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FAILURE MODES AND EFFECTS ANALYSIS (FMEA)

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ABSTRACT

FMEA stands for Failure Modes and Effects Analysis. It is also known as Failure Modes Effects and Criticality Analysis (FMECA). It is a method of predicting potential failure modes in product design and manufacturing and leads to safer, better quality products.

Applied correctly a FMEA should be performed by a team with experience in the product area and specific skills in design, manufacturing and service. From the initial design concepts, the team should brainstorm potential ways the product or its manufacturing process could fail, the likelihood of failure and its consequence. For each potential failure ratings are hence given for the likelihood of failure (occurrence) severity of failure (severity) and likelihood of such a failure being detected (detection). The product of these three numbers forms a risk priority number (RPN) which indicates any high risk failures so that preventative action can be taken.

This workshop will introduce the topic of Failure Modes and Effects Analysis (FMEA) and will give a general guidance in the application of this powerful prevention technique. The application of this technique is to identify critical parameters and support a company’s commitment to continually improve its products and service whenever possible. Upfront time spent in doing a comprehensive FMEA well, when product /process can be most easily and inexpensively implemented, will alleviate late change crises. This process is disciplined and interactive, and never ending. Many industries, such as Automotive, Aerospace, Health Care, Medical, Chemical, etc., require FMEAs as a preventive tool.

FMEA WORKSHOP -OUTLINE

General Information
Overview
History
Manual Format
FMEA Implementation

DESIGN AND PROCESS FMEAs

-Identification requirements
-Core team
-Potential Failure Modes
-Potential Effects of Failure
-Severity - suggested evaluation criteria
-Potential Causes/Mechanisms of Failure
-Occurrence - suggested evaluation criteria
-Current Design controls
-Detection - suggested evaluation criteria
-Risk Priority Number - RPN
-Recommended Actions
-Actions Taken
-Resulting RPN
-Follow-up
-Identification of Critical Characteristics
-Potential problems with preparing an FMEA
-Completed DESIGN FMEA example
-Completed PROCESS FMEA example

After this course, participants will be able to:

-Understand how to develop the Design FMEA (including a review of documentation requirements)
-Evaluate and classify potential failure modes
-Define evaluation, detection criteria and Risk Priority Numbers
-Examine Process FMEAs
-Determine the need of a complete team effort
-Discuss the analysis of potential failures
-Review evaluation criteria
-Define the corrective action process for eliminating potential failure modes


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