ME410/411 Senior Design

FMEA

ME410/411 Senior
Design
Course Updates
Today - Introduction to FMEA
No class on Thursday - work on your
projects
Next Tuesday - Personal e!elop"ent
Christ"as #reak
Class will resu"e on Thursday$ %anuary
&'

ME410/411 Senior
Design
(hat is FMEA)
Failure
Modes
E**ects
Analysis
-+ee pa,e --. o* your /ook

ME410/411 Senior
Design
0easons to do FMEA
e*ine and ,uide a lo,ical desi,n process
Identi*y$ 1uanti*y$ and reduce desi,n risk
Pro!ide a tracea/le docu"ent *or desi,n
and de!elop"ent
%usti*y desi,n acti!ities
Pro!ide a "eans *or continuous product
i"pro!e"ent

ME410/411 Senior
Design
+cope o* FMEA
The FMEA is a team *unction
All tea" "e"/ers "ust participate
Multi-disciplinary expertise and input is /ene*icial
Input *ro" all en,ineerin, *ields is desira/le
0epresentati!es *ro" all areas 2not just technical
disciplines3 are ,enerally included as tea"
"e"/ers
The FMEA is not a one "eetin, acti!ity
The FMEA will /e re*ined and e!ol!e with the product
Numerous re!isions are re1uired to o/tain the *ull
/ene*it o* the FMEA
The FMEA should include all syste"s$ su/-
syste"s$ and co"ponents in the product desi,n

ME410/411 Senior
Design
FMEA Methodolo,y
4ist ite"s and *unctions
+tart with the syste"$ then su/syste"s$ and *inally
co"ponents
ocu"ent potential *ailure "odes
5ow could the desi,n potentially *ail to "eet the
desi,n intent)
Note: this might be the cause of failure at a
higher level (i.e. component to subsystem) or
the effect of a failure at a lower level.
Consider all types o* *ailure
ocu"ent the potential e**ects o* *ailure - 5ow
would the desi,n potentially *ail to "eet the
desi,n intent)

ME410/411 Senior
Design
FMEA Methodolo,y
0ate the se!erity o* the *ailure e**ect
ocu"ent potential causes and "echanis"s o*
*ailure Potential failure modes are the
consequences o* the failure causes
A sin,le *ailure "ode "ay ha!e "ultiple *ailure
"echanis"s
Use ,roup /rainstor"in, sessions to identi*y
possi/le *ailure "echanis"s
o not /e a*raid to identi*y as "any potential causes as
you can
This section o* the FMEA will help ,uide you in
necessary desi,n chan,es
The output o* the FMEA will indicate on which ite" to
*ocus desi,n e**orts

ME410/411 Senior
Design
FMEA Methodolo,y
0ate the occurrence
Are any ele"ents o* the desi,n related to a pre!ious
de!ice or desi,n)
5ow si,ni*icant are the chan,es *ro" a pre!ious desi,n)
4ist the desi,n controls$ which are intended to6
Pre!ent the cause o* the *ailure "ode
etect the cause o* the *ailure "ode
etect the *ailure "ode directly
Applica/le desi,n controls include6
Predicti!e code analysis$ si"ulation$ and "odelin,
Tolerance stack-up studies Prototype test results

ME410/411 Senior
Design
FMEA Methodolo,y
0epeat6 undertake the next re!ision o*
the FMEA
Your FMEA is an evolving document!
(as is a QFD)
Revise your FMEA frequently!
Diligence will eliminate design ris!
!nclude documentation of your
results!

ME410/411 Senior
Design
Fre1uency 0ankin,

ME410/411 Senior
Design
+e!erity 0ankin,s

ME410/411 Senior
Design
Classi*ication o* 70isk8
Possi/ility
9*
9ccurrence
+e!erity o* 9utco"e
5i,h 0isk
Moderate 0isk

ME410/411 Senior
Design
FMEA 2Failure Mode and E**ects Analysis3
Method *or analy:in, the causes and e**ects
o* *ailures;
5i,hli,hts desi,ns and asse"/lies "ost likely
to cause *ailures;
5elps identi*y and prioriti:e correcti!e action
Indicates where the "ost i"pro!e"ent in
ter"s o* se!erity$ *re1uency$ and detecta/ility
can /e "ade;
(idely used "anu*acturin, techni1ue 2Mil
standards$ +AE$ AN+I +pecs3

ME410/411 Senior
Design
Course +chedule
Failure Modes and E**ects Analysis
2FMEAplus36 +o*tware de!eloped /y Ford
Motor Co"pany; An FMEA can /e descri/ed
as a syste"i:ed ,roup o* acti!ities intended
to6 2a3 reco,ni:e and e!aluate the potential
*ailure o* a product<process and its e**ects$ 2/3
identi*y actions which could eli"inate or
reduce the chance o* the potential *ailure
occurrin,$ and 2c3 docu"ent the process; It is
co"ple"entary to the desi,n process o*
de*inin, positi!ely what a desi,n "ust do to
satis*y the custo"er;

ME410/411 Senior
Design
Course +chedule

ME410/411 Senior
Design
Course +chedule

ME410/411 Senior
Design
Course +chedule
No class on Tuesday No!; .=
Thursday No!; .-
More tea" >?A6
For"ula tea"
Ethanol tea"
4AN4-controls tea"

ME410/411 Senior
Design
Course +chedule
No class on Tuesday No!; .=
Thursday No!; .-
More tea" >?A6
For"ula tea"
Ethanol tea"
4AN4-controls tea"

ME410/411 Senior
Design
+teps in the Process
>F@s
I* you ha!e not done one yet$ you
should start one
I* you did one *or the proposal$ you
should update it with new in*or"ation
A >F expands as you ,et new data
New custo"er re1uire"ents
New en,r; +pecs
New /ench"arks