 Extremely Likely 10 Extremely Likely 1

Slight customer annoyance

2 9 2
operator inconvenience
3 Probable/Highly Likely 8 Highly Likely 3

Moderate Customer
4 7 4
Annoyance minor in house cost
5 6 5

High degree of customer

6 Possible/Likely 5 Likely 6
annoyance major in house cost
7 4 7

Failure to provide service, loss

8 Improbable/Unlikely 3 Unlikely 8
of production
9 2 9
Catastrophic - H&S implications 10 Very Unlikely 1 Very Unlikely 10
Please see additional pages for detail definitions and examples.
 Severity Definitions and examples

No effect on customer/process 1 Fault is purely cosmetic e.g. minor scratch/dented panel on machine.

Minor QC fault observed, approval to run given. Intermittent interaction required by operator to prevent
2 downtime e.g. acknowledging a warning on operator panel. A portion of production may have to be re-
worked (<100%) - on-line (in station). Defect noticed by discriminating customer
Slight customer annoyance
operator inconvenience
3 Can continue production until there is an opportunity to undertake repair. Defect noticed by average
customer

4 Efficiency losses present. Production may have to be sorted and a portion (<100%) re-worked
Moderate Customer
Annoyance minor in house cost
5 Likely to require replacement of component/part, production or process must pause for rectification.
Product / equipment operable, but at slightly reduced level of performance

6 Constant intervention required to keep process running to desired specifications. Product / equipment
operable, but at reduced level of performance (some secondary functions inoperable)
High degree of customer
annoyance major in house cost
7 Expensive component or part replacement or time consuming overhaul required.Production may have to be
sorted and a portion (<100%) written off or scrapped.

8 Machine running intermittently or at reduced run rate. Some production may be impacted but not all.
Failure to provide service, loss
of production
9 Machine stopped, production unable to continue. Major SKUs impacted. Affects safe operation of product /
production and / or involves non-compliance with government regulation

Failure will occur without warning and may endager person or machine. E.g. Damage to guarding, interlocks
Catastrophic - H&S implications 10 or safety mechanisms. Note a machine risk assessment should be undertaken before any attempts to
operate the machine with this failure present.
 Occurrence Definitions and examples
If no action is taken this mode of failure is "extremely likely" in the immediate future
Extremely Likely 10 80% - 99% likely to happen
repeated examples of this failure mode recorded/observed

9
Probable/Highly Likely 8 All indications are that this failure will occur

6
Possible/Likely 5 If no action is taken this mode of failure "could occur"
An example of this failure mode recorded/observed previously

4
Improbable/Unlikely 3 If no action is taken it is "unlikely" that this failure mode would occur.

2
Very Unlikely 1 No known examples of this failure mode
 Detection Definitions and examples

Extremely Likely 1 Visible defect identified immediately

2
Probable/Highly Likely 3 Monitoring instruments will detect failure (e.g. temperature sensors, flow switch's, pressure transmitters)

5
Possible/Likely 6 Manual process in place should detect failure. E.g. routine running inspections/product sampling QA checks.
Root cause may not be evident but tell tale signs are present (e.g. leaks)

7
Improbable/Unlikely 8 Specific equipment required to detect failure. May not be detectable during normal operation (e.g. requires
disambling)

9
Product defect unrecognisable by end user
Very Unlikely 10 Destructive testing required to detect failure
 Make me White

Extremely Likely No effect on customer/process 1

Probable/Highly Likely
Slight customer annoyance operator inconvenience
2.5

Possible/Likely
Moderate Customer Annoyance minor in house cost
4.5

Improbable/Unlikely
High degree of customer annoyance major in house
6.5cost

Very Unlikely Failure to provide service, loss of production8.5

Catastrophic - H&S implications 10