INDUSTRIAL PRODUCT DESIGN

EXPERIMENT NO. 6
TITLE: A case study on Failure Modes and Effects Analysis (FMEA) in product design for
eyewear

AIM: Implementing Failure Modes and Effects Analysis (FMEA) in product design for
eyewear is to systematically identify potential failure modes, assess their effects on product
performance and user safety, prioritize them based on severity, occurrence, and detection,
and implement proactive measures to mitigate or eliminate these failures during the design
phase.

OBJECTIVES:

By implementing Failure Modes and Effects Analysis (FMEA) in the product design process,
VisionOptic successfully achieves the following objectives:
 Proactively identify and mitigate potential failure modes in eyewear design.
 Enhance product reliability and safety by addressing root causes of failures.
 Improve customer satisfaction and brand reputation by delivering high-quality
eyewear products that exceed industry standards.
 Minimize risks associated with product defects and recalls, thereby reducing
warranty claims and liability costs.
 Foster a culture of continuous improvement and innovation by systematically
addressing design weaknesses and enhancing product performance.
Through the systematic application of FMEA, VisionOptic demonstrates its commitment to
excellence in product design and manufacturing, ensuring that its eyewear products meet
the highest standards of quality, safety, and reliability.

THEORY:

"VisionOptic" is a leading eyewear manufacturer known for its innovative designs and high-
quality products. The company is committed to delivering eyewear that not only meets
customer expectations but also exceeds industry standards for safety and reliability.

Product Design Process: During the product design phase for a new line of eyewear,
VisionOptic incorporates Failure Modes and Effects Analysis (FMEA) to systematically assess
and mitigate potential failure modes. The FMEA process is integrated into the overall design
process to ensure that all identified risks are addressed effectively.

Implementation of FMEA:

1. Identification of Failure Modes:

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 Cross-functional teams consisting of design engineers, quality assurance

specialists, and manufacturing experts collaborate to identify potential failure
modes associated with eyewear design.

 Failure modes are categorized based on their potential impact on product

performance, safety, and customer satisfaction. Common failure modes may
include lens scratches, frame breakage, hinge malfunction, and misalignment.

2. Assessment of Failure Effects:

 For each identified failure mode, the team assesses the potential effects on
product functionality, safety, and customer experience.

 Effects are categorized based on severity, ranging from minor inconveniences

to serious safety hazards. The team considers potential consequences such as
impaired vision, discomfort to the wearer, and reputational damage to the
brand.

3. Determination of Failure Causes:

 Root causes contributing to each failure mode are identified through detailed
analysis and testing. Causes may include material defects, design flaws,
manufacturing errors, or environmental factors.

 Understanding the underlying causes enables the team to implement

targeted corrective actions to prevent similar failures in the future.

4. Risk Prioritization and Mitigation:

 Using a risk prioritization matrix, the team evaluates and prioritizes failure
modes based on their severity, occurrence likelihood, and detectability.

 Mitigation strategies are developed to address high-priority failure modes,

focusing on preventive measures such as design modifications, material
selection improvements, and manufacturing process enhancements.

5. Implementation of Corrective Actions:

 The team implements identified corrective actions and validates their

effectiveness through rigorous testing and validation procedures.

 Continuous monitoring and review processes are established to track the

implementation progress and ensure sustained improvement in product
quality and reliability.

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Summary :

Summary: Failure Modes and Effects Analysis (FMEA) in Eyewear Product Design

In the context of eyewear product design, Failure Modes and Effects Analysis (FMEA) serves
as a proactive risk management tool to identify and mitigate potential failure modes that
could compromise product safety, quality, and performance. This systematic approach is
integrated into the product design process of "VisionOptic," a leading eyewear
manufacturer, to ensure that their products meet and exceed customer expectations while
adhering to industry standards.

The implementation of FMEA involves several key steps:

1. Identification of Failure Modes: Cross-functional teams collaborate to identify

potential failure modes associated with eyewear design, considering factors such as
lens scratches, frame breakage, hinge malfunction, and misalignment.

2. Assessment of Failure Effects: Each identified failure mode is assessed for its
potential impact on product functionality, safety, and customer experience. Effects
are categorized based on severity, ranging from minor inconveniences to serious
safety hazards.

3. Determination of Failure Causes: Root causes contributing to each failure mode are
identified, enabling the team to implement targeted corrective actions to prevent
similar failures in the future.

4. Risk Prioritization and Mitigation: Using a risk prioritization matrix, high-priority

failure modes are identified and addressed through preventive measures such as
design modifications, material selection improvements, and manufacturing process
enhancements.

5. Implementation of Corrective Actions: Identified corrective actions are

implemented and validated through rigorous testing and validation procedures,
ensuring sustained improvement in product quality and reliability.

Through the systematic application of FMEA, VisionOptic achieves several objectives:

 Proactively identify and mitigate potential failure modes, enhancing product

reliability and safety.

 Improve customer satisfaction and brand reputation by delivering high-quality

eyewear products that exceed industry standards.

 Minimize risks associated with product defects and recalls, reducing warranty claims
and liability costs.

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 INDUSTRIAL PRODUCT DESIGN

 Foster a culture of continuous improvement and innovation by systematically

addressing design weaknesses and enhancing product performance.

Overall, FMEA plays a crucial role in ensuring that VisionOptic's eyewear products meet the
highest standards of quality, safety, and reliability, thereby reinforcing their position as a
trusted leader in the eyewear industry.

Department of Robotics and Automation, BV(DU)COE, Pune Page 4