Failure Mode Effects Analysis

Proprietary Material of Duracell Global Business Management
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FMEA History and Types

History



50’ 60’ 70’ 80’ 90’
Fighter Plane Design Apollo Plan Automobile/Medical Instrument Micro-electronic QS9000, ISO9000
Recommended Action(s) Area/Individual Responsible & Completion Date Actions Taken
(Rev.) Action Results s e v o c c d e t S * O R P N
Proprietary Material of Duracell Global Business Management


Recommended to be Process Owner

Must be Empowered to implement actions Functional experts can be pulled in as needed Smaller “Core” group may be useful initially to provide framework.
Operator involvement is imperative at this step!
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Severity Rating
Severity Severity is a rating corresponding to the seriousness of an effect of a potential failure mode. No Effect Very Slight Effect Slight Effect Minor Effect Moderate Effect Significant Effect Major Effect Serious Effect Very Serious Effect Hazardous Effect 1 2 3 4 5 6 7 7 8 9 9 10 10 4 1 No effect on system or output performance or on subsequent processes. Customer will probably not notice the failure. Nuisance Fault noticed. Slight effect on output performance. Customer slightly annoyed. Nuisance fault obvious. Minor effect on output or process performance. Slight deterioration. Chronic nuisance fault. Moderate effect on performance. Customer dissatisfied. Nuisance repair required. Performance degraded but safe. Discomfort. Repair required. Non-vital part nonfunctional. Rework/Repairs necessary. Performance severely affected but safe. Dissatisfied customer. Subsystem inoperable. Equipment damaged. System inoperable but safe. Very dissatisfied customer. Potentially hazardous failure. Safety related but gradual failure. Hazardous failure. Safety related – sudden failure, Government regulation non-compliance. Proprietary Material of Duracell 13 Global Business Management

Types

DFMEA PFMEA
Proprietary Material of Duracell Global Business Management
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Process FMEA Form
Process Process Cell Size Cell Size Cell Chemistry Cell Chemistry
Proprietary Material of Duracell Global Business Management 10
Process FMEA Flow
Team Selection
Define Process
Detail Failure Mode Causes Effects
Calculate Risk Numbers
Failure Mode Effects Analysis (FMEA)
Abbr. Version
DTQS-NPQ
July 2000
FAILURE

What’s the failure

Failure class Failure occurrence

What’s the reason for failure

FMEA A systematic group of activities intended to:




Recognize the potential failure(s) of a product or process and the severity of effect of that failure(s). Identify critical characteristics. Rank order potential design and process deficiencies. Identify actions that can eliminate or reduce the chance of the potential failure from occurring and reaching the customer. Document the process.
Proprietary Material of Duracell Global Business Management
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FMEA Purpose

To eliminate the cause of failure …if this is not possible

reduce how often the failure occurs improve the ability to detect the failure before it reaches the customer
Potential cause(s) of Failure O c c Current Controls D e t S * O R P N
Page 1 of 1 Prepared by Page 1 of 1 Prepared by FMEA Date (Orig.) Date (Orig.) (Rev.) FMEA
Process Function Potential Failure Mode Potential Effect(s) of Failure S e v C l a s s
Process Responsibility FMEAProcess Responsibility Due Date FMEA Due Date FMEAFMEA Number Number
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Process FMEA Flow
Team Selection
Define Process
Detail Failure Mode Causes Effects
Calculate Risk Numbers
Build Pareto Chart
Proprietary Material of Duracell Global Business Management
Develop Recommended Actions
8
Process FMEA Flow
Team Selection
Define Process
Detail Failure Mode Causes Effects
Calculate Risk Numbers
Build Pareto Chart
Proprietary Material of Duracell Global Business Management
Develop Recommended Actions
9
Process FMEA
Team Selection

Cross Functional and Multilevel


Operators, Mechanics, Engineers, Leaders Team Leader Designated
Build Pareto Chart
Proprietary Material of Duracell Global Business Management
Develop Recommended Actions
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Process FMEA