FMEA - FAILURE MODE AND

EFFECTS ANALYSIS
PHD PROGRAM
SUPPLY CHAIN AND OPERATION MANAGEMENT

Prepared by::
1. Ayman Muhammad Pasha Muhammad
2. Yasser Bin Haif Bin Saleh Al-mutairi
3. Abdel Monem Ayoub Abdel Monem
Ayoub
4. Anas Abu Al-saud Shazli, Muhareb
Donkul
Under Supervision of:
Dr. Mohamed Saad
Content
1. Overview of FMEA
2. Importance of FMEA
3. Steps in FMEA
4. Failure mode effects analysais (FMEA)
Template.
Overview of FMEA
Failure Mode and Effects Analysis (FMEA) provides a comprehensive
understanding of this important quality management tool. FMEA is a
systematic approach used to identify and prioritize potential failure
modes in a process or product, assess their impact, and develop
mitigation strategies to prevent or reduce the risks associated with
these failures. By conducting an FMEA, organizations can proactively
address potential issues, improve product quality, enhance reliability,
and ultimately increase customer satisfaction. The process typically
involves analyzing failure modes, their effects, and the likelihood of
detection, helping organizations prioritize their efforts and resources
effectively.
Importance of FMEA
The importance of Failure Mode and Effects Analysis (FMEA) lies in its ability to proactively
identify and address potential risks and failures in processes or products. By conducting an
FMEA, organizations can:

1. Prevent Failures: FMEA helps in identifying potential failure modes early in the design or
production stage, allowing for preventive measures to be implemented to avoid costly failures
later on.

2. Improve Quality: By systematically analyzing failure modes and their effects,

organizations can enhance product quality, reduce defects, and improve overall customer
satisfaction.

3. Enhance Reliability: FMEA helps in enhancing the reliability of products or processes by

addressing potential weak points and vulnerabilities that could lead to failures.
 Importance of FMEA
4. Cost Savings: Implementing FMEA can lead to cost savings by preventing failures,
reducing rework, and minimizing warranty claims or product recalls.

5. Risk Management: FMEA is an essential tool for risk management as it helps

organizations prioritize and focus on the most critical areas that could impact product
performance or customer satisfaction.

Overall, FMEA plays a crucial role in ensuring product quality, reliability, and customer
satisfaction while also helping organizations mitigate risks and improve their overall
business performance.
 Importance of FMEA
Emphasize the role of FMEA in risk management and prevention

Failure Mode and Effects Analysis (FMEA) plays a crucial role in risk management and
prevention in various industries and processes. Here are key points emphasizing its
significance:

1. Proactive Risk Identification: FMEA helps in proactively identifying potential failure

modes, their causes, and effects. By systematically analyzing risks, organizations can
anticipate and prevent failures before they occur.

2. Prioritizing Risks: FMEA allows organizations to prioritize risks based on their severity,
occurrence likelihood, and detectability. This helps in focusing resources on addressing high-
priority risks that could have the most significant impact.

3. Mitigation Strategies: Through FMEA, organizations can develop mitigation strategies

to reduce the likelihood of failures and their potential consequences. This proactive
approach minimizes risks and enhances overall process or product reliability.
Importance of FMEA
Emphasize the role of FMEA in risk management and prevention

4. Compliance and Standards: FMEA assists organizations in meeting regulatory requirements

and industry standards by identifying and addressing potential risks that could lead to non-
compliance. This ensures adherence to quality and safety regulations.

5. Continuous Improvement: FMEA fosters a culture of continuous improvement by encouraging

teams to regularly review and update risk assessments. This ongoing process helps in identifying
new risks, implementing preventive measures, and enhancing overall risk management practices.

6. Cost Savings: Effective risk management through FMEA can result in cost savings by
preventing failures, reducing downtime, minimizing rework, and avoiding costly recalls or customer
complaints.

In summary, FMEA is an essential tool for risk management and prevention as it enables
organizations to proactively identify, assess, and mitigate risks, ultimately leading to improved
reliability, quality, and operational efficiency.
Steps in FMEA
The Failure Mode and Effects Analysis (FMEA) process typically involves the following steps:

1. Define the Scope: Clearly define the scope of the analysis, including the process, system,
or product to be evaluated.

2. Assemble the Team: Form a cross-functional team with members from different areas of
expertise to ensure a comprehensive analysis.

3. Identify Potential Failure Modes: Brainstorm and list all possible ways in which the
process or product could fail.

4. Determine Potential Effects: Assess the potential effects or consequences of each

identified failure mode on the system, process, or end-users
Steps in FMEA
5. Assign Severity Ratings: Rate the severity of each potential failure mode based on its
impact if it were to occur.

6. Identify Causes and Mechanisms: Determine the root causes and mechanisms
behind each potential failure mode.

7. Assign Occurrence Ratings: Evaluate the likelihood or frequency of each failure mode
occurring.

8. Assess Current Controls: Review existing controls or measures in place to prevent or

detect failures.

9. Assign Detection Ratings: Rate the effectiveness of current controls in detecting or

preventing each failure mode.
 Steps in FMEA
10. Calculate Risk Priority Number (RPN): Calculate the Risk Priority Number by multiplying
severity, occurrence, and detection ratings for each failure mode.

11. Prioritize Actions: Focus on addressing high-risk failure modes with the highest RPN values
by developing action plans to mitigate risks.

12. Implement Action Plans: Implement preventive actions to reduce the likelihood of failures
and corrective actions to address existing issues.

13. Monitor and Review: Regularly monitor the effectiveness of implemented actions, review the
FMEA periodically, and update it as needed to ensure continuous improvement.

Following these steps systematically helps organizations identify potential risks, prioritize actions,
and improve processes or products to enhance quality, reliability, and customer satisfaction.
 results after
action

Detection
Occurren
Severity
Potential Potential Potential Current Responsibility

RPN
Process Recommended
Failure Effect(s) of Failure Process and Target
Function Action(s)
Mode Failure Causes Controls Completion Date

Occ

Sev
Det

RPN
Regular
Incomplete
Drill Blind Drill bit Dull or worn drill inspection and Use sharp drill bits,
1 or damaged 5 3 4 60 Operator 2024-05-10 1 4 5 20
Hole breakage bit replacement of monitor wear regularly
hole
drill bits

Training and
Misalignmen guidelines for Provide clear
Drill Blind Incorrect hole Supervisor 2024-05-
2 t or incorrect 3 Operator error 2 proper hole 5 30 instructions, training for 2 5 3 30
Hole depth alignment and 05
settings operators
depth settings

Regular
Regular maintenance,
Drill Blind Machine Unable to Mechanical maintenance, Maintenance team
3 8 1 9 72 inspection, and 1 7 6 42
Hole malfunction drill holes failure inspection, and 2024-05-15
lubrication
lubrication

Adequate coolant Improve coolant flow,

Drill Blind Chip Poor chip Inadequate
4 4 4 flow and regular 7 112 implement regular chip Operator 2024-05-12 3 9 3 81
Hole accumulation evacuation coolant flow
chip removal removal
About the FMEA table and the columns:

Item/Function: This column identifies the specific item or function being analyzed. In the case of the
Drill Blind Hole project, it refers to the drill blind hole process.

Potential Failure Mode: This column lists the potential ways in which the item or function could fail.
For example, in the case of the Drill Blind Hole project, potential failure modes could include drill bit
breakage, incorrect hole depth, machine malfunction, or chip accumulation.

Potential Failure Effects: This column describes the consequences or effects that would occur if the
potential failure modes were to happen. For instance, incomplete or damaged holes, inaccurate hole
depths, inability to drill holes, or poor chip evacuation.

Potential Failure Causes: This column identifies the underlying factors or causes that could lead to
the potential failure modes. Examples of potential failure causes for the Drill Blind Hole project might
include dull or worn drill bits, operator error, mechanical failure, or inadequate coolant flow.

Current Process Controls: This column outlines the existing controls or measures that are currently
in place to prevent or mitigate the potential failure causes. It describes the steps, procedures, or
practices implemented to reduce the likelihood or severity of failures. For example, regular inspection
and replacement of drill bits, training and guidelines for proper alignment and depth settings, regular
maintenance, inspection, and lubrication, or ensuring adequate coolant flow and regular chip removal.
About the FMEA table and the columns:

Occurrence: This column rates the likelihood or frequency of the potential failure mode occurring on a
scale from 1 to 10, with 1 being highly unlikely and 10 being highly likely.

Detection: This column rates the ability to detect or identify the potential failure mode before it leads
to adverse effects on a scale from 1 to 10, with 1 being highly detectable and 10 being difficult to
detect.
Severity: This column assesses the potential severity or impact of the failure mode's effects on a scale
from 1 to 10, with 1 being minor consequences and 10 being catastrophic consequences.

RPN (Risk Priority Number): This column is calculated by multiplying the Occurrence, Detection, and
Severity ratings together. It helps prioritize the potential failure modes based on their overall risk level.

Recommended Actions: This column suggests actions or measures that should be taken to reduce
the risks associated with the potential failure modes. It includes specific steps or improvements to
prevent or mitigate failures.
About the FMEA table and the columns:

Responsibility: This column assigns the individuals or teams responsible for implementing the
recommended actions.

Response Date: This column specifies the date by which the recommended actions should be
completed or implemented.

Occurrence after Actions, Detection after Actions, Severity after Actions, RPN after Actions:
These columns represent the ratings for occurrence, detection, severity, and RPN after the
recommended actions have been implemented. It helps assess the effectiveness of the actions in
reducing the risks
Risk Assessment Criteria Table:
Severity
Rating Severity Description

Negligible impact on safety, quality, or operation. Easily correctable with minimal effort or
1-2 Negligible
resources.

3-4 Minor Minor impact on safety, quality, or operation. Correctable with moderate effort or resources.

Moderate impact on safety, quality, or operation. Correctable with significant effort or

5-6 Moderate
resources.

7-8 Major Major impact on safety, quality, or operation. Correctable with substantial effort or resources.

Critical impact on safety, quality, or operation. Immediate corrective action required. Possible
9-10 Critical
safety hazards or severe consequences.
Risk Assessment Criteria Table:
Occurrence
Rating Occurrence Description

Failure mode is highly unlikely to occur. Very rare circumstances or conditions

1-2 Highly Unlikely
would lead to its occurrence.

Failure mode is unlikely to occur. It may occur under specific conditions or

3-4 Unlikely
circumstances.

Failure mode has a moderate chance of occurring. It may occur periodically or

5-6 Possible
under certain conditions.

Failure mode is likely to occur. It may occur frequently or consistently under

7-8 Likely
normal operating conditions.

Failure mode is highly likely to occur. It is expected to occur regularly or

9-10 Highly Likely
consistently under most operating conditions.
Risk Assessment Criteria Table:
Detection
Ratin
Detection Description
g

1-2 Highly Effective Failure mode almost always detected through routine inspections, tests, or monitoring.

3-4 Effective Failure mode usually detected through regular inspections, tests, or monitoring.

5-6 Moderately Effective Failure mode occasionally detected through sporadic inspections, tests, or monitoring.

7-8 Ineffective Failure mode rarely detected, even during inspections, tests, or monitoring.

Failure mode not detected at all or detected only after significant consequences or
9-10 Highly Ineffective
failures occur.
THANK
S