INTERNATIONAL UNIVERSITY
DEPARTMENT OF INDUSTRIAL & SYSTEM ENGINEERING
FAILURE MODE EFFECT ANALYSIS
(FMEA)
 Course: Quality
Management
 Instructor: DƯƠng Võ NhỊ
Anh
CONTENT
Objective
Basic concepts
Methodology
Case study
Reference
OBJECTIVE
Understand the concept of Failure Mode
Affect Analysis methodology.
Apply the FMEAs in the real cases.
BASIC CONCEPTS
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What is FMEA ?
Application of FMEA
Application of FMEA example
When to conduct an FMEA ?
BASIC CONCEPTS
What is FMEA ?
▪ FMEA stand for FAILURE MODE &
EFFECTS ANALYSIS.
▪ FMEA is a systematic approach to analyzing
the causes and effects of product failures.
BASIC CONCEPTS
Application of FMEA
▪ In Manufacturing
▪ In Design
▪ In Software
▪ ...
 Improve quality, reliability and
safety of product/service/process.
 Reduce system development time
and cost.
 Reduce the occurrence of failures.
 Maximize the profit.
BASIC CONCEPTS
Application of FMEA example
▪ Manufacturing: A manager is responsible for moving a manufacturing
operation to a new facility. He/she wants to be sure the move goes as
smoothly as possible and that there are no surprises.
▪ Design: A design engineer wants to think of all the possible ways a
product being designed could fail so that robustness can be built into
the product.
▪ Software: A software engineer wants to think of possible problems a
software product could fail when scaled up to large databases. This is a
core issue for the Internet.
BASIC CONCEPTS
When to conduct an FMEA ?
▪ Early in the process improvement investigation
▪ When new systems, products, and processes are being designed
▪ When existing designs or processes are being changed
▪ When carry-over designs are used in new applications
▪ After system, product, or process functions are defined, but before
specific hardware is selected or released to manufacturing
METHODOLOGY
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Types of FMEA
Procedure
Specific parameter
The FMEA form
The logical relationship between FMEA elements
METHODOLOGY
 DESIGN (DFMEA)
Improve the design of the subsystem or
component in order to reduce risk of
failures.
Types of FMEA
 PROCESS (PFMEA)
Improve the design of the manufacturing
process in order to reduce risk of
failures.
 SYSTEM (SFMEA)
Improve design of the whole of system in
order to reduce risk of failures.
METHODOLOGY
Procedure
STEP
1
Review the process or product.
2
Brainstorm potential failure modes.
3
List potential effects of each failure mode.
4
Assign a severity ranking for each effect.
5
Assign an occurrence ranking for each failure mode.
6
Assign a detection ranking for each failure mode and/or effect.
7
Calculate the risk priority number for each effect.
8
Prioritize the failure modes for action.
9
Take action to eliminate or reduce the high-risk failure modes.
10
Calculate the resulting RPN as the failure modes are reduced or eliminated.
METHODOLOGY
Specific parameter
S = Severity Rating - To measure the level of affection when
some failures occur in the process (product). The severity
rating also scales goes from 1 to 10.
METHODOLOGY
Specific parameter
O = Occurrence Rating - That is the probability that the
failure in process (product) appear. The rating scale is from 1
to 10.
METHODOLOGY
Specific parameter
D = Detection Rating - To express the ability of identifying any
potential failure to occurring. This scaling is also from 1 to 10.
METHODOLOGY
Specific parameter
RPN = Risk Priority Number
• Is the product of the severity, occurrence, and detection scores.
• To determine failure mode probability
• To make some actions on the design
METHODOLOGY
The FMEA form
METHODOLOGY
The FMEA form
CASE STUDY
CASE STUDY
 Step 1: Review the process or product
• Process: Adding milk to cake mix
• Type of FMEA: Process FMEA
CASE STUDY
 Step 2: Brainstorm potential failure modes
• Wrong amount of milk
• Flour still in measuring cup
CASE STUDY
 Step 3: List potential effects of each failure mode
• Cake too dry or too soggy
• Lumps in cake
CASE STUDY
 Step 4: Determined severity
CASE STUDY
 Step 5: Determined occurrence
CASE STUDY
 Step 6: Determined detection
CASE STUDY
 Step 7: Calculation the risk priority number of each effect
CASE STUDY
 Step 8,9: Taken action to reduce RPN
CASE STUDY
 Step 10: Calculating the resulting RPN
REFFERENCE
(1) Robin E. McDermott - Basic of FMEA – Second
Edition.
(2) Russell & Taylor – Operations Management – Seventh
Edition
(3) Failure and Mode & Effects Analysis - IEEE
THANK YOU FOR YOUR LISTENING !!!
Student’s name
Student’s ID
Tasks
Võ Phúc Thịnh ( Leader )
IEIEIU14044
*Basic Concept
*Methodology
*Case study
Nguyễn Xuân Trường
IEIEIU14049
*Presentation
*Slide
Nguyễn Nhật Quang
IEIEIU14086
*Presentation
*Slide
Đỗ Hoàng Lân
IEIEIU14021
*Objective
Nguyễn Lâm Gia Bảo
IEIEIU14083
*Basic Concept