FAILURE MODE AND Apparel

Quality
EFFECT ANALYSIS Management
 INTRODUCTION

 Failure modes and ef fects analysis (FMEA) is a step -by -step

approach for identifying all possible failures in a design, a
manufacturing or assembly process, or a product or service.

 “Failure modes” means the ways, or modes, in which

something might fail. Failures are any errors or
defects, especially ones that af fect the customer, and can be
potential or actual.

 “Ef fects analysis” refers to studying the consequences of

those failures.
 INTRODUCTION

 Failures are prioritized according to how serious their

consequences are, how frequently they occur and how easily
they can be detected. The purpose of the FMEA is to take
actions to eliminate or reduce failures, starting with the
highest-priority ones.

 Failure modes and ef fects analysis also documents current

knowledge and actions about the risks of failures, for use in
continuous improvement. FMEA is used during design to
prevent failures. Later it‟s used for control, before and during
ongoing operation of the process. Ideally, FMEA begins during
the earliest conceptual stages of design and continues
throughout the life of the product or service .
 T YPES OF FMEA

System FMEA: After completion of all equipment and design, a

method used to make the most favorable analysis and the flow
of sub-systems such as manufacturing and quality assurance.
FMEA system focuses on the different types of potential errors
that cause disturbances in the system. It examines system
interaction with other systems and sub-elements.

Design FMEA: It is an analytical technique, which all possible

types of errors that may arise and also their respective causes
are addressed and resolved by it. Design FMEA creates a
reference to provide additional information about design
requirements, evaluation of alternatives, and types of errors that
may occur in processing system and also their results to consider
the design/ development process, and planning of the full and
effective design and test development programs . Design FMEA is
a method of analyzing the design in order to determine the weak
points or any critical situation that can do more harm
on, especially product reliability and / or safety.
 T YPES OF FMEA

Process FMEA: It is an analytical technique that provides

consideration and resolution of all possible problems that may
be taken into account during the creation of the product. The
purpose of FMEA process is to take measures for identifying and
correcting weaknesses in the production process . Moreover, it
can be used to analyze manufacturing and assembly processes.

Ser vice FMEA: It is the method which is applied with

coordination of production quality assurance (QA) and marketing
in order to improve the customer service. It helps to analyze the
defects in the organization. It indicates that determination of
priority between the activities of the organization and
workflow, and system and process analysis in an efficient way
and identifies and control errors on the process of carrying out
plans
 WHEN TO USE FMEA?

When a process, product or service is being designed or

redesigned, after quality function deployment.
When an existing process, product or service is being applied
in a new way.
Before developing control plans for a new or modified
process.
When improvement goals are planned for an existing
process, product or service.
When analyzing failures of an existing process, product or
service.
Periodically throughout the life of the process, product or
service
 HOW DOES IT WORK?

 First, List the characteristics of a product or service design or

the steps of a process.

 The Team then identifies all the ways the design or process
could fail, referred to as potential failure modes.

 The 3 main types of design failure modes are

materials, processes and costs.

 The 4 main types of process failure modes are too much, too
little, missing or wrong.
 HOW DOES IT WORK?

 A traditional FMEA quantifies risk. This is done by calculating

the Risk Priority Number (RPN) derived from 3 subjective
ratings – Severity(S), Occurrence(O) and Detection(D)

 The Severity rating is based on how serious the impact would

be if the potential failure were to occur.

 The Occurrence rating is based on the probability of the

potential failure occurring.

 The Detection rating is based on how easily the potential

failure could be detected prior to occurrence.
 HOW DOES IT WORK?

The Risk Priority

Number is Step 1: Detect a
Failure Mode
calculated by:
RPN = S x O x D Risk Priority
Step 2: Severity
number (RPN) =
number (S)
S*O*D

The smaller the

number, lesser is the
Step 4: Step 3:
risk. Detection Probability
number (D) number (O)
 PHASES OF AN FMEA

I. The pre-work: In this phase it determines the objectives and

the level of FMEA. During this phase criteria on the basic
concepts and special procedures for the prevention of
unnecessary loss of time and cost are defined.
II. Systems analysis: Development and analysis of the
system, processes, and fault tree diagrams operates according
to specified functions, areas of interaction , stages, and their
types.
III. Review of results: potential types of errors are
identified, effects of them are evaluated, and control measures
to prevent errors are defined according to the analysis and
evaluation.
IV. Monitoring / Implementation: During this phase, results and
data documentation are obtained.
V. Verification
 CREATING A LIFE-CYCLE FMEA

1) Form an FMEA team that consists of representatives from

all stages of the product‟s life cycle.
2) Identify all the systems, sub -systems and components and
list them in the first three columns on the FMEA.
3) Make the next column a D -M- A -I-O code for the phase of the
equipment‟s life cycle in which the failure originates ( can
also add a „S‟ code for Shutdown if desired)
4) Continue to fill in the remaining columns of the FMEA
D = Design. Includes potential failures of design that surface
in a design FMEA

D-M- A -I-O
M=Manufacturing. Includes the potential failures of CODES
the components or manufacturing of standard details
that might be produced or machined in-house

A = Assembly. Includes potential failures of

assembling the equipment

I = Installation. Potential failures of installation might

be overlooked.

O = Operation. Includes all the potential failures associated

with Operators and Operations.
FMEA ANALYSIS AND
APPLICATIONS IN Case Study

KNITTING INDUSTRY
 ABSTRACT

 In this study relevant products errors were determined with

error probabilities, severity values, and values of
discoverability were calculated at a knitting company by types
of Failure Modes and Ef fects Analysis‟s (FMEA); process FMEA.
Correction steps were determined with RPN (Risk Priority
Number) values due to occurred errors. According to the
obtained results, it was determined that traces of platen, fly,
broken needle, lycra eccentric, number of hole, transverse
band, and lycra cut are the most critical errors. These errors
have been occurred by knitting machines. Furthermore,
workers' education and improvement of working conditions
critical factors on eliminating errors.
 GOALS OF FMEA

Identifying and testing to eliminate

Defining potential error / fault or minimize Avoid potential errors that may occur Eliminate potential types of errors to
Identify the critical and determinant Sorting potential errors of design
types, rates, effects and the degree errors, defects, malfunctions, and along to the product or process, by take corrective actions or reduce the
characteristics and process based on severity
of importance changes and to ensure product predefining them possibility of formation.
development
 INTRODUCTION

 The benefits of FMEA are:

 Enhances quality, reliability, image , security, and level of competition

of the product.
 Helps to increase customer satisfaction .
 Reduces product development time and cost, and provides selecting
the most appropriate system and the oppor tunity to optimize
processes.
 Reduce risks by monitoring and documenting methods.
 These documents would be a good guide for the design of system and
process that will be developed in the future.

 The information obtained from the design FMEA , is used on changes in

the production process, material selection, quality control, and quality
inspection criteria. Hence, the method can be used as a decision
making tool. Types of error s are reviewed systematic in order to prevent
even the smallest damage on product, process, or ser vice.
 MATERIAL AND METHOD

 Material:  Method
ERROR CODE ERROR NAME
HT 1 Number of Hole
Two fleece HT 2 Fly
fabric, single jersey HT 3 Broken Needle
and rib fabrics HT 4 Lycra Eccentric
measured for this HT 5 Traces of Platin

study because of their HT 6 Transverse Band

widely usage in HT 7 Lycra Cut

knitting HT 8 Oil Stain
industry, which HT 9 Empty Iro Error
supplied from Ethem HT 10 Color Difference

Örme Textile company

HT 11 Longitudinal
Lines
 MATERIAL AND METHOD

 Number of hole (HT1): It may cause because of yarn, or the

machine elements.
 Fly (HT2):Fly-adhesive cotton dusts from machines will cause
an error on colorless, knitted fabric during the knitting with
colored yarn.
 Broken needle (HT3):Errors that may occur on the fabric
surface in case of working with broken needle.
 Lycra Eccentric (HT4): The error is observed with the needle
does not receive during the knitting process because of the
rotation of the lycra in the fabric.
 Traces of Platin (HT5): The error is formed by the traces seen
on the fabric due to the use of worn or deformed platin.
 MATERIAL AND METHOD

 Transverse band (HT6): Yarn and machine are two important

factors in the formation of this error.
 Lycra cut (HT7): Error caused by wear needles used on the
bench or feeding type of lycra.
 Oil stain (HT8): Discolorations on the fabric due to the use of
oil, haunting with water, in the machine .
 Empty iro error (Meninger) (HT9): A type of error caused by
can‟t wind yarns on iro properly.
 Color dif ference (HT10): Using of dif ferent yarn lots at the
same time cause that error.
 Longitudinal lines (HT11): A jump occurs due to motionless of
tongue of needle, the loop does not occur on the needle. It
occurs an open longitudinal line on fabric.
 MATERIAL AND METHOD

 Identifying t he Ef fects of Error: These error s are not met positive by the
customer and included in the second quality class .

 Identification of Error Reasons: These error s are occur because of raw

materials, machiner y, and human .

 Applicable Control Measures

 Controlling of yarns that required for knitting
 Setting of machine due to knitting fabric type
 Measuring weight of knitted fabric af ter beginning of knitting
 Doing raw quality control of fabric
 Controlling of fabrics af ter dyeing

 Application of Scoring: Relevant products error probabilities , severity

values, and values of discoverability were calculated by process FMEA
 RESULTS AND DISCUSSION

 The Possibility Of The Error

 In this study unit of measured samples that kilograms. The
number of working days in the business was 303 days in
2011 . Three month‟s data chose for this study due to business
prepared the most order in that months. Table 2 shows the
production information and the probability values according to
data from the factory. In tables 3 and 4 values of the error
severity and detectability of error type are shown.
RESULT TABLES
 RESULT AND DISCUSSION

 Identifying of Risk Priority Number ( RPN)

 Based on the value of PRN, we can decide to star t working on which
type of error for improvement . The types of error s are usually caused by
a lack of training of per sonnel were encountered in business. The
training should be about planning of work time , place and business
plan. Worker should be under stand the aim and do it carefully.
Business manager must be make a point of training for that situation .
Companies engaged in training activities as required for cer tification of
quality assurance systems and quality assurance . However, af ter
receiving this document, many businesses have failed to continue
training activities. continuity of approach of quality production can be
achieved with but the continuity of training activities. Failure to
precise settings of looms can be defined as the cause of an error. To
obtain the required characteristics of the production is possible by
made a complete and precision looms settings . The operator, who
make loom setting , must be educated and experienced . These
improvement activities have to be mind in for zero -defect
production , elimination of error s that were encountered and customer
satisfaction.
 Error Values of RPN
160 THE
DISTRIBUTIO
140 N OF ERROR
VALUES OF
120 RPN

100
RPN

80

60

40

20

0
HT HT HT HT HT HT HT HT HT HT HT
1 2 3 4 5 6 7 8 9 10 11
RPN 14 14 14 12 12 12 11 10 96 84 84
 CONCLUSION

 Traces of platin, fly, broken needle , lycra eccentric, number of

hole, transverse band, and lycra cut are determined as the
most critical errors . Calculating of RPN has indicated the
necessity of applying corrective and preventive actions for
each type of error. Most critical errors have been occurred by
knitting machines. Although some errors are due to
workers, the main reason of errors are depend on making the
necessary settings of equipment incompletely and hasty.

 Workers' education and improvement of working conditions

must be considered, and skilled workers should be introduced
to other workers as examples. Dif ferent types of training
should be given to workers to troubleshoot errors.
 CONCLUSION

 Maintenance and settings up of the machines and soft wares

should be reviewed. After making discussion for eliminating
errors primarily, we should control deformation of needle
surface. Especially HT1 and HT3 errors occur because of
needle and machine. Clean machine and area are too
important factor for decreasing fly amount. In
addition, working time should be reorganized, and number of
break time should be increased, so lack of attention due to
fatigue can be eliminated in this way.
 RPN should be push down to have zero defect by reducing
occurrence probability.
 Widely usage of that analysis in sector should be increases
customer satisfaction due to increasing of quality, reliability
and competitiveness. For this reason representatives of the
sector should be informed.
 REFERENCES

 FMEA -Something Old, Something New - Reid, R Dan - Quality

Progress; May 2005; 38, 5; ABI/INFORM - Complete pg. 90

 An innovative methodology: The life cycle FMEA -

Lore, Jonathan - Quality Progress; Apr 1998; 31 , 4;
ABI/INFORM - Complete pg. 144

 Case Study - FMEA ANALYSIS AND APPLICATIONS IN

KNITTING INDUSTRY - Istanbul Technical
University, Depar tment of Textile Engineering, Istanbul, Turkey

 FailureModesandEf fectsAnalysis_FMEA_1.pdf – Institute for

Healthcare Improvement