Failure Mode

Effective Analysis
(FMEA)
Failures

•severity ,
•probability of occurrence ,
•and probability of detection
FMEA
 Failure
Mode and Effect Analysis (FMEA) is a
systematic method of identifying and
preventing product and process problems
before they occur.
 FMEAs are focused on preventing defects,
enhancing safety, and increasing customer
satisfaction.
FMEA
 FailureMode Effect Analysis (FMEA) is an
analytical technique that goes in for
combining Technology and Experience of
people to identify foreseen failures in a
product or process and planning to eliminate
the Failure
FMEA
 FMEA includes
 Recognize and evaluate the potential failure of a
product / Process and its effects
 Identify
actions that could eliminate / reduce the
chance of potential failures
 Document the process
Types of FMEA
 Process FMEA
 Equipment FMEA
 Environmental FMEA
 Service FMEA
 Design FMEA
 MaintenanceFMEA
 Concept FMEA
 System FMEA – Combination of Process and
Design
Design FMEA
 Used in the design process by identifying
known and foreseeable failure modes and
ranking failures according to their impact on
the product.
 It
reduces development time and cost of
manufacturing process
Process FMEA
 Itis used to identify potential process failure
modes by ranking failures and establishing
priorities, and its impact on the Internal or
external customers.
RELIABILITY
 Reliability
is defined as the probability that the
product will perform as per the expectation for
a certain period of time, under the given
operating conditions, and the given set of
product performance characteristics.
FAILURE RATE
 Majority of products flow a very familiar
pattern of failure.
 When no information is known, except the
failure rate with constant period, reliability can
be expressed as
𝑡
−
 Rt = 𝑒 −𝑡𝜆 = 𝑒 𝜃

 Rt – Reliability 𝜆 – failure Rate 𝜃 – mean time

to failure
 t = Specified time without Failure
FAILURE RATE
𝜆 – failure Rate
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹𝑎𝑖𝑙𝑢𝑟𝑒𝑠
𝜆 =
𝑡𝑜𝑡𝑎𝑙 𝑈𝑛𝑖𝑡 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐻𝑜𝑢𝑟𝑠

 or
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹𝑎𝑖𝑙𝑢𝑟𝑒𝑠
𝜆 =
𝑈𝑛𝑖𝑡 𝑇𝑒𝑠𝑡𝑒𝑑 𝑋 𝑁𝑜 𝑜𝑓 𝐻𝑜𝑢𝑟𝑠 𝑡𝑒𝑠𝑡𝑒𝑑
FAILURE RATE
 Mean Time To Failure (MTTF) (for non repairable
systems)
 MTTF = 1/ 𝜆
 Mean Time Between Failure (MTBF) for
repairable systems
 MTBF = T/R
 Where
T – Total Time
R – Number of Failures
Failure Rate Calculation
 Product has constant failure rate of 𝜆 = 0.002,
per hour . What is the reliability or survive during
the first 10 hours?
 Answer
Given 𝜆 = 0.002 / hour
t = 10 hours
Reliability is Rt = 𝑒 −𝑡𝜆 = 𝑒 −10 𝑋 0.002 = 0.9802 = 98%
Failure Rate Calculation
 The components in the system below are
exponentially distributed with the indicated
failure rates. Develop an expression for the
reliability of the system. What is the system
reliability at time = 100 hours ?
Failure Rate Calculation
 For the exponential distribution, the reliability
Rt = 𝑒 −𝑡𝜆
 Rt = 𝑒 −𝑡0.002 X𝑒 −𝑡0.002 X𝑒 −𝑡0.001 X𝑒 −𝑡0.003
 Rt = 𝑒 −𝑡0.008
 Rt = 𝑒 −100 𝑋 0.008 = 0.4493 = 45%
Failure Rate Calculation
A system has three components in series with
reliabilities 0.9, 0.7, and 0.5. What is the
reliability of the system ?
 Ans
RS = R1 x R2 x R3 x……x Rn\
RS = 0.8 x 0.7 x 0.5 = 0.28 = 28%
Documentation of FMEA
 Allow all involved engineers to have access to
others thoughts and to design and manufacture
products / services
 Which includes
 Block Diagram
 Shows different flows involved within the components
 Boundary diagram and Interface matrix
 Illustration
of the relationships among the subsystems,
assemblies, subassemblies with neighboring systems
 Parameter diagram
 Representation of input and output response
Stages of FMEA
 Specifying Possibilities
 Functions
 Possible failure modes
 Root Causes
 Effects
 Detection / Prevention
Stages of FMEA
 Quantifying Risks
 Probability of Cause
 Severity of Effect
 Effectiveness of Control to Prevent cause
 Risk Priority Number
Stages of FMEA
 Correcting High Risk Causes
 Prioritizing Work
 Detailing Action
 Assigning Action Responsibility
 Check Points on Completion
Stages of FMEA
 Re-evaluation of risk
 Recalculation of Risk Priority number
DFMEA Documentation

0.6. 0.6.
FMEA Procedure
 Describe the product or process functions
 Create a block diagram of product or process
 Complete the header on the FMEA form
 Enumerate the items that make up the
product / service
 Identify all potential failure modes
 List down each failure mode using technical
team
 Describe the effects of each failure modes
FMEA Procedure
 Identify all possible cause(s) of each failure mode
 Quantify the probability of occurrence
 Identify all possible existing controls to prevent
failure mode causes
 Detecting the failure modes
 Calculate RPN
 Determine the recommended actions
 Implement the defined actions
 Review the results
 Keep update the FMEA table