FEMA
Slide 1: Introduction to FMEA
• FMEA (Failure Modes and Effects Analysis) is a systematic approach to
identifying potential failures in a product or process before they happen.
• It helps teams predict, prevent, and minimize risks rather than reacting after failures
occur.
Exam Notes:
• Define FMEA
• Purpose: Identify failure risks, assess their impact, and implement preventive
measures.
• Proactive, not reactive approach.
Slide 2: Steps in the FMEA Process
1. Identify failure modes – What could go wrong?
2. Determine failure causes – Why might it happen?
3. Assess failure effects – What are the consequences?
4. Evaluate and prioritize failures
5. Take corrective actions
Exam Notes:
• List the steps in FMEA.
• Key focus: Prevent issues before implementation.
Slide 3: Categories of FMEA
• Design FMEA (DFMEA): Focuses on failures in the product’s design (e.g., material
selection, geometry, tolerances).
• Process FMEA (PFMEA): Focuses on failures in the manufacturing or operational
process (e.g., human error, machine failure, environmental factors).
Exam Notes:
• Two types: DFMEA (product design) & PFMEA (process execution).
• DFMEA deals with product malfunctions; PFMEA focuses on production issues.
Slide 4: DFMEA (Design FMEA)
• Used to identify risks in product design before production.
• Evaluates how material properties, system interactions, or environmental factors
can lead to failures.
• Uses Risk Priority Number (RPN) to measure risk levels.
Exam Notes:
• Purpose of DFMEA: Improve design reliability and safety.
• Factors: Material properties, tolerances, environmental stress.
• Importance of RPN: Helps prioritize risk reduction efforts.
Slide 5: PFMEA (Process FMEA)
• Identifies process-related failures (e.g., incorrect assembly, human errors, machine
breakdowns).
• Helps to improve quality control and reduce customer dissatisfaction.
• Uses detection rankings to assess if failure can be caught before reaching customers.
Exam Notes:
• Focuses on process failures, unlike DFMEA (product failures).
• Detection rankings assess how well failures can be caught.
Slide 6: 10 Steps of FMEA
1. Review the process (Flowchart, components).
2. Identify failure modes (Brainstorm potential failures).
3. List failure effects (Impact on customers/process).
4. Assign severity ranking (How serious is the failure?).
5. Assign occurrence ranking (How often will it happen?).
6. Assign detection ranking (How likely is it to be caught?).
7. Calculate RPN (Severity × Occurrence × Detection).
8. Develop action plan (Who will fix what?).
9. Implement improvements.
10. Recalculate RPN (Measure improvement).
Exam Notes:
• 10 steps must be memorized.
• RPN formula: Severity × Occurrence × Detection.
Slide 7: FMEA Scoring & Risk Priority Number (RPN)
• Severity (S): How dangerous is the failure?
• Occurrence (O): How often does it happen?
• Detection (D): How easily can it be detected?
• Formula: S × O × D = RPN
Exam Notes:
• RPN formula must be memorized.
• High RPN → High risk → Immediate action required.
Slide 8: Benefits of FMEA
• Helps create safer, more reliable designs and processes.
• Prevents costly failures and customer dissatisfaction.
• Provides systematic problem-solving and decision-making.
Exam Notes:
• Key benefits: Risk reduction, cost savings, reliability improvement.
• Used before launching new products or process changes.
