tOTAL QUALITY MANAGEMENT - FMEA, FINAL YEAR B.E.CS- PRESENTED BY DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGEMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNOLOGY (sit) CHENNAI

1. Failure Mode and
Effect Analysis
FMEA
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2. Meaning
• It is a preventive measure to
systematically display the
causes, effects and possible
actions regarding observed
failures.
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3. FMEA
an engineering technique use to
define, Identify and Eliminate
known and / or potential failures,
problems, errors which occur in
the system, design, process and
service “before they reach the
customer”.
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4. FMEA
is “before-the-event” action and is
done when existing
system/products/processes are
changed or redesigned
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5. FMEA
is a never-ending-process
improvement tool
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6. objective
• The objective of FMEA
is to anticipate failures and
prevent them from occurring.
FMEA prioritizes failures and
attempts to eliminate their
causes
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7. Types
• 1.System FMEA:-
• Analyzes components, subsystem
and main system in early stage of
design.
• 2.Design FMEA:-
• Analyzes the products/parts before
they are released to manufacturing.
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8. Types
• 3.Process FMEA:-
• Focuses on manufacturing and
assembly processes.
• 4.Service FMEA:-
• Analyzes services industry process
before they are released to impact
the customer. And
Equipment, Maintenance, Concept
FMEA,
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9. 5.Environmental FMEA
• However, in practice, all the
above types can be broadly
categorized into two types…..
• 1.Design FMEA involves the
analysis of the potential failures
of product or service due to
component or subsystem
unreliability.
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10. 2.Process FMEA -Manufacturing
process-The Process FMEA is
used primarily to identify areas of
critically of control and to emphasize
the design and more reliable process
– It may be noted the
equipment, service, and
environmental FMEA are slightly
modified
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11. Benefits
• Properly used FMEA provides several
benefits….
• Improve product/process reliability and
quality
• Increase customer satisfaction
• Early identification and elimination of
potential product/process failure modes
• Prioritize product/process deficiencies
• Capture engineering/organization knowledge
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12. .Document and track the actions taken
to reduce risk
.Provide focus for improved testing
and development
.Minimize late changes and associate
cost.
.Act as catalyst for team work and idea
exchange betweens.
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13. Inputs for preparation of FMEA
• 1.PEOPLE INPUTS:
• The FMEA methodology is a team effort.
The FMEA team should have assembly
engineer, manufacturing engineer,
materials engineer, quality engineer,
service engineer, suppliers and the
customers
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14. 2. DATA INPUTS: the data inputs
needed to prepare FMEA are product
and process specifications, reliability
data, customers priority data, process
variability data, process descriptions
and inspection data
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15. Stages or Methodology
• The FMEA methodology has four stages,
They are…
• Step 1. SPECIFYING POSSIBILITIES
• Functions
• Possible failure modes
• Root causes
• Effects
• Detection/Prevention
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16. 2.Step . QUANTIFYING RISK
.Probability of cause
.Severity of effect
.Effectiveness of control to prevent
cause
.Risk priority number (RPN)
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17. Step 3. CORRECTING HIGH RISK
CAUSES
.Prioritizing work
.Detailing action
.Assigning action responsibility
.Check points on completion
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18. Step 4. RE-EVALUATION OF RISK
Recalculation of risk priority
number
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19. Design FMEA Format
Item C O D Action Results
Potential Current Response &
Potential Potential S l c Design e R
Cause(s)/ Recommended Target S O D R
Failure Effect(s) of e a c Controls t P Action
Mechanism(s) Actions Complete E C E P
Mode Failure v s u e N Taken
Of Failure Date V C T N
s r c
Function Prevent Detect
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20. THANK YOU
FMEA
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