Failure Modes &
F M E A Effects Analysis
What is FMEA?
Imagine you are building a tower of blocks, and you want to make sure it doesn't fall apart.
How do you do that? You think about what could go wrong, right? That's pretty much what
companies do with their products, from gadgets to machines. They use a tool called Failure
Mode and Effects Analysis, or FMEA for short.
FMEA is like a superhero checklist. It helps companies figure out what might go wrong with
their stuff and how it could affect people. In simpler terms, it's a way for them to be like
superheroes, trying to fix problems before they happen. Whether it's a new smartphone, a
kitchen appliance, or even a car, FMEA is there to ensure the safety and reliability of various
products.
Key components of FMEA
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Identify Components and Functions:
• List all the important parts and what they do.
Brainstorm Possible Failures:
• Think about what could go wrong with each part.
Rate the Severity, Occurrence, and Detection:
• Figure out how bad the problem would be, how likely it is to happen, and how
easy it is to notice.
Calculate Risk Priority Number (RPN):
• Multiply the severity, occurrence, and detection ratings to prioritize problems.
Take Action:
• Focus on fixing the most critical issues to make things safer.
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F M E A Example : Case Study
Now, let's take a look at an example of how the car manufacturing company ABC Ltd is using the
FMEA technique.
ABC Ltd. is all about making sure their cars are super safe for everyone. They want to be like
superheroes, predicting problems and stopping them in their tracks.
Step 1: What's in the Car?
ABC Ltd. starts by making a list of all the important parts of their cars. This includes things like the
engine, brakes, lights, and airbags. Each part has a job to do in keeping people safe while driving.
Step 2: What Could Go Wrong?
The team at ABC Ltd. gathers like friends discussing what could go wrong with their tower of blocks.
They ask questions like, "What if the brakes stop working?" or "What if the airbags don't work during a
crash?" This helps them think about all the things that might cause trouble.
Step 3: How Bad Is It? @5S BalaMurugan
Now, they rate how bad each problem would be if it actually happened. Is it a small problem, a medium
one, or a really big one? For example, if the brakes not working is a big problem, they know they need
to pay extra attention to that.
Step 4: How Likely Is It?
Next, ABC Ltd. thinks about how likely each problem is to happen. Is it something that could happen
all the time, sometimes, or hardly ever? This helps them understand which problems they should worry
about the most.
Step 5: Can We Stop It?
Lastly, they figure out how easy it is to notice the problem before it becomes a big deal. If they can
catch it early, it's like stopping a tower of blocks from falling before it happens.
Putting it All Together:
By doing these steps, ABC Ltd. gets a special number for each problem. It's called the Risk Priority
Number (RPN). The higher the RPN, the more urgent it is to fix that problem.
With their RPNs in hand, ABC Ltd. knows where to focus their superhero efforts. They start working on
ways to make sure the most important problems are fixed. For example, if the brakes not working has a
high RPN, they might make the brakes even better or do more tests to catch any issues early.
In the end, FMEA helps companies like ABC Ltd. be superhero-like in keeping their products safe for
everyone. So, the next time you buckle up for a ride, remember that FMEA is one of the tools making
sure you stay safe on the road.
- 5S BALAMURUGAN
Lean Practitioner | HRD Professional
https://www.linkedin.com/in/tqmbala/ tqmbala@gmail.com
