POTENTIAL FAILURE MODE
AND EFFECTS ANALYSIS
(PFMEA - Awareness)
Pre-Requisite Knowledge
• Minimum Qualification: Diploma Engineer
• Product Awareness training Completed
• Process flow diagram and Control plan training Completed
•Understanding of manufacturing and assembly operations
Programme Objectives
• Understand the activities involved in realization of new product
and processes
•Understand the role of FMEA’s
• Understand the linkages between designing the product and
developing process
Programme Overview
1. What is an FMEA
2. Types of FMEA
3. FMEA process
4. PFMEA Overview
5. Inputs for PFMEA
6. Understanding of the PFMEA format
7. Benefits
What is an FMEA?
• An FMEA is a disciplined analytical process
•An FMEA allow the team to anticipate failure and prevent
their occurrence in design and manufacturing
Concept
Identify ways the product or process can fail
Then plan to prevent those failure
Failure Mode Effects Analysis
A systematic group of activities intended to:
• Recognize potential failure(s) of a product and process
• Severity of effect of failure(s)
• Multi disciplined activity in “Product Realization Process”
• Rank potential Design and Process deficiencies
• Identify actions for eliminating Occurrence and Detection
• Document the process
• Guided by Internal & External Customer requirements
• Living Document throughout the Product Life Cycle.
• Should reflect the latest design level actions, including those
occurring after the start of production
TYPES OF FMEA
Types of FMEA
System FMEA Focus on interface and interaction among
•System
•Subsystem
•Environment
•Customer
Design FMEA Focus on potential failure modes and causes that
can occur due to design deficiencies and errors
Process FMEA Focus on potential failure modes caused by
process deficiencies
FMEA Process
FMEA PROCESS SEQUENCE
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
C O D
Sub system S I c Current e R. Action Results
Potential Potential e a Potential Cause (s)/ c controls t P. Recommended Responsibility
Function Failure effect(s) v s mechanism (s) u e N. action (s) & target Actions S O D RPN
Requirement Mode of failure s of failure r Prevention Detection c completion date taken
What How What can be done ?
are the bad
Effect(s)? is it ? - Design Change
What are the
Functions, - Process Change
Features or
Requirements
- Special Control
What can go wrong What How
? are the often - Change to
Cause(s)? does it standards
- No Function happen Procedures or
? Guides
- Partial/Over/ How can
Degradred this How good
Function be is this
prevented method at
- Intermittent and detecting it?
Function
- Unintended
Function
FMEA Process
FMEA Process
Cross Functional and Multilevel teams
• Across the Hierarchy : Operators,
Engineers, Senior Management
• Across Functions : Maintenance,
Production, Quality, R&D, VD, P&F
• Designated Team Leader
• Must be Empowered to implement
actions
FMEA Process
FMEA Process
• Develop a Process Flow diagram
• Process Flow diagram is representative of the process
as it truly is.
• Define the scope of the analysis
FMEA Process
FMEA Process
• Brainstorm each failure modes.
• Identify root causes.
• Define effects of failure mode.
• Determine how often failure modes occur.
• Determine current controls ability to detect.
FMEA Process
FMEA Process
Calculate Risk Priority Number (RPN) for each failure mode
RPN = Worst Severity X Most Frequent Occurrence X Worst ability to
Detect
• Severity is the rank associated with the most serious effect for a given failure
mode.
• Occurrence is the likelihood that a specific cause / mechanism of failure will
occur.
• Detection is the rank associated with the best detection control listed in the
process control.
FMEA Process
FMEA Process
Build Pareto on RPN No.
• Develop Countermeasure based on Pareto as per company
rule of RPN no not acceptable
• Plan for Counter Measure for them
• Subros RPN no beyond 100 is not acceptable
FMEA Process
FMEA Process
• Identify the control in place to prevent or detect
the cause or failure mode.
• Identify and implement continual improvement
actions
FMEA Process
Detail
Develop
Failure Mode Calculate Build
Recommended
Causes Risk Numbers Pareto Chart
Actions
Effects
• Evaluate effect of actions taken on process in terms of
severity, occurrence and detection.
• Recalculate RPN and reassess risk number.
• Reprioritize and repeat.
DFMEA
PFMEA
PFMEA Overview
1. The process FMEA supports manufacturing process development in
reducing the risk of failures by-
- Identifying and evaluating the process functions and requirements
- Identifying and evaluating potential product and process related failures
modes and the effects of the potential failures on process and customers
- Identifying the potential manufacturing or assembly process causes
2. Is used to anticipate failures and prevent their occurrences in manufacturing
processes
3. Always identify the ways the product or process can fail. Then Plan to
prevent those failures
INPUTS FOR PFMEA
Preparation of Process FMEA
The following documents are useful in preparing the process
FMEA
• - Process flow diagram
• - DFMEA
• - Customer specific special characteristics
• - Lessons learned from similar products
• - Team’s knowledge of the process
PFMEA FORMAT
Benefits
• Prevention better than cure
• Increase Probability of Detection
• Identify biggest contributor to failure and eliminate them
• Reduce probability of failure
• Built quality in product and process
THANKS
