Nikhil Kandwal - 19020841022

Nikhil Kandwal - 19020841022
FMEA is a procedure in product development and

operations management for analysis of potential failure
modes within a system for classification by the severity and
likelihood of the failures.
• Failure modes are any errors or defects in a process,

design, or item, especially those that affect the customer,
and can be potential or actual.
• Effects analysis refers to studying the consequences of

those failures.
Main terms to know:
•Failure
The loss of an intended function of a device under
stated conditions.
•Failure mode
The manner by which a failure is observed; it generally
describes the way the failure occurs.
•Failure effect
Immediate consequences of a failure on operation, function or
functionality, or status of some item
•Failure cause
Defects in design, process, quality, or part application, which
are the underlying cause of the failure or which initiate a
process which leads to failure.
•Severity
The consequences of a failure mode.
It considers the worst potential consequence of a failure,

determined by the degree of injury, property damage, or system
damage that could ultimately occur.
The FMEA Form
Identify failure modes Determine and assess

Identify causes of the Prioritize
and their effects actions
failure modes
and controls
The process for conducting an FMEA is typically
developed in three main phases
Step 1: Severity
Step 2: Occurrence
Step 3: Detection
Step 1:
Severity
•Determine all failure modes based on the functional
requirements and their effects.
•Examples of failure modes are: Electrical short-circuiting,

corrosion or deformation.
•A failure mode in one component can lead to a failure mode in

another component, therefore should be listed in technical
terms and for function. Hereafter the ultimate effect of each
failure mode needs to be considered
•A failure effect is defined as the result of a failure mode on the

function of the system as perceived by the user.
•Examples of failure effects are: degraded performance, noise
or even injury to a user.
•Each effect is given a severity number (S) from 1 (no danger)

to 10 (critical). These numbers help an engineer to prioritize
the failure modes and their effects.
•If the sensitivity of an effect has a number 9 or 10, actions are

considered to change the design by eliminating the failure
mode, if possible, or protecting the user from the effect.
Step 2:
Occurrence
•Looks at the cause of a failure mode and the number of times it
occurs.
•All the potential causes for a failure mode should be identified

and documented in technical terms.
•A failure mode is given an occurrence ranking (O), again 1–10.

This step is called the detailed development section of the FMEA
process.
•Occurrence also can be defined as %. If a non-safety issue

happened less than 1%, we can give 1 to it based on your
product and customer specification.
Step 3:
Detection
•First, an engineer should look at the current controls of the
system, that prevent failure modes from occurring or
which detect the failure before it reaches the customer.
•identify testing, analysis, monitoring and other techniques that

can be or have been used on similar systems to detect failures.
•Likeliness for a failure is identified or detected.

•Each combination from the previous 2 steps receives
a detection number (D). This ranks the ability of
planned tests and inspections to remove defects or
detect failure modes in time.
•The assigned detection number measures the risk that the

failure will escape detection.
•A high detection number indicates that the chances are high

that the failure will escape detection, or in other words, that
the chances of detection are low.
Risk priority number (RPN)
•RPN play an important part in the choice of an action against

failure modes.
•They are threshold values in the evaluation of these actions.
•RPN can be easily calculated by multiplying the severity,

occurrence and detectability
RPN = S × O × D
•This has to be done for the entire process and/or design.
•Once this is done it is easy to determine the areas of

greatest concern.
•The failure modes that have the highest RPN should be

given the highest priority for corrective action.
•This means it is not always the failure modes with the

highest severity numbers that should be treated first.
There could be less severe failures, but which occur more
often and are less detectable.
•After these values are allocated, recommended actions with
targets, responsibility and dates of implementation are noted.
•These actions can include specific inspection, testing or

quality procedures, redesign (such as selection of new
components), adding more redundancy and limiting
environmental stresses or operating range.
•Once the actions have been implemented in the design/process,

the new RPN should be checked, to confirm the improvements.
•These tests are often put in graphs, for easy visualization.
•Whenever a design or a process changes, an FMEA should be

updated.
The FMEA should be updated
whenever
• A new cycle begins (new product/process)
• Changes are made to the operating conditions
• A change is made in the design
• New regulations are instituted
• Customer feedback indicates a problem

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Nikhil Kandwal - 19020841022

FMEA is a procedure in product development and

• Failure modes are any errors or defects in a process,

• Effects analysis refers to studying the consequences of

It considers the worst potential consequence of a failure,

Identify failure modes Determine and assess

•Examples of failure modes are: Electrical short-circuiting,

•A failure mode in one component can lead to a failure mode in

•A failure effect is defined as the result of a failure mode on the

•Each effect is given a severity number (S) from 1 (no danger)

•If the sensitivity of an effect has a number 9 or 10, actions are

•All the potential causes for a failure mode should be identified

•A failure mode is given an occurrence ranking (O), again 1–10.

•Occurrence also can be defined as %. If a non-safety issue

•identify testing, analysis, monitoring and other techniques that

•Likeliness for a failure is identified or detected.

•The assigned detection number measures the risk that the

•A high detection number indicates that the chances are high

•RPN play an important part in the choice of an action against

•They are threshold values in the evaluation of these actions.

•RPN can be easily calculated by multiplying the severity,

•Once this is done it is easy to determine the areas of

•The failure modes that have the highest RPN should be

•This means it is not always the failure modes with the

•These actions can include specific inspection, testing or

•Once the actions have been implemented in the design/process,

•These tests are often put in graphs, for easy visualization.

•Whenever a design or a process changes, an FMEA should be

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