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Failure Mode and Effects Analysis - FMEA

A structured and systematic approach for analyzing potential failure modes during product development
Introduction to Failure Mode and Effects Analysis (FMEA)
FMEA is a highly structured and systematic approach for analyzing potential failure modes during product development, product assembly or process analysis.
Kinectrics has many years of experience in design, assembly, testing, and deployment of complex tooling. FMEA is extensively used for failure analysis and reliability study.
Why use FMEA?
FMEA was developed in the late 1950s for failure analysis of the US military systems. It is widely adopted in automotive, aerospace, electricity, and many other industries. It is an essential system reliability study tool where a risk associated with a potential failure mode is analyzed, quantified and mitigated (reduced) to an appropriate level. It is based on an inductive reasoning approach that considers how the failure mode of each system component can affect the performance of the system.
FMEA Types
FMEA can be used to analyze all potential failure modes related to design, manufacturing, and use of a product.
DFMEA (Design Failure Mode and Effects Analysis) is used during design to analyze how failure modes of different components can affect the functionality of the system and what are consequences of the failures.
PFMEA (Process Failure Mode and Effects Analysis) is used to analyze potential effects of process failure on the product being produced.
How to perform FMEA
  • FMEA is always done in a team-based setting, with involvement of different disciplines
  • Use classification tables for quantification of severity, occurrence, and detection
  • Establish RPN (Risk Priority Number) ranking scheme
  • Analyze functions of a system and associated sub-systems
  • Develop functional block diagram
  • List all failure modes
  • Analyze how singular functionality can be affected by different failure modes of the components
  • Analyze effects of the failure modes
  • Assign severity ranking(S)
  • Assign probability of occurrence (O)
  • Analyze how a failure mode can be detected and prevented(D)
  • Calculate RPN (RPN = S*O*D)
  • Based on the RPN value determine if an action is required to reduce RPN
  • If required, specify recommended actions
  • After recommended actions are taken recalculate RPN
  • Severity will stay the same before and recommended actions are taken
  • Re-asses new RPN and determine if it is acceptable

 Kinectrics FMEA expertise and value added 

Kinectrics is the category leader in providing life cycle management solutions for the electricity industry. We develop complex FMEAs utilizing subject matter experts in:
·         Design, manufacturing, and deployment of Inspection Tooling and Systems
·         Qualification of Nuclear Parts
·         Materials and Major Components
·         Station and Chemistry Waste
·         Transmission and Distribution
·         Safety and Licensing
We have developed methodology and FMEA tools that could be successfully applied in different areas of product and process development where reliability and risk mitigation are an integral part of a successful project.