Failure Mode & Effects Analysis

1. FAILURE MODE & EFFECTS ANALYSIS
(FMEA)
By Fahmi Ramadhan Putra
QC/Lab Supervisor
1

2. WHY PERFORM FMEA ?
Effective at identifying and correcting
process failure early on
Multiple choices for mitigating the risk
Lower cost solution
etc
2

3. WHAT IS FMEA ?
FMEA  proactive tool & quality method
that enables the identification & prevention
of process or product errors before they
occur
3

4. BENEFITS OF FMEA
 Early identification & elimination of process failure
 Improve product / process quality, reliability & safety
 Provides cutomer satisfaction
4

5. PROCEDURE TO MAKE FMEA SHEET
Identify the functions
of your scope
Identify the failure
mode
Identify the
consequences on
the process /
system
Give severity rating
for the
consequences
scale from ( 1 – 10)
Determine the
potential root
cause
Determine the
occurrence rating
for the cause scale
from (1-10)
Identify current
process control
Determine the
detection rating
scale from (1-10)
Calculate the risk
priority number
(RPN = Severity x
Occurrence x
Detection)
Make recommended
actions
As actions are
completed, make
new RPN
5
Source : http://asq.org/learn-
about-quality/process-analysis-
tools/overview/fmea.html

6. EXAMPLE OF FMEA
 Item : Cool the compound using cold water
 Core Team : Production & QC Team
 Responsibility : Production / Mixing Operator
 Prepared by : QC Supervisor
 FMEA Number : 654321
 FMEA Date : December 16th 2016
6
Valve position is
opened ( normal)
Valve position is closed
( potential failure)

7. EXAMPLE OF FMEA (CONTINUED)
7
PROCESS
FUNCTION
FAILURE MODE
POTENTIAL
IMPACT
SEVERITY POTENTIAL
CAUSE
OCCURENCE
DETECTION
MODE
DETECTION
Cool the
compound
using cold water
Cooling Water
Valve is not
opened
Compound is
not cooled 
low mooney /
low viscosity
10
Operator forget
to open the
cooling water
valve
5
QC Inspector
check the valve
position
1
RPN
RECOMMENDED
ACTION
RESPONSIBILITY
ACTION RESULT
SEVERITY OCCURENCE DETECTION RPN
50
Provide
preliminary check
sheet before
process
Mixing Operator 1 2 1 2

8. REMEMBER !!!
“ Anything that can go
wrong will go wrong “
(Murphy’s Law)
8

9. THANK YOU
9

10. REFFERENCES
 http://asq.org/learn-about-quality/process-analysis-
tools/overview/fmea.html
 https://www.isixsigma.com/tools-templates/fmea/quick-guide-
failure-mode-and-effects-analysis/
10