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FMEA: Comprehensive Approach to Identifying Failures and Consequences, Exercícios de Gestão de Custos

Centro de Ensino Superior Tecnológico Superior do Brasil (CESTECH)Gestão de Custos

Failure modes and effects analysis (fmea) is a systematic approach used to identify potential failures in design, manufacturing, or assembly processes, products, or services. By analyzing the ways in which something might fail (failure modes) and the consequences of those failures, fmea helps prevent failures and improve overall system performance. A summary of the fmea process, including steps, examples, and rating scales.

O que você vai aprender

What is the purpose of Failure Modes and Effects Analysis (FMEA)?
How do you identify failure modes in FMEA?
What are the consequences of a failure mode in FMEA?

Tipologia: Exercícios

2020

Compartilhado em 28/06/2020

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FMEA

A summary by André Duarte B. L. Ferreira

Last edit: 16th May 2017

FMEA = Failure Modes and Effects Analysis. FMEA is an approach to identify 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. FMEA is used during design to prevent failures.

Fig. 1 Example of FMEA table of an ATM machine.

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FMEA

A summary by André Duarte B. L. Ferreira Last edit: 16 th May 2017 FMEA = Failure Modes and Effects Analysis. FMEA is an approach to identify 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. FMEA is used during design to prevent failures. Fig. 1 Example of FMEA table of an ATM machine.

Fig. 2 Example of simple FMEA analysis for a LED light bulb. Steps:

Identify the functions and the purpose of the thing. “What do our customers expect it to do?” Then divide the item into separate assemblies/parts/process steps and identify each one’s function.
For each function, identify all the ways it could fail. To fail means to lose their function or make other items lose theirs.
Then for each failure mode identify all the consequences it can have everywhere – system, related systems, process, related processes, product, service, customer or regulations. These are potential effects of failure. Ask, “What does the customer experience because of this failure? What happens when this failure occurs?”
Determine how serious each effect is. This is the severity rating, or S. Severity is usually rated on a scale from 1 to 10, where 1 is insignificant and 10 is catastrophic. If a failure mode has more than one effect, write on the FMEA table only the highest severity rating for that failure mode.
For each failure mode, determine all the potential root causes. Use tools classified as cause analysis tool, as well as the best knowledge and experience of the team. List all possible causes for each failure mode on the FMEA form.
For each cause, determine the occurrence rating, or O. This rating estimates the probability of failure occurring for that reason during the lifetime of your scope. Occurrence is usually rated on a scale from 1 to 10, where 1 is extremely unlikely and 10 is inevitable. On the FMEA table, list the occurrence rating for each cause.
For each cause, identify current process controls. These are tests, procedures or mechanisms that you now have in place to keep failures from reaching the customer. These controls might prevent the cause from happening, reduce the likelihood that it will happen or detect failure after the cause has already happened but before the customer is affected.
For each control, determine the detection rating, or D. This rating estimates how well the controls can detect either the cause or its failure mode after they have happened but before the customer is affected. Detection is usually rated on a scale from 1 to 10, where 1 means the control is absolutely certain to detect the problem and 10 means the control is certain not to detect the problem (or no control exists). On the FMEA table, list the detection rating for each cause.