📊

Introduction to FMEA (Failure Modes and Effects Analysis)

Jul 15, 2024

Introduction to FMEA (Failure Modes and Effects Analysis)

Instructor: Kevin Clay, Lean Six Sigma Instructor at Six Sigma Development Solutions

Overview of FMEA in Lean Six Sigma

  • FMEA is one of four tools used for qualitative root cause analysis in Lean Six Sigma.
  • The four tools are:
    1. SIPOC (Suppliers, Inputs, Process, Outputs, Customers)
    2. Input Map
    3. C&E (Cause & Effect) matrix
    4. FMEA
  • Tools are used sequentially: From SIPOC -> Input Map -> C&E matrix -> FMEA.
  • Focus on qualitative data to understand problems and their causes.
  • Introductory videos for each tool are available on the website.

FMEA Breakdown

  • FMEA consists of columns from Process Step to RPN (Risk Priority Number).
  • The FMEA analysis is just two-thirds of the tool; the final section is the improvement section, which measures the impact of improvements.
  • Focus will be on the analysis side today.

Columns in FMEA:

  1. Process Step
  2. Process Input
    • Information sourced from C&E matrix (prioritizes inputs).
  3. Potential Failure Mode
    • Identifies how the process input might fail.
  4. Potential Failure Effect
    • The impact of the failure mode on the process.
  5. Severity
  6. Occurrence
  7. Detection
  8. Potential Causes
    • Causes behind each failure mode.
  9. Current Controls
    • Measures in place to detect or prevent the failure mode.
  10. Risk Priority Number (RPN)
    • Calculated as: Severity × Occurrence × Detection

Example Breakdown

  • Example used in training: Peanut Butter and Jelly Incorporated (a fictional company).
  • Problem: Higher costs for PB&J sandwich construction than target cost.
  • Identified key inputs: Setup, Standard Work Instructions, Applying Peanut Butter and Jelly.
  • Possible Failure Modes:
    • Standard work instructions not available.
    • Standard work instructions out of date.
  • Effects: Operators producing PB&J to perceived standards (varied quality).
  • Controls: The best controls prevent failure mode; otherwise, they detect it at various stages.
  • Scoring:
    • Severity: Impact of the failure effect (1-10 scale).
    • Occurrence: Frequency of the cause (1-10 scale).
    • Detection: How well the failure mode is detected (1-10 scale).

Expansion and Sorting

  • FMEA can expand from one input leading to multiple failure modes and effects.
  • For clarity in sorting by RPN, each row/cell must be filled to trace origins clearly.

Further Learning and Certification

  • More in-depth lessons and certifications are available on the website.
  • Certification involves a module with a quiz.
  • Contact Information:

Full transcript