Beer Brewing Pfmea

FMEA
Process
Type/Model/Fabrication/Load:
Beer making (based on Indian Pale Ale)
Item Code:
5% IPA
Revision State:
FMEA/Process Step:
Complete beer brewing process
Item Code:
Revision State:
Effects
S
C
Failure Mode Causes
Process Element: Sterilisation
Function: Sterilise all of the equipment and then rinse with clean water and allo
[5% Indian Pale 8
Equipment is [Instructions]
Ale Beer]
40
pints of beer is
not sterilised Ambiguous
scapped
methodolo[5% Indian Pale 9
Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale 7
Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer is too
gaseous (bad)
gy
[5% Indian Pale

Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
weights and
volumes
not specified
(including
U.S. imperial)
[Instructions]
Metric /
imperial
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[Brewer]
Fails to sterilise
container
used to carry
water
[Brewer]
Does not wash
hands
beforehand
[Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
[Steriliser]
insufficent
concentration / ratios
[Home]
Poor air quality

(micro
organisms
present)
[Brewer]
Washes out
sterilising fluid too early
[Water]
Domestic
supply quality
is contaminated
(micro
organisms
present)
[5% Indian Pale

Ale Beer]
Beer tastes of
detergent
Steriliser not [Brewer]

fully rinsed
Does not rinse
from
equip-
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
equipment
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
ment properly
[Brewer]
Forgets to rinse
equipment properly
Process Element: Preparing the Wort

Characteristics: Place Malt & Hops container into warm water for a time of >= 5
[5% Indian Pale 6
Malt & Hops [Instructions]
Ale Beer]
Brewing process
not warmed Ambiguous
takes
methodololonger than
sufficiently
gy
required
[5% Indian Pale
Ale Beer]
Beer is watery
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[Kettle]
Thermostat
failure
[Brewer]
Impatientience /
carelessness or
inexperience
Characteristics: Add boiling water to the fermentation bucket = 5 litres +1

[5% Indian Pale 6
Excessive
[Instructions]
Ale Beer]
boilBrewing process
ing water
Metric /
takes
imperial
longer than
required
added
weights and
volumes
not specified
(including
U.S. imperial)
[Fermentation
Bucket &
lid]
Volume
measurements
are illegible
[5% Indian Pale 6
Ale Beer]
Brewing process
takes
Insufficient
boiling water
[Instructions]
longer than
required
added
weights and
volumes
not specified
(including
Metric /
imperial
U.S. imperial)
[Fermentation
Bucket &
lid]
Volume
measurements
are illegible
[Brewer]
Impatientience /
carelessness or
inexperience
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale
Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale

Ale Beer]
Beer is too
gaseous (bad)
Water added [Brewer]

is not at boil- Impatientience /
careing point
lessness or
inexperience
[5% Indian Pale

Ale Beer]
[Brewer]
40 pints of beer
is scapped
Omits a stage
Characteristics: Add the ingredients to the

1.8kg Malt & Hops
Excessive
[5% Indian Pale 5
Ale Beer]
Beer is too
quantity of
gaseous
sug-
fermentation bucket = 1 kg beer enh
[5% Indian Pale

Ale Beer]
Beer tastes
yeasty
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Party goers are
inebriat-
ed to early in
the night
[Scales]
Batteries are
flat
ar
[Instructions]
Ambiguous
methodology
[Brewer]
Adds more
sugar than
required
[Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
[Brewer]
Incorrect type
of sugar
used (e.g.
brown sugar /
Muscovado)
[Scales]
Out of
calibration
[Instructions]
Metric /
imperial
weights and
volumes
not specified
(including
U.S. imperial)
[Brewer]
Impatientience /
carelessness or
inexperience
[5% Indian Pale

Ale Beer]
Beer tastes
caramelly/
malty
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
Beer is too
gaseous
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Incorrect
[Brewer]
ingredients added Incorrect type
of sugar
used (e.g.
brown sugar /
Muscovado)
[Instructions]
Insufficient
detail about
alternative
ingredients
6
Brewing process
takes
longer than
required
(does & don'ts)
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[Brewer]
Impatientience /
carelessness or
inexperience
[Brewer]
Experimentatio
n with
process (Brewer
has a
'good' idea!)
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is watery
Insufficient
[Instructions]
quantity of
Ambiguous
methodology
Malt & Hops
[Brewer]
Fails to rinse
out Malt &
Hops container
[Brewer]
Impatientience /
carelessness or
inexperience
[5% Indian Pale

Ale Beer]
Beer is flat
[5% Indian Pale

Ale Beer]
Beer is watery
Insufficient
[Instructions]
quantity of
sug-
Ambiguous
methodolo-
ar
gy
[5% Indian Pale

Ale Beer]
Insufficient
alcoholic beverages for the
party goers
[Scales]
Batteries are
flat
[Brewer]
Incorrect type
of sugar
used (e.g.
brown sugar /
Muscovado)
[Scales]
Out of
calibration
[Instructions]
Metric /
imperial
weights and
volumes
not specified
(including
U.S. imperial)
[Brewer]
Impatientience /
carelessness or
inexperience
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Sugar
omitted
[Brewer]
Omits a stage
Gavin's 40th
birthday party
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale
Ale Beer]
Beer is not
ready for
Wort is
contamination
[Brewer]
Fails to cover
the wort
[Instructions]
Ambiguous
methodology
Gavin's 40th
birthday party
[5% Indian Pale
Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[Fermentation
Bucket &
lid]
Bacterial
contamination
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
present
[Malt & Hops]

Bacterial
contamination
present
[Scales]
Bacterial
contamination
present
[Brewer]
Does not wash
hands
beforehand
[Home]
Poor air quality
(micro
organisms
present)
[Sugar]
Bacterial
contamination
present
[Brewer]
Washes out
sterilising fluid too early
[Brewer]
Impatientience /
carelessness or
inexperience
[Spoon]
Bacterial
contamination
present
[Malt & Hops]
Poor quality
product /
batch
Function: Mix contents until ingredients are dissolved

[5% Indian Pale 6
Ingredients
[Brewer]
Ale Beer]
Beer is flat
mixing not
Impatientience /
care[5% Indian Pale 6
Ale Beer]
Brewing process
takes
longer than
required
[5% Indian Pale
Ale Beer]
Beer is watery
mixed to a
soluble state
lessness or
inexperience
[Spoon]
Insufficient
length
[Brewer]
Omits a stage
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
Wort is
contamination
[Brewer]
Does not wash
hands
beforehand
vinegary)
[5% Indian Pale
Ale Beer]
Beer is
cloudy/hazy
[Instructions]
Ambiguous
methodolo-
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale

Ale Beer]
gy
[Home]
Poor air quality
(micro
40 pints of beer
is scapped
organisms
present)
[Spoon]
Bacterial
contamination
present
Characteristics: Fill the fermentation bucket to the correct volume = 40 pints
Insufficient
[Brewer]
[5% Indian Pale 6
Ale Beer]
water added Experimentatio
Insufficient
alcoholic bevn with
erages for the
process (Brewer
party goers
has a
[5% Indian Pale
Ale Beer]
Beer is too
gaseous
[5% Indian Pale

Ale Beer]
'good' idea!)
6
Party goers are
inebriated to early in
the night
[5% Indian Pale
Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Beer tastes
caramelly/
malty
[Fermentation
Bucket &
lid]
Volume
measurements
are illegible
[Instructions]
Metric /
imperial
weights and
volumes
not specified
(including
U.S. imperial)
[Brewer]
Impatientience /
carelessness or
inexperience
[Fermentation
Bucket &
lid]
Insufficient
capacity
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale
Ale Beer]
Beer is not
ready for
[Instructions]
Ambiguous
methodology
[Brewer]
Fails to sterilise
container
Gavin's 40th
birthday party
[5% Indian Pale
Ale Beer]
Wort is
contamination
used to carry
water
9
9
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale
Ale Beer]
40 pints of beer
is scapped
[Brewer]
Does not wash
hands
beforehand
[Home]
Poor air quality

(micro
organisms
present)
[Water]
Domestic
supply quality
is contaminated
(micro
organisms
present)
[Brewer]
Impatientience /
carelessness or
inexperience
Function: Cover fermentation bucket and insert airlock whilst temperature settl
[5% Indian Pale 7
Wort is
[Fermentation
Ale Beer]
contamiBucket &
Beer taste has a
nation
lid]
bitterness
to it
Bacterial
contamination
[5% Indian Pale
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale
Ale Beer]
Beer is
cloudy/hazy
present
[Airlock]
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
contaminated
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[Brewer]
[5% Indian Pale

Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
Airlock or fluid
content is
Impatientience /
carelessness or
inexperience
[Fermentation
Bucket &
lid]
Plastic fatigue
(cracks /
orange peel)
[Brewer]
Omits a stage
[Thermometer]
Bacterial
contamination
present
Process Element: Add yeast

Characteristics: Mix the yeast into the wort at a specified temperature = 22 Cen
[5% Indian Pale 8
Yeast
[Brewer]
Ale Beer]
omitted
Beer is not
Impatientience /
ready for
careGavin's 40th
lessness or
birthday party
inexperience
[5% Indian Pale 6
Ale Beer]
Brewing process
takes
longer than
required
[Brewer]
Omits a stage
[5% Indian Pale

Ale Beer]
Beer is watery
[5% Indian Pale

Ale Beer]
Beer is flat
Yeast added
[Instructions]
when wort is Ambiguous

methodolotoo hot
gy
[5% Indian Pale 6

Ale Beer]
Brewing process
takes
longer than
required
[5% Indian Pale
Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[Instructions]
Metric /
imperial
weights and
volumes
[5% Indian Pale 8

Ale Beer]
Airlock does not
bubble
during the
fermentation
not specified
(including
U.S. imperial)
[5% Indian Pale

Ale Beer]
yeast is killed
[Brewer]
Impatientience /
carelessness or
inexperience
[Thermometer]
Out of
calibration
[5% Indian Pale
Ale Beer]
Brewing process
takes
longer than
required
Yeat not
[Instructions]
mixed to a
soluble state
Ambiguous
methodology
[Brewer]
Omits a stage
[Brewer]
Impatientience /
care-
lessness or
inexperience
[5% Indian Pale

Ale Beer]
Yeast added
[Brewer]
Brewing process
takes
longer than
required
when wort is Impatientience /

caretoo cold
lessness or
inexperience
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
Wort is
contamination
[Spoon]
Bacterial
contamination
present
[Home]
Poor air quality
(micro
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
organisms
present)
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[Thermometer]
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
Bacterial
contamination
present
9
[Brewer]
Does not wash
hands
beforehand
Function: Cover fermentation bucket and insert airlock
[5% Indian Pale 7
Airlock is not [Brewer]
Ale Beer]
Beer taste has a
inserted into Impatientience /
bitterness
lid
careto it
lessness or
inexperience
[5% Indian Pale
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale
Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale
Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[Brewer]
Omits a stage
[5% Indian Pale 8

Ale Beer]
Airlock does not
bubble
during the
fermentation
[5% Indian Pale 7
Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
Beer is
contaminated
[Airlock]
Airlock or fluid
content is
contaminated
[Fermentation
Bucket &
lid]
Bacterial
contamination
[5% Indian Pale

Ale Beer]
Beer is not
ready for
present
Gavin's 40th
birthday party
[5% Indian Pale
Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
[Brewer]
Does not wash
hands
beforehand
Lid is not
fully
sealed /
Airlock does not

bubble
during the
fermentation
Impatientience /
carepushed home lessness or
inexperience
Process Element: Primary Fermentation

Characteristics: Beer is allowed to ferment
[5% Indian Pale 7
Beer is
Ale Beer]
contaminated
Beer taste has a
bitterness
to it
[5% Indian Pale
Ale Beer]
[Brewer]
for = 6 days 2
[Fermentation
Bucket &
lid]
Plastic fatigue
(cracks /
orange peel)
9
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale
Ale Beer]
Beer is
cloudy/hazy
[Airlock]
Airlock or fluid
content is
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
Insufficient
party goers
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
contaminated
Beer leakage [Fermentation

Bucket &
lid]
Plastic fatigue
(cracks /
orange peel)
[Home]
Shelf strength
in airing
cupboard is
inadequate
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
Fermentation [Brewer]
does not
occur (no
bub-
Uses only
boiling water
when preparing
the wort
bles exit airlock)
[Water]
Domestic
supply quality
is contaminated
(micro
organisms
present)
[Water]
Domestic
supply quality
is contaminated
(chlorine content)
[Home]
Ambient
temperature is
too low /
incorrect proximity to heat
source
[Home]
Ambient
temperature is
too high /
source
[Yeast]
Past best
before date
[5% Indian Pale

Ale Beer]
Fermentation [Instructions]
6
Alcohol content
is not as
per product
description
process
stopped too
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
Beer tastes
caramelly/
malty
[5% Indian Pale
Ale Beer]
Beer tastes
yeasty
[5% Indian Pale

Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Beer is too
gaseous
Ambiguous
methodology
early
[Brewer]
Impatientience /
carelessness or
inexperience
Characteristics: Beer is allowed to ferment in constistent temperature of = 20-2

[5% Indian Pale 6
Temperature [Home]
Ale Beer]
Beer is flat
fluctuations Location is
close to
[5% Indian Pale
Ale Beer]
Beer is too
sweet
draughts / UV
light source
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 6
Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale
Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
yeast is killed
[5% Indian Pale
Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
yeast is killed
[Instructions]
Ambiguous
methodolo-
gy
Temperature [Home]
is
too high
Ambient
temperature is
too high /
source
[Instructions]
Ambiguous
methodology
[5% Indian Pale 6

Ale Beer]
Brewing process
takes
longer than
required
[5% Indian Pale
Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
Temperature [Home]
is
too low
Ambient
temperature is
too low /
source
[5% Indian Pale 8

Ale Beer]
Airlock does not
bubble
during the
fermentation
[Instructions]
Ambiguous
methodology
Process Element: Keg Fermentation

Function: Syphon the fermenting beer into a keg avoiding the sediment
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
Beer is
contaminated
[Syphon]
Bacterial
contamination
present
[Home]
Poor air quality
(micro
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
organisms
present)
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[Brewer]
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
Does not wash

hands
beforehand
9
[Keg]
Plastic fatigue
(cracks /
orange peel)
[Keg]
Bacterial
contamination
present
[5% Indian Pale

Ale Beer]
Beer spillage [Brewer]
Beer spillage
Insufficient
party goers
[5% Indian Pale
Ale Beer]
40 pints of beer
is scapped
Impatientience /
carelessness or
inexperience
8
[Syphon]
Insufficient
length
[Syphon]
Multi-section
product
[Keg]
Insufficient
capacity
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale 4

Ale Beer]
Party goers have
'wind'
Excess sedi-
[Brewer]
ment
decanted
Impatientience /
carelessness or
inexperience
the next day
[Instructions]
Ambiguous
methodology
Characteristics: Add additional ingredients

[5% Indian Pale 7
Beer is
Ale Beer]
contamiBeer taste has a
nated
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
= 150 g 30g
[Keg]
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
present
[5% Indian Pale

Ale Beer]
Beer makes the
party
[Sugar]
Bacterial
contamination
present
[Scales]
Bacterial
contamination
Bacterial
contamination
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale
Ale Beer]
40 pints of beer
is scapped
present
9
[Spoon]
Bacterial
contamination
present
[Brewer]
Does not wash
hands
[5% Indian Pale
Ale Beer]
Beer is too
gaseous
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Party goers are
the night
Excessive
beforehand
[Instructions]
quantity of
sug-
Metric /
imperial
ar
weights and
volumes
not specified
(including
U.S. imperial)
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale 6

Ale Beer]
Brewing process
takes
longer than
required
[Brewer]
Impatientience /
carelessness or
inexperience
[Brewer]
Adds more
sugar than
required
[Instructions]
Ambiguous
methodology
[Scales]
Out of
calibration
[Scales]
Batteries are
flat
[5% Indian Pale

Ale Beer]
Beer is too
gaseous
Incorrect
[Brewer]
ingredients added Incorrect type
of sugar
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
used (e.g.
brown sugar /
Muscovado)
[5% Indian Pale

Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Beer tastes
caramelly/
malty
[5% Indian Pale
Ale Beer]
Party goers are
the night
[5% Indian Pale

Ale Beer]
Beer is flat
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is watery
Insufficient
[Brewer]
quantity of
sug-
Experimentatio
n with
ar
process (Brewer
has a
'good' idea!)
[Brewer]
Omits a stage
[Instructions]
Metric /
imperial
weights and
volumes
not specified
(including
U.S. imperial)
[Brewer]
Impatientience /
carelessness or
inexperience
[Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
[Instructions]
Ambiguous
methodology
[5% Indian Pale

Ale Beer]
Beer is flat
[5% Indian Pale

Ale Beer]
Beer is watery
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
Sugar
omitted
[Brewer]
Impatientience /
carelessness or
inexperience
Characteristics: Beer is allowed to ferment for = 7 days +6

[5% Indian Pale 7
Beer is
[Keg]
Ale Beer]
contami-
7
Beer taste has a
bitterness
to it
[5% Indian Pale 9
Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
[5% Indian Pale 7
Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale
Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
Beer makes the
party
goers unwell
[5% Indian Pale
Ale Beer]
Beer is too
gaseous (bad)
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
Insufficient
party goers
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
nated
Bacterial
contamination
present
Beer leakage [Keg]

Plastic fatigue
(cracks /
orange peel)
[Keg]
Insufficient
capacity
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is too
sweet
[5% Indian Pale

Ale Beer]
Beer tastes
yeasty
Fermentation [Brewer]
process
Impatientience /
care-
stopped too
lessness or
inexperience
early
[5% Indian Pale 4

Ale Beer]
Party goers have
'wind'
the next day
[Instructions]
Ambiguous
methodology
[Brewer]
Experimentatio
n with
process (Brewer
has a
'good' idea!)
[Yeast]
Insufficient
resistance to
high alcohol
content
Characteristics: Beer is allowed to ferment

[5% Indian Pale 7
Temperature
Ale Beer]
is
Beer is
too low
cloudy/hazy
[5% Indian Pale
Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
Beer is too
sweet
in constistent temperature of = 20-2

[Home]
Ambient
temperature is
too low /
source
[5% Indian Pale

Ale Beer]
Beer tastes
yeasty
[5% Indian Pale 4

Ale Beer]
Party goers have
'wind'
the next day
[5% Indian Pale 4
Ale Beer]
Beer is too
sweet
[5% Indian Pale
Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
Beer is
cloudy/hazy
[5% Indian Pale

Ale Beer]
yeast is killed
Temperature [Instructions]
is
too high
Metric /
imperial
weights and
volumes
not specified
(including
U.S. imperial)
[Home]
Ambient
temperature is
too high /
source
[Instructions]
Ambiguous
methodology
[5% Indian Pale

Ale Beer]
Beer is flat
[5% Indian Pale

Ale Beer]
Beer is too
sweet
Temperature [Brewer]
fluctuations
Impatientience /
carelessness or
inexperience
[5% Indian Pale 7

Ale Beer]
Beer taste has a
bitterness
to it
[5% Indian Pale
Ale Beer]
Alcohol content
is not as
per product
description
[5% Indian Pale

Ale Beer]
40 pints of beer
is scapped
[5% Indian Pale

Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
[5% Indian Pale

Ale Beer]
[Home]
8
yeast is killed
Excessive
variations in
the ambient
temperature
[Instructions]
Ambiguous
methodology
FMEA
Process
Responsible:
Company:
Responsible:
Company:
Preventive Action
O Detection Action
RPN
2 Instructions are
54
36
se with clean water and allow to dry

Initial State: 13/03/2013
Use of good quality brew kit

ingredients
read thoroughly
Shop owner / supplier
before commencing brewing
advice

ingredients
2 Directions are read

and re-read at
each stage of the
36
brewing process
advice
Measuring devices at
Gavin's home display both
imperial & metric units
Instructions clearly express
3 none
10 270
Common sense / hygiene

3 none
10 270
2 Instructions are
that all equipment needs to

be sterilised
ingredients

advice
Quantity is specified in the
instructions
Instructions specify imperial
and metric weights and volumes
90
108
read thoroughly
3 Sterilising solution
has a strong smell
Controlled environment
3 none
10 270

be sterilised
Water quality is assured by
has a strong smell
2 none
54
10 180
water board
Revision State: 20/03/2013

2 Beer clarity and
smell are checked
during the seconadary fermentation stage
8 {144
}
48
has a strong smell
32
be sterilised

be sterilised
Past experiences with simi-
has a strong smell
lar brew kits that are being

drank with gusto!
arm water for a time of >= 5 mins +5


ingredients
2 Instructions are
42
14
read thoroughly
advice
TPM on all devices
2 Visual inspection

3 none
10 210

drank with gusto!
Instructions supplied with
each brewing kit & can be
downbloaded from the
internet
on bucket = 5 litres +1
3 Regular referal to
the instructions
5 {105
}
ingredients
and re-read at

advice
each stage of the

brewing process
24
Products recently purchased (JIT)

1 Visual inspection
12
24
12
ingredients
and re-read at

advice
each stage of the

brewing process

Past experiences with similar brew kits that are being
1 Visual inspection
3 none
10 180
3 none
10 180
drank with gusto!

internet
5 {90}
the instructions
3 none
10 270

drank with gusto!
internet
the instructions
5 {135
}

3 subsequent stages
189
28
42
35

drank with gusto!
will be affected
(detection post
process)
ation bucket = 1 kg beer enhancer (sugar)
Alternative scales available
4 Scales clearly display a battery level symbol

ingredients
2 Instructions are
read thoroughly
before commenc-
ing brewing
advice
Ingredients and quantities

are specified in the instructions
5 Electronic scales
within accurate to
0.25g

ingredients

advice
2 Instructions are
14
63
28
2 Sugar packaging
is clearly labelled
tions
drank with gusto!
advice
TPM on all devices
3 1 standard bag of
70
read thoroughly
are specified in the instruc-
Digital scales used

white cane sugar

should weigh
approx. 1kg (Gold
sample)
ingredients
and re-read at

advice
each stage of the

brewing process
3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions

2 Sugar packaging
16
80
is clearly labelled
tions
drank with gusto!
advice
2 Instructions are
2
ingredients
80
read thoroughly
before commenc-
ing brewing
advice

3 none
10 240

drank with gusto!
internet
5 {120
}
the instructions
5 none
10 400

drank with gusto!
internet
5 Smell & clarity
checks - small
glass poured
before 6 days into
final fermentation
6 {240
}
process

ingredients
advice
2 Instructions are
42
28
read thoroughly
Instructions include special
2 Visual inspection
care points
3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions

ingredients
2 Instructions are
read thoroughly
42
42
28
14
63
28
advice
4 Scales clearly display a battery level symbol

2 Sugar packaging
is clearly labelled
tions
drank with gusto!
advice
TPM on all devices
3 1 standard bag of
Digital scales used

white cane sugar

should weigh
approx. 1kg (Gold
sample)
ingredients
and re-read at

advice
each stage of the

brewing process

3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions

drank with gusto!
3 subsequent stages
168
will be affected
(detection post
process)
3 none
10 270

ingredients
2 Instructions are
read thoroughly
54
54
before commencShop owner / supplier
ing brewing
advice
2 none
10 180
2 none
10 180

care points
2 none
10 180

3 none
10 270
3 none
10 270
care points

advice
ingredients
Basic hygiene practice
Mixed with boiling water to
ensure sterility
2 none
10 180
advice
ingredients
ensure sterility

be sterilised
has a strong smell
3 none
54
10 270

drank with gusto!
internet
5 {135
}
the instructions

care points
advice
ingredients
2 none
10 180
2 none
10 180

drank with gusto!
ed
3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions
advice
drank with gusto!
1 Cannot complete
147
and move on to
next operation
3 subsequent stages
will be affected
(detection post
process)
3 none
10 270
3 none
10 270

ingredients
2 Instructions are
54
read thoroughly
before commenc-
ing brewing
advice
3 none
10 270

care points
correct volume = 40 pints
2 none
10 180
5 none
10 300

drank with gusto!

internet
5 Smell & clarity
6 {180
}
checks - small
glass poured
before 6 days into
final fermentation
process

1 Visual inspection
12
24
ingredients
and re-read at

advice
each stage of the

brewing process
3 none
10 180
3 none
10 180
drank with gusto!

internet
5 {90}
the instructions
2 Visual inspection
12
2 Instructions are
54
drank with gusto!

advice

ingredients
read thoroughly
advice
3 none
10 270
3 none
10 270
3 none
10 270
3 none
10 270

2 none
10 180

be sterilised

water board

2 Beer clarity and
smell are checked
drank with gusto!
internet
3 none
8 {144
}
10 270
5 {135
}
the instructions
ock whilst temperature settles

2 none
10 180
care points
2 Visual inspection
90
care points

drank with gusto!
3 none
10 270
internet
5 {135
}
the instructions

drank with gusto!
1 Visual inspection
45
3 subsequent stages
will be affected
(detection post
process)
189

care points
2 none
10 180
cified temperature = 22 Centigrade 5C


drank with gusto!
internet
3 none
10 240

5 {120
}
the instructions
drank with gusto!
3 subsequent stages
will be affected
(detection post
process)
168
2 Instructions are
48
32

ingredients
read thoroughly
advice
ingredients
and re-read at
each stage of the
advice
brewing process
3 none
10 240

drank with gusto!
internet
5 {120
}
the instructions
Mechanical thermometer
2 Visual inspection
48
2 Instructions are
36
126
used
ingredients

advice
drank with gusto!
read thoroughly
3 subsequent stages
will be affected
(detection post
process)
3 none
10 180
3 none
10 180

drank with gusto!
internet
5 {90}
the instructions
3 none
10 180

drank with gusto!
internet
5 {90}
the instructions

care points
2 none
10 180
3 none
10 270
2 none
10 180
3 none
10 270
3 none
10 270

care points
ock

drank with gusto!
internet
5 {135
}
the instructions
3 subsequent stages
will be affected
drank with gusto!
(detection post
189
90
process)
2 Visual inspection
care points

care points
2 none
10 180
2 none
10 180
3 none
10 270
3 none
10 240

drank with gusto!
internet
5 {120
}
the instructions
ays 2
Products recently pur-
1 Visual inspection
45
1 Visual inspection
45
2 Visual inspection
90
1 Visual inspection
40
1 none
chased (JIT)

care points
Office floor used instead
Cost and time limitations
1 Primary fermenta-
56
tion will be imped-
ed / airlock does
not bubble
2 none
10 160
water board

2 Beer clarity and
smell are checked
8 {128
}
2 Water Chlorination
can be smelt from
the tap (US
tap=faucet)
32
2 Climate supervisor
48

water board

Home is in a temperate cli-
2
mate and centrally heated
(wife)
Lack of hot domes-

drank with gusto!
tic water supply (discovered when

teenage son want
to shower)
Home is in the UK, which is

unlikely to lead to excessively high temperatures
Home is in a temperate cli2 Climate supervisor
(wife)
Lack of hot domes-

drank with gusto!

teenage son want
to shower)
Warm floor space in office

has been assigned (location where the cat usually
sleeps!)
2 none
48
48
10 160
ingredients
drank with gusto!
2 Visual inspection
Audible sounds of
bubbles exiting the
airlock expected
within 24 hours
32
2 Instructions are
ingredients
read thoroughly
42
advice
3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions
stent temperature of = 20-25C

Home is double glazed
(wife)
24
24
2 Instructions are
48
48
fermentation bucket is covered

ingredients
read thoroughly
before commenc-
ing brewing
advice
(wife)
Lack of hot domes-

drank with gusto!

teenage son want
to shower)

has been assigned (loca-
tion where the cat usually

sleeps!)
ingredients
advice
2 Instructions are
48
48
48
read thoroughly
(wife)
Lack of hot domes-
tic water supply (dis-
drank with gusto!
covered when
teenage son want
to shower)

unlikely to lead to excessively high temperatures
Use of good quality brew kit 2 Instructions are
ingredients
advice
oiding the sediment
read thoroughly
2 none
10 180
3 none
10 270
3 none
10 270
care points

1 Visual inspection

care points
2 none
45
10 180
3 none
10 240
drank with gusto!

internet
5 {120
}
the instructions
advice
1 Cannot complete
and move on to
next operation

Compression fit at joint
3 Visual inspection
48

2 Visual inspection
16

drank with gusto!
advice
3 none
10 210
3 none
10 210
drank with gusto!

internet
5 {105
}
the instructions
2 Instructions are
ingredients
read thoroughly
before commenc-

advice
ing brewing
42
30g
2 none
10 180
2 none
10 180
care points

care points
2 none
10 180

care points
2 none
10 180

3 none
10 270
advice
ingredients

ensure sterility
ingredients
and re-read at
each stage of the

advice
brewing process
28
3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions

are specified in the instructions
ingredients
advice
TPM on all devices
Digital scales used

5 Electronic scales
within accurate to
0.25g
35
2 Instructions are
42
63
read thoroughly
3 1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
4 Scales clearly dis-
28
12
play a battery level symbol


2 Sugar packaging
is clearly labelled
tions
drank with gusto!
advice

drank with gusto!
5 none
10 350

internet

drank with gusto!
5 Smell & clarity

checks - small
glass poured
before 6 days into
final fermentation
process
6 {210
}
3 subsequent stages
will be affected
(detection post
process)
147
28

ingredients
and re-read at

advice
each stage of the

brewing process
3 none
10 210

drank with gusto!
internet
the instructions
5 {105
}
5 {105
}
2 Instructions are
70
42

ingredients

advice
ingredients
advice
read thoroughly
2 Instructions are
read thoroughly
3 none
10 210

drank with gusto!
internet
the instructions
ays +6
5 {105
}
2 none
10 180
care points
1 Visual inspection
40

2 Visual inspection
16

drank with gusto!
advice
3 none
10 210

drank with gusto!
internet
5 {105
}
the instructions

ingredients
advice
2 Instructions are
42
read thoroughly
5 none
10 350
5 none
10 350

drank with gusto!
internet
5 Smell & clarity
checks - small
glass poured
before 6 days into
final fermentation
process
3 none
6 {210
}
10 210
advice

ingredients
drank with gusto!
stent temperature of = 20-25C
(wife)
Lack of hot domes-
tic water supply (dis-
drank with gusto!
covered when
42
teenage son want
unlikely to lead to excessive-
to shower)
ly high temperatures

ingredients
32
48
and re-read at
each stage of the
brewing process
advice
(wife)
Lack of hot domes-

drank with gusto!

teenage son want
to shower)

has been assigned (location where the cat usually
sleeps!)
ingredients
advice
2 Instructions are
48
read thoroughly
3 none
10 240

drank with gusto!
internet
the instructions
5 {120
}
Home is in a temperate climate and centrally heated
48
48
(wife)
Lack of hot domestic water supply (discovered when
teenage son want
to shower)

ingredients
advice
2 Instructions are
read thoroughly
Number:1.1
Page:
Created:13/03/2013
Created:13/03/2013
Modified:13/03/2013
R/D
Robbins, Gavin, Penkridge, FMEA

Facilitator / Trainer
3/22/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

3/27/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

3/27/2013
in revision

4/3/2013
in revision

3/22/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

3/22/2013
in revision

3/15/2013
completed

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

3/27/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

4/3/2013
in revision

3/27/2013
in revision

4/3/2013
in revision

Beer Brewing Pfmea

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Beer Brewing Pfmea

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FMEA

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

Poor air quality

[5% Indian Pale

Steriliser not [Brewer]

[5% Indian Pale

[5% Indian Pale

Process Element: Preparing the Wort

[5% Indian Pale

Characteristics: Add boiling water to the fermentation bucket = 5 litres +1

[5% Indian Pale 7

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

Water added [Brewer]

[5% Indian Pale

Characteristics: Add the ingredients to the

fermentation bucket = 1 kg beer enh

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

(does & don'ts)

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

Malt & Hops

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale 7

[5% Indian Pale

[Malt & Hops]

Function: Mix contents until ingredients are dissolved

[5% Indian Pale 7

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale 7

Poor air quality

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

[5% Indian Pale

Process Element: Add yeast

[5% Indian Pale

[5% Indian Pale

when wort is Ambiguous

[5% Indian Pale 6

[5% Indian Pale

[5% Indian Pale 8