Failure Mode ond Effect

Analysis 16.1
Chapter 16: Failure
Mode and Effect Analysis
Introduction
(Failure
in for
Mode and Effect Analysis
combining technology and (FMEA) is an analytical technique that goes
failures in a or a processexperience ofpeople
failure. FMEAproduct
to identify foreseeable
and goes in for
can also be defined as a
group
planning to elirninate te
understand and evaluate the potential failure of a activities intended to
its effects, and then
of
to identify actions that product or process and
chance of potential failures. Finally goes in could eliminate or reduCe the
for documenting the
FMEA is a "before-the-event" action that process.
and inexpensively, improves changes in requires a team effort to easily
design and production.
The types of FMEA can be broadly classified into
two types; they are: Design
FMEA and Process FMEA The other FMEA's like the Equipment FMEA,
Maintenance FMEA, Concept FMEA, Service FMEA, System FMEA,
Environmental FMEA, and others are nothing but small variations of process
FMEA and Design FMEA. Equipment, service, and environmental FMEA are
modified versions of process FMEA, while system FMEA is acombination of
design and process FMEA. So it would be enough if we look into design
FMEA and process FMEA.
6.2 Design FMEA
Design FMEA comes into use in the design process by identifying known
and foreseeable failure modes and then by going iF for ranking failures
according to their relative impact on the product. Implementing Design
FMEA helps to establish priorities based on expected failures and severity
of those failures and also helps to uncover oversights, misjudgments, and
reduce
errors that may have been made.( Design FMEA also helps to
development time and cost of manufacturing by eliminating many potential
to check
failures prior to operation. It also specifies the appropriate tests
the designed product)
b3 Process FMEA
Process FMEA 0s used to identify potential process failure modes by ranking
according the failure's
the failures and then goes in for establishing priorities
Process FMEA also helne to
impact on the internal or external customer.
in order to
identify potential manufacturing and assembly level failures
of failures
establish controls for reduction
16.2 Totol Quality Monagement

16.4 Reliability
Reliability is one of the most important characteristics of any product. The
in any product they buy. It's immaterial
customers
the customers arereliability
expect internal or external. Customers prefer products with a whether
relatively long service life, with long gaps between failures. But, as products
become more complex in nature, traditional design methods are not
adequate enough to ensure low rates of failure. This problem has given rise
concept of designing reliability into the product itself.
to the
perform e
Reliability is defined as the probability that the product will
the expectations for a certain period of time, under the given operating
performance characteristire
conditions, and for the given set of productperforming reliability studiec ie
important factor to be considered while
check the safety of the product or the prOcess.factors Ihe criticality of a product
drastically when safety are incorporated i
or a process will change
it.

Reliability Requirements
or process is subject to it meeting
The acceptance of a particular productprerequisite for the reliability of the
the given set of requirements that is understand that even though the
product or process. lt is, important to
customers and the suppliers
definition for reliability is relatively simple, the to failure of a product or
constitutes
may have different definitions of what definition
process. So when one wants to define reliability so that the
a
the definition should incorporate
satisfies all the segments of people then
the products impact on other systems, the reliability of similar products, the
failure.
complexity of failures and the criticality of the
define reliability by incorporating all or
It becomes the engineer's task to
engineer has only past experience and
the previously-stated items, but the defire these different aspects o
personal knowledge of similar systems to
failure accurately.
process under
assembly, or
Based on the definition of the part, and the factors that
consideration, the reliability of each sub-system appropriate relationship
contribute to failures must be found. Now the must
found out be
critical
between each part, class, or module of the product application study. FMEA
This helps to develop an approved parts list, parts for managing the
components list. This database leads to aformal system probability that the
based on probability of nonconformity occurring. the the customer annd
nonconformity is not detected and is shipped to
probabjlity that the customer will notice the nonconformity.
 Failure Mode and Efect
Failure Rate Andlysis 16.3
Amajority of the
there is no products follow a very
component, information about the familiar pattern
syStem process. But ifreliability
of failure. When
the failure(i.e.ratefailure)
or of the product,
known, periods of
distribution. failure can be found out by
which is a
constant is
using the given exponential

R, =e e

where R, = the reliability or probability of survival

t =the time specified for operation without failure
2= the failure rate

= the mean time to failure

EXAMPLE PROBLEM
Assume that a product has a constant failure rate of 7 = 0.0002 per hour.
What is-the probability that it will survive or be reliable during the first 200
hours of operation?

Solution
R, =e

=e-(200)(0.0002)
Thus, there is a 96.08% chance that the product will survive during the first
200 hours of operation.

Types of failures
three major
The failures that occur in any product can be classified into
Ypes: They are debug, chance, and wear out.
inappropriate
Debug failures means failures at the initial stages because of
Use or flaws in the design or manutacturing.
maintenance,
Chance failures occur in the product due to accidents, poor
or limitations on the design.
 16.5 16.4
Intent Total
Quality
of
to Occur FMEA
organization
require
had more more
current has Theprocess analyze
document carried product with phase identified
is machinery. The document important FMEAcombination
happening.(FMEA the techniqueFMEA reliability product
product,Continuously
to machines, becomes manufacturer processperformedMonagement, Wear
done become use the FMEA continuously prioritization
planning provide out of in is out
products of
or al meets
plannedproduct and has tothe an attempts of or it
is an shoul d
10 a
provides as One
evaluation with used process. creating
the always failuresas
FMEAproduct.possible reason addressed to
important
treat essential
measuring
years to more soon the manufacturing as
application change
be of
severity process
to idelly texpec he
are in manufacturing FMEA uses to becomes
The a occur
produce important customers'
the for as and updated corrective fin d part te d
earlier. both
nonconformities should step anticipate new fail
product
more a th e or
most the in
formalsettingfailure certainly quickly. as occurrence
criteria out only fo r
the of product of a
products and a in necessary product, reliability
FMEA bedocument toprocess. live the powertul Total in product at
onsumers complextoday
requirements. debugging actions. or
least
precaution product up is or
carried ensure tocauses th is
manner identified. document. potential is Quality process
with
aassembly before is develop and or
than than and process to as FMEA of FMEA. method to of ast theafter
are the and that even
in compare out new and detection
failure determine a method.
life. the
than ever problems purchasing the risk Managenent. machine, amount
far same ever process whichAnother
Corrective
in methodsimmediately This to product-related
preventing
most available while Soproduct
ever before. a problems be and
more before. the means prioritization a of
reliability particular
engineers
that probability modifying the product, successful
before. areas application design to and criticalsuccessful, prevent time the or
problems for
particular SoThe of Would actions
confirm setting after are the reliability While
failures. measuríng given
as ltthey
reason manner. characterstcs company
problemsfound. numbers th em buying
an or proess
the wil the it criteria design
than acturing arise shouid
of that isthat existingcf prors. by
is have up
design
natural y in FMEA re any are The very may
has
fro Thi the new orhthe has
for in
rctohmpaey.eqnuiy res manuf
that to bethe
 9. 7. FMEA manner and So and that ever important
legal carriedFMEApossible. lowest
8. 6. 5. 4. 3. 2. 1.
cost have
generate
redundancies,
Helps both.or or it
Helps effectProvidesof
predictions.
reliabilitysub-assemblies, orprocess. the finally
appear
Helps Helps Helps whichfailureHelpsprocess. productHelps failure
or Gives
provides becomes before.system been
process changes delivery all out also
to to of going with
to to failures
to in in that a changes to in
determine
minimize modifications input establish establish determining wildetermining systematic critical So has allows
in calculate the necessary ensure
the
the
can have happens of in become it
a
data following becomes the past,
proposed products wil the and for andcustonmers'
be test critical a
the how for test cause product continuously
concerns to engineers they
tailored those review to safe
to the the would increasingly
adverse programs documentdocument extremely
the tradeoff program
an and effects
these benefits and demand
product probabilities parts impact current
high-failure-rateexisting result of to
processes. that reliable to
effects for damaging on component the
studies to of of to updating
or in consumer. happen inimportant the strict document products Failure
igher-reliability product requirements determine the the any the a knowledge
process minimal thorough, concerns product.
that to product failure company: and
ofproduct
effects. the Mode
ascertain failure in-between all of
assembly
components failures tofar
or damage FMEA This the the
and failures or on and about and
process. or precise, followmore
highest
to to thoughts
tothe the other document. the becomes Effect
check in th e ensure the the
components, determine
failures process to unforgiving
changes up
of
effectiveness assemblies, process and product.
items the design on quality Anaysis
a empirical
product product that organized conicerns extremely and
could whose in made, actions for
the and stage
the any than The 16.5
the
 16.6 16.6

Stages Totol

Quality
Gf
4.
Quantifying
3. Risk2. for Management
Possibilities
Specifying1.Theremanufacturing be others process.
FMEA process. thusdocument
Enginters resußs records
Aspargpetion.
FSA actions tirne and The FMEA Team
ation
Correcting customers. workers, 14. 13. 12. 1 . 10.
continuously the discussed
are promotingviews
use But, on of and people FMEA problems. Helps Helps Helps Helps made. beenHelps
is have Documepttion assigning
four to of the FMEA place,
High can FA earfier, There manufacturing The from process
to in to to to
of a allowothers always form
stages updated team be trackingprovide reduce uncover
Risk Risk responsibilities
communicating
andshould
forms,works quality communicate is
in incorporated does the a
by
approach. team
engineersincorporated
Causes FMEA hel p distributes keep and le vel thetraining
developmentoversights,
asdocumenting concept be department,
and keep following
the of effort progress
to a to for
process. For in recorder team with teamworkers,
when th e
have those the of results
which other made new timemisjudgments,
the it. FMEA e
itthleader
design access concepts active,
servicepeople
They changes
document The ideas to in -up. rest involves employees. in and
is professionals a
are to
very participants the Has
is from cost
and available nothing of by department, of to project. and
as
others' team the engineers,
assembly of
drawing determine
to errorsthat
Occur to FMEA
manufacturing purpose materials manufacturing.
given in be for new on who maintainteam, who
effective thoughts. in
the future e.everyone face
below: of their to timrecords the iers
suppldepartment, havemay
design the engineer coordi n at i
So usethinkin files meeting similar
Itproc level
 These 4. 3.
a.
Re-evaluation d. c. Quantifying
Risk2. In
a.
b. Correcting d. C. b. a.
are Go Now Action The e. d. C. b. a. this
Recalculate The The Severity
Probability Steps out The The
the in The The stage
for the work risk
effectiveness effects
activities is involved Root Possiblefunctions
of Check actionexplained High of we
the is prioritized is the of
Risk prioritized Risk ofCauses go
Sibilities
Risk is failure Cause in the Failure involved
carried Points of in
Priority assigned in Causes the failures for for
a Control is
out to detail and Detection/Prevention
determined the Modes the
are
inNumber check to its on
failures following
the manner system effect other areidentifed
each
the determined
and necessary to is components are activities
Completion determined
Prevent found
every
people of out
stage Cause failures of
level the
of is is systern
FMEA. checked found
is
out found