Failure Modes and Effects Analysis (FMEA): 9 aéx/2— ¢ A design tool used to: oCritique adesign oldentify potential failures and their effects on the product. oReduce the incidence of problems olnexpensively implement changes. (Pareto 80/20 rule). ¢ Can be used on a component or an entire product. It is completed on a standard FMEA form. x 20% of He wok. 18 Be af Ligue of fae ~ 3% 0 Conttng 20% off wo wnseoanetyPotential Failure Mode: Failure mode is the manner ia which a system, subsystem, or component could potentially fail to meet the design requirements. Examples include: * Cracked © Lonsened * Leaking * Deformed © Worn Sticking © Fractured * Binding © Slipping Potential Effect(s) of the Feilure: Potential effeet(s) of the failure is defined as the consequence of the failure as perceived by the customer. Examples include: # Noise © Poor appearance @ Poor fit © Loss of power © Odor Loss of function © No output © Excess friction Erratic operation Loss of fluid © Sezure * Deterioration of neighboring, ‘component Severity (S): Severity is defined as an assessment of the seriousness of the failure on the system performance. Rark each effect: 1 - Minor effect on sysem performance 3 - Slight customer anroyance 6 - Some customer dissatisfaction 8 - High degree of customer dissatisfaction 10 - Product endangers the customerPotential Cause(s) of the Failure: Potential cause(s) of the failure are design weaknesses that can resut in the failure mode, Exanples include: Insufficient * Tolerance © Insufficient material thickness build-up material strength * Vibration * Interference * Overload © Contamination © Insufficient bond» Insufficient coating/plating ‘© Temperature © Environment * Electric power (snow, salt water) interrupt Occurrence: Occurrence refers to the likelihood or frequency of the failure moce occurring due to its related cause, Rank each effect: 1 - Failure is unlikely (0) 3 - Isolated cases (1 in4000) 6 - Occasional failure (1 in 80) 8 - Frequent failures (1 in 20) 10 ~ Inevitable failures (1 in 2) Design Controls: Des gn controls are lab tests, field tests, mathematical studies, and other inspection that can be implemented, yyDetection (D): Detection refers to the ability of design controls to detect potential failure modes. Rank the effectiveness of the design control: 1 - Design control will almost certainly detect a defect 3 - Design control has a good chance to detect a defect. 5 - Design control may detect a defect. 7 - Design control has a poor chance of detecting a defect. 9 - Design control probably will not detect a defect, 10 - Design control will not detect a defect. Risk Priority Number (RPN): The risk priority number is used to prioritize product concerns. It is computed as the product of the severity, occurrence and detection values. The greater the number, the greater the concern. The numbers, all relative to each other, will determine what to work on firs. Recommended Actions: Recommend actions are suggestion to reduce the RPN number. Examples include: © Reliability tests © Fisld tests © Advanced design calculations. oYDesisn Team: Design FMEA Date: Product Teen or | Potential | Potential [S| Potential | O] Design ]D] PN | Recommended] Fanctca | Failure | Effects) | | Cose(s) | | Controls ‘Actions Mode ann [Tan aA oA aN an | Tan A a | a A man [an | aan AN awn [a A ARR Laan Donn] an ony a a AN aA | Tan Tay AN ae OS [as [Pan ay aw arn | an aA aaa Tas ay Definitions for the FMEA Form Item/Function: Function is defined as the action the system or component is de igned to perform Examples include: Positionlocate Supportireinforce Seal in/out >Protect/shield Vent Retain/attach/secure Lubricate Isolate Transfer/transport Provide signal