K. J.

Somaiya College of Engineering

(A Constituent College of Somaiya Vidyavihar University)
Department of Mechanical Engineering
Subject: Failure Analysis (Design Engineering) Sem: V (2022)

Name: Anirudh Acharya

Batch: B4 Roll No.: 16010521815 Ass. No.: 01

Grade: AA / AB / BB / BC / CC / CD /DD: ……………………..

Signature of Faculty in-charge with date: ……………………………..

ASSIGNMENT NO:1
Aim: Analysis of failure by FMEA theory for a given

component/system.

Prepare FMEA for a given component or a system and do failure analysis for the same. Draw

relevant diagrams and explain the failure and effects of failure clearly.

• What is FMEA?

Failure Mode and Effects Analysis (FMEA for short) is a systematic way to recognize and

evaluate the potential failures of a product or process. It provides a formal mental discipline

for eliminating or reducing the risks of product failure. It also serves as a living document,

providing a method of organizing and tracking concerns and changes through product

development.

• Important Terms:

1. Cause: Cause of Failure mode is a deficiency that results in a failure mode. It is

description of how the process could result in a failure.

2. Severity: Is an assessment of the seriousness of the effect of the potential failure

mode to the customer. Severity applies to the effect only

3. Occurrence: The number of times the cause has resulted in the failure mode before
 K. J. Somaiya College of Engineering
(A Constituent College of Somaiya Vidyavihar University)
Department of Mechanical Engineering
Subject: Failure Analysis (Design Engineering) Sem: V (2022)
any additional control are applied.

4. Detection: is the rating corresponding to the likelihood that current process will detect
the failure mode before it gets to the customer.

5. RPN (Risk Priority Number): It is the product of Severity, Occurrence and

detection numbers.

RPN = Severity x Occurrence x Detection

Severity Rankings
Ranking Effect Design FMEA Severity Process FMEA Severity
Hazardous-no affects safe operation may endanger machine or
10
warning without warning operator without warning
Hazardous- w/ affects safe operation may endanger machine or
9
warning with warning operator with warning
makes product major disruption in operations
8 Very High
inoperable (100% scrap)
makes product operable
minor disruption in operations
at reduced performance
7 High (may require sorting and some
(customer
scrap)
dissatisfaction)
results in customer minor disruption in operations (no
6 Moderate
discomfort sorting but some scrap)
results in comfort and
minor disruption in operations
5 Low convenience at a
(portion may require rework)
reduced level

minor disruption in operations

results in dissatisfication
4 Very Low (some sorting and portion may
by most customers.
require rework)

results in dissatisfication minor disruption (some rework

3 Minor
by average customer. but little affect on production rate)

results in dissatisfication minor disruption (minimal affect

2 Very Minor
by few customers. on production rate)
1 None No effect No effect
 K. J. Somaiya College of Engineering
(A Constituent College of Somaiya Vidyavihar University)
Department of Mechanical Engineering
Subject: Failure Analysis (Design Engineering) Sem: V (2022)

Occurrence Rankings
Percent
Ranking Effect Failure Rates Cpk
Defective
10 Extremely High > 1 in 2 50% Cpk < 0.33
9 Very High 1 in 3 33% Cpk ~ 0.5
8 Very High 1 in 8 10-15% Cpk ~ 0.75
7 High 1 in 20 5%
6 Marginal 1 in 100 1%
5 Marginal 1 in 400 0.25% Cpk ~ 1
4 Unlikely 1 in 2000 0.05%
3 Low 1 in 15,000 0.007% Cpk > 1.33
2 Very Low 1 in 150,000 0.0007% Cpk > 1.5
1 Remote < 1 in 1,500,000 0.000007% Cpk > 1.67

Detection Rankings
Ranking Effect Design FMEA Detection Process FMEA Detection
No chance that design control will No known process control to detect
Absolute
10 detect cause mechanism and cause mechanism and subsequent
uncertainty
subsequent failure. failure.
Very remote chance that design
Very
9 control will detect cause mechanism
remote
and subsequent failure.
Remote chance that design control Remote chance that process control
8 Remote will detect cause mechanism and to detect cause mechanism and
subsequent failure. subsequent failure.
Very low chance that design control
7 Very Low will detect cause mechanism and
subsequent failure.
Low chance that design control will Low chance that process control to
6 Low detect cause mechanism and detect cause mechanism and
subsequent failure. subsequent failure.
Moderate chance that design
5 Moderate control will detect cause mechanism
and subsequent failure.
Moderately high chance that design
Moderately
4 control will detect cause mechanism
High
and subsequent failure.
very remote chance that design High chance that process control to
3 High control will detect cause mechanism detect cause mechanism and
and subsequent failure. subsequent failure.
Very high chance that design
2 Very High control will detect cause mechanism
and subsequent failure.
Design control will almost certainly Current control almost certain to
Almost
1 detect cause mechanism and detect cause mechanism and failure
Certain
subsequent failure. mode.
 K. J. Somaiya College of Engineering
(A Constituent College of Somaiya Vidyavihar University)
Department of Mechanical Engineering
Subject: Failure Analysis (Design Engineering) Sem: V (2022)

• Some Failures in clutch

Clutch Disc failure

 K. J. Somaiya College of Engineering
(A Constituent College of Somaiya Vidyavihar University)
Department of Mechanical Engineering
Subject: Failure Analysis (Design Engineering) Sem: V (2022)

• FMEA TABLE

Action Results

Potential Potential Effect(s) Potential Cause(s)/

Component S O D RPN
Failure Mode of Failure Mechanism(s) of Failure
Actions Taken

Incorrect gear Selection of a Driving with proper

Improper power
Clutch plate Wear 6 low gear while driving at 7 4 168 gear shifting
Transmission
high speed knowledge

Don’t allow the

Very high Engine Plate accelerates past its
Clutch hub Breakage 10 4 8 320 engine to reach at
speed facing burst strength
very high RPM

Pressure Proper releasing of

Wear Slippage 7 Overheating 7 5 245
Plate clutch pedal

Friction Impacting during Avoid impacting the

Crack Impact load 8 4 6 192
Material Installation clutch

Do not miss-shift
Backing plate Fracture Miss shifting gears 10 Load above the safe limits 5 5 250
gears

Conclusion:-
Hence, the FMEA for the clutch was done.