FAILURE MODE AND EFFECT ANALYSIS

PART I HENRY JOHN NUEVA

Introduction to

Presented by:

Minimize the Risk of Failures And Improve Reliability

How to prevent a problem from occurring again in the future ?

How to minimize the risk of potential failure ?

How to produce an error free product or service ?

How to reduce the warranty cost ?

How to improve safety condition in the workplace ?

PROCESS DATA

DOCUMENTATIONOF PROCEDURES

COST SAVING

IMPROVEDESIGN

IMPROVEMENT

• Higher reliability • Better quality • Increase Safety

• Decrease development time and redesign cost• Decrease warranty cost • Decrease waste

• Develop• Research • Progress

PROCESS FMEA SYSTEM FMEA CONSTRUCTIONFMEA

HARDWAREFMEA

SOFTWAREFMEA

Analyzes procedures of the considered system Determines possible weaknesses in the production process. Examines the process related to error causes Process suitability, reliability and quality at an early stage. Design drawing like flowcharts are the basis

Explore the interaction of subsystems or components of the entire system. Aims to identify potential weaknesses, that could arise at the interaction of single components. Considers random and systematic failures during operations.

Makes early assessment of the manufacturing suitability of a product. Considers systematic failures during the construction phase. Possible breakdowns and errors that can occur on separate parts of the system are regarded and proactively avoided. Construction Plan are the basis.

Aims to analyze, evaluate and eliminate risks from the hardware and electronic fields.

Same purpose as Hardware FMEA, but for generated program codes.

FAILURE MODES

Any event which causes a Functional Failure.

Ways in which product, services or processes

can fail.

FAIL

URE

EFF

ECTS

DES

CRIP

TIO

NLOCAL EFFECT

NEXT HIGHER EFFECT

END EFFECT

(Failure effect as it applies to the item under analysis)

(Failure effect as it applies at the next higher indenture level)

(Failure effect at the highest indenture level or total system)

FMEA

The recommended Team Size should be between 4 to 6 person. However, the number of people varies by the number of areas affected by the FMEA.

SAM

PLE

FM

EA F

ORM

1Review the process. Check people involve with various responsibilities and level of experience

2Breakdown the system into components or sub-components

3Brainstorm potential failure modes and list potential effects

4Assign severity ranking for each effect and assign an occurrence and detection ranking for each failure mode

5Calculate the risk priority number (RPN) for each effect and prioritize the failure modes and take action to eliminate or reduce high-risk failure modes

Steps in conducting FMEA

STEP 1If the team is considering a

PRODUCT, then review the engineering drawing of the product.

See the actual product and operate it

If the team is considering a PROCESS/SERVICE, review the operation flowchart.

Physically walk through the process exactly as the process flows

STEP 2To prevent complexity and get

data clearly, use the following techniques in breaking down the system

Filtering Separating Grouping Isolating Other methods

STEP 3During brainstorming, the team

should focus on the different elements below and afterwards organize according to its classification.

People Material Equipment Resources Methods Etc.

STEP 3Information must be thorough

as it will feed into the of risk ranking

Take note of the following: One failure mode can have several

effects. Several failure modes could have one

The Team must determine the END-EFFECTeach failure mode has on the system. This means examining how each failure affects the entire system or facility.

STEP 4Use a 10-point scale with 1

being the lowest ranking and 10 as the highest is recommended but other related ways to assigning and ranking is also applicable.

The best method for determining the occurrence raking is to use Actual Data from the process in the form of failure logs.

STEP 5RPN methodology is a technique

for analyzing the risk associated with potential problems identified during FMEA.

RPN Calculation Benefits

1. Contribute in Risk Assessment 2. Compare components to determine

priority for corrective action

STEP 5Use the formula below in

calculating the Risk Priority Number (RPN)

RPN = Severity x Occurrence x Detection

(RPN = S x O s D)

SAMPLE RISK MATRIX