FMEA_Analysis_LEC 3 CONT_Engg proff practice. (1).pptx

FMEA_Analysis

1. Failure Mode and Effects Analysis (FMEA) A Proactive Approach to Identifying and Mitigating Risk

2. What is FMEA? - FMEA is a systematic method for evaluating systems or processes. - It identifies how and where a system might fail. - Analyzes the effects of these failures. - Prioritizes actions to minimize or eliminate risk.

3. Objectives of FMEA - Increase product reliability and customer safety. - Reduce warranty costs and field failures. - Identify potential weak points early in design or process. - Create a knowledge base for future improvements.

4. Key Elements of FMEA F ailure Mode – How a component/process can fail Effect – Consequence of the failure Cause – Root cause of the failure Severity (S) – Impact on the system/user Occurrence (O) – Likelihood of the failure happening Detection (D) – Ability to detect the failure before it reaches the user RPN (Risk Priority Number) = S × O × D

5. Calculating RPN RPN = Severity × Occurrence × Detection Example: - Severity = 9 (severe injury possible) - Occurrence = 3 (failure occurs occasionally) - Detection = 2 (easy to detect before failure) RPN = 9 × 3 × 2 = 54

6. Failure Mode Effect of Failure Severity (S) Occurrence (O) Detection (D) RPN (S×O×D) Recommended Action Battery does not charge Battery drain, laptop shutdown 8 4 3 96 Check charging IC and firmware Overheating sensor fails No shutdown on overheating 9 3 2 54 Add redundant thermal sensors Power source switching fails No transition from battery to AC 7 3 3 63 Improve switching circuit design Battery percentage misread Unexpected shutdown 6 5 4 120 Calibrate battery level sensing logic OS does not trigger hibernate Data loss in low battery condition 9 2 3 54 Improve power management software Adapter detection error Charging disabled unnecessarily 6 3 2 36 Add redundant adapter detection logic System Under Analysis: Laptop Power Management Objective: Ensure reliable switching between battery and AC power, proper charging, and shutdown during overheat or low battery conditions.

7. Benefits of Using FMEA - Reduces risk proactively - Improves reliability and quality - Saves cost by addressing issues early - Documents organizational knowledge - Supports compliance with standards (ISO 9001, IATF 16949)

8. FMEA in Real Life Applications - Automotive: Airbags, brakes, steering systems - Aerospace: Flight control systems - Healthcare: Medical devices - Manufacturing: Production line equipment - Software: Embedded control systems

9. Summary FMEA helps us to: - Understand potential failures - Quantify and prioritize risks - Drive preventive measures A powerful tool for risk management and continuous improvement