Risk analysis method: FMEA/FMECA in organization

1 International Journal of Basic & Applied Sciences IJBAS-IJENS Vol: 11 No: 05 49. Risk analysis Method: FMEA/FMECA in the Organizations By Lefayet Sultan Lipol ( in Textile Technology & in Applied Textile Management, University of Boras, Sweden). and Jahirul Haq ( in Industrial Engineering with major Quality and Environmental Management, University of Boras, Sweden). Abstract-- This is a report on the FMEA/FMECA risk A vital step is anticipating what might go incorrect with a analysis method in industries. We have visited at Parker product.

2 Whereas anticipating each failure mode is not Hannifin, Boras to know their techniques to implement it and possible, the improvement squad ought to invent as found that the company is familiar with Design and Process extensive a record of likely failure modes as probable. FMEA only and organization 's FMEA software is based on MS Near the beginning and steady use of FMEAs in the design Excel sheet to put all of the data's of FMEA team's risk process let to the engineer to drawing out failures and analysis investigation.

3 The company follows a limit of RPN's manufacture dependable, protected, and customer satisfying 200 and any value beyond this limit and equal to this is marked goods. FMEAs also carry chronological information for use red. The software presents a graph of RPN's of before action in upcoming product development. taken and after action taken. The industry is not so familiar with FMECA but using qualitative part of criticality analysis (criticality matrix of severity on Y-axis and occurrence on X- 2. B ACKGROUND. axis).

4 We tried to find some differences of FMEA and FMECA. Definitions of FMEA/FMECA : Failure Modes and The company is making risk analysis if they are asked to do so Effects analysis (FMEA) and Failure Modes, Effects and by the top management. It is helping the company to avoid Criticality analysis (FMECA) are methodologies designed accident, re-design and making a reliable design or process. to identify potential failure modes for a product or process Index Term-- FMEA, FMECA, RPN, APQP, Criticality before the problems occur, to assess the risk.

5 Ideally, Matrix, Cpk, Ppk FMEA's are conducted in the product design or process [FMEA= Failure Mode and Effects analysis . development stages, although conducting an FMEA on FMECA= Failure Mode Effect and Criticality analysis . existing products or processes may also yield benefits. RPN= Risk Priority Numbers. The FMEA team determines, by failure mode analysis , the ASAP= As early as possible. effect of each failure and identifies single failure points that APQP= Advanced Product Quality Planning and Control are crucial.]

6 It may also rank each failure according to the Planning]. criticality of a failure effect and its probability of occurring. The FMECA is the result of two steps: -Failure Mode and Effect analysis (FMEA). 1. INTRODUCTION. -Criticality analysis (CA). Customers are placing increased demands on companies for FMECA is just extended version of FMEA with Criticality high quality, reliable products. The rising capabilities and analysis . [3]. functionality of many products are creating it additional complex for producer to keep up the quality and reliability.

7 FMEA Components: For calculating the risk in FMEA. Conventionally, reliability has been accomplished through method, risk has three components which are multiplied to widespread testing and applies of method such as produce a risk priority number (RPN): probabilistic reliability modeling. These are techniques done in the delayed phase of improvement. The challenge is to 1. Severity (S): Severity is described on a 10-point scale devise in quality and reliability early in the expansion phase. where 10 is highest. Failure Modes and Effects analysis (FMEA) is a tactic for 2.

8 Occurrence (O): Occurrence is described on a 10-point evaluate possible reliability troubles in the early hours at the scale where 10 is highest. progress cycle where it is simpler to acquire actions to 3. Detection (D): Detection is described on a 10-point scale overcome these matters, thereby improving consistency where 10 is highest. through design. FMEA can be apply to recognize probable failure modes, conclude their effect on the process of the RPN= S*O*D. product, and categorize actions to diminish the failures.

9 117705-3535 IJBAS-IJENS October 2011 IJENS. IJENS. International Journal of Basic & Applied Sciences IJBAS-IJENS Vol: 11 No: 05 50. RPNmin= 1 while RPNmax= 1000. [1] o Define the reliability/unreliability for each item, at a given operating time. RPN concept: o Identify the portion of the items unreliability that Here we shall try to explain the techniques to take decision can be attributed to each potential failure mode. of prioritizing a process based on RPN. o Rate the probability of loss (or severity) that will Table I result from each failure mode that may occur.

10 Example of a risk calculation by FMEA. o Calculate the criticality for each potential failure Severity Occurrence Detection RPN=S*O*D. (S) (O) (D). mode by obtaining the product of the three factors: Potential 2 10 5 100. failure 1 Mode Criticality = Item Unreliability x Mode Ratio of Potential 10 2 5 100 Unreliability x Probability of Loss failure 2. Potential 2 5 10 100. failure 3 o Calculate the criticality for each item by obtaining Potential 10 5 2 100 the sum of the criticalities for each failure mode failure 4.