"Failure Modes and Effect Analysis of S - Type Nozzle": A Project On

A
Project on
“Failure Modes and Effect Analysis
of S – type Nozzle”
The above topic is selected on the basis of the following :
FMEA Defined
What is Failure Modes & Effects Analysis?
• A FMEA is a systematic method to:
1. Recognize, evaluate, and prioritize (score)

potential failures and their effects
2. Identify actions which could eliminate or reduce
the chance of potential failure occurring
3. Document and share the process.
• FMEA generates a living document that can be used to anticipate and
prevent failures from occurring.
 Evaluating design validation plan (design FMEA) or current control plan

(process FMEA).
What is FMEA ?
• FMEA is a tool that allows you to:
– Prevent System, Product and Process problems
before they occur
– Reduce costs by identifying system, product and
process improvements early in the development
cycle
– Create more robust/reliable processes
– Prioritize actions that decrease risk of failure
– Evaluate the system, design and processes from a
new vantage point
What Can Go
Wrong?
What Is A Failure Mode?
• A Failure Mode is:

– The way in which the component, subassembly,
product, input, or process could fail to perform its
intended function
• Failure modes may be the result of upstream
operations or may cause downstream operations to fail
– Things that could go wrong
5
What Is Effects Analysis?
• “Effects analysis” refers to studying the

consequences of those failures.
• The analysis is prioritized acc. to

– How serious their consequences are
– How frequently they occur
– How easily they can be detected
Learning Objectives
• To understand the use of Failure Modes Effect Analysis
(FMEA)
• To learn the steps to developing FMEAs
• To summarize the different types of FMEAs
• To learn how to link the FMEA to other Process tools
• Uncover problems with the product that will result in
safety hazards, product malfunctions or shortened
product life.
7
Why to use FMEA ?
 Methodology that facilitates process improvement
 Identifies and eliminates concerns early in the development of a process
or design
• Preventing problems is cheaper and easier than cleaning them up.
• ISO requirement-Quality Planning
– “ensuring the compatibility of the design, the production process,
installation, servicing, inspection and test procedures, and the
applicable documentation”
• Ensures that all conceivable effects on operational success have been

considered.
Why Use FMEA -(continued)
• Improves the quality, reliability and safety of products and
processes in a proactive manner
• Helps to increase customer satisfaction, by proactively addressing
failures that keep us from meeting critical customer requirements
in processes or products
• Reduces product development timing and cost
• Reduces operational risk
• Documents and tracks actions taken to reduce risk; Prioritize
areas of focus.
Benefits
• Identify potential and known failures
• Reduce the number of engineering changes
• Reduce product development time
• Lower start-up costs
• Greater customer satisfaction
• Increased cooperation and teamwork between various functions
• Continuous improvement
• cost effective tool for maximizing and documenting the collective
knowledge, experience, and insights of the manufacturing community
• Contributes to improved designs for products and processes.
– Higher reliability
– Increased safety
Types of FMEA
FMEA Process
2
1 Start with the For each step,
process map brainstorm potential
failure modes and
effects
Determine
severity
Determine the
3 potential causes to Determine
each failure mode likelihood of
occurrence
Determine
4 Evaluate current detectability
controls
5
6
Identify actions Determine RPN

Calculations
Risk Priority Number
The Risk Priority Number (RPN) identifies the greatest areas

of concern.
RPN is the product of:
(1) Severity rating

(2) Occurrence rating
(3) Detection rating
Severity X Occurrence X Detection = RPN

Calculations of FMEA Variables
• Severity
– A customer rating corresponding to the seriousness of an effect of a potential
failure mode. (scale: 1-10. 1: no effect on the customer, 10: hazardous effect)
• Occurrence
– Frequency with which a given cause occurs and
creates failure modes. (scale: 1-10. 1: failure unlikely, 10: failures certain)
• Detection
– A rating corresponding to the likelihood that the detection methods or current
controls will detect the potential failure mode before the product is released for
production for design, or for process before it leaves the production facility.
(scale: 1-10. 1: will detect failure, 10: almost certain not to detect failures)
FMEA of a S-type Nozzle
• A nozzle is a device designed to control the direction or characteristics of
a fluid flow (especially to increase velocity) as it exits (or enters) an enclosed
chamber or pipe.
• A nozzle is often a pipe or tube of varying cross sectional area, and it can be used to
direct or modify the flow of a fluid (liquid or gas). Nozzles are frequently used to
control the rate of flow, speed, direction, mass, shape, and/or the pressure of the
stream that emerges from them. In a nozzle, the velocity of fluid increases at the
expense of its pressure energy.

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A

• A FMEA is a systematic method to:

1. Recognize, evaluate, and prioritize (score)

 Evaluating design validation plan (design FMEA) or current control plan

What Is A Failure Mode?

• A Failure Mode is:

• “Effects analysis” refers to studying the

• The analysis is prioritized acc. to

• Ensures that all conceivable effects on operational success have been

Identify actions Determine RPN

The Risk Priority Number (RPN) identifies the greatest areas

(1) Severity rating

Severity X Occurrence X Detection = RPN

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