Failure mode and effects analysis (FMEA)—also "failure modes", plural, in many publications—was one of the first highly structured, systematic techniques for failure analysis. It was developed by reliability engineers in the late 1950s to study problems that might arise from malfunctions of military systems. An FMEA is often the first step of a system reliability study. It involves reviewing as many components, assemblies, and subsystems as possible to identify failure modes, and their causes and effects. For each component, the failure modes and their resulting effects on the rest of the system are recorded in a specific FMEA worksheet. There are numerous variations of such worksheets. An FMEA can be a qualitative analysis.

1. FMEA
(FAILURE MODE EFFECTS ANALYSIS )
Presented by :
Soumyajit Bhuin

2. WHAT IS FMEA ?
 Systematic method of identifying and
preventing system.
 Focused on preventing problems,
enhancing safety, and increasing
customer satisfaction.
 Ideally, FMEA’s are conducted in the
product design or process development
stages.

3. HISTORY OF FMEA
First used in the 1960’s in the
Aerospace industry during the Apollo
missions.
In 1974, the Navy developed MIL-STD-
1629 regarding the use of FMEA.
In the late 1970’s, the automotive
industry was driven by liability costs to
use FMEA.
Later, the automotive industry saw the
advantages of using this tool to reduce
risks related to poor quality.

4. WHY DO A FMEA ?
 Preventing problems is cheaper and easier than
cleaning them up.
 Some things are too risky or costly to incur
mistakes.
 ISO requirement-Quality Planning
 “ensuring the compatibility of the design, the
production process, installation, servicing,
inspection and test procedures, and the
applicable documentation”

5. TYPES OF FEEA

6. FMEA INPUTS AND OUTPUTS
 C&E Matrix
 Process Map
 Process History
 Procedures
 Knowledge
 Experience
List of actions to
prevent causes or
detect failure
modes
History of actions
taken
FMEA
Input
Output

7. RISK ASSESSMENT FACTORS
 Severity:
 Definition: assessment of the seriousness of the
effect(s) of the potential failure mode on the next
component, subsystem, or customer if it occurs
 Severity applies to effects.
 A number from 1 to 5, depending on the severity of the
potential failure mode’s effect
1 = no effect 5 = maximum severity

8. RISK ASSESSMENT FACTORS (COUNT.)
 Probability of occurrence (O):
 A number from 1 to 5, depending on the likelihood of the
failure mode’s occurrence.
1 = very unlikely to occur.
5 = almost certain to occur.
 Probability of detection (D):
 A number from 1 to 5, depending on how unlikely it is
that the fault will be detected by the system responsible
(design control process, quality testing, etc.)
1 = nearly certain detention
5 = impossible to detect

9. RISK PRIORITY NUMBER (RPN)
 RPN is the product of the severity, occurrence, and
detection scores.
Severity Occurrence Detection RPN
RPN will be a number between 1 (virtually
no risk) and 125 (extreme risk).

10. LIMITATIONS
 Employee training requirements
 Initial impact on product and manufacturing
schedules
 Financial impact required to upgrade design,
manufacturing, and process equipment and tools

11. Thank You 