Failure Mode and Effect Analysis (FMEA) Implementation: A Literature Review

FMEA is a systematic method of identifying and preventing system, product and process problems before they occur. It is focused on preventing problems, enhancing safety, and increasing customer satisfaction. Formally FMEA was introduced in the late 1940s by the US military Forces. In 1960s it was used by the aerospace industry as a design methodology, with their obvious reliability and safety requirements. In the late 1970s, the Ford Motor Company introduced FMEA to the automotive industry for safety and regulatory consideration. They also used it to improve production and design. FMEA is widely used in manufacturing industries in various phases of the product life cycle and it now extensively used in a variety of industries including semiconductor processing, food service, plastics, power plant, software, and healthcare. A successful FMEA activity enables a team to identify potential failure modes based on past experience with similar products or processes, enabling the team to design those failures out of the system with the minimum of effort and resource expenditure, thereby reducing development time and costs. This paper highlights the various approaches and applications of FMEA have been developed so far.

[1]  Joan K. Plastiras.  Intersystem Common Cause Analysis of a Diesel Generator Failure , 1986 .

[2]  Seung J. Rhee,et al.  Using cost based FMEA to enhance reliability and serviceability , 2003, Adv. Eng. Informatics.

[3]  Dong‐Shang Chang,et al.  Applying DEA to enhance assessment capability of FMEA , 2009 .

[4]  R. Esmail,et al.  Using Healthcare Failure Mode and Effect Analysis tool to review the process of ordering and administrating potassium chloride and potassium phosphate. , 2005, Healthcare quarterly.

[5]  Houston G Wood,et al.  Methods of failure and reliability assessment for mechanical heart pumps. , 2005, Artificial organs.

[6]  B. G. Dale,et al.  The Application of Failure Mode and Effects Analysis at an Automotive Components Manufacturer , 1991 .

[7]  Sheng‐Hsien Teng,et al.  Failure mode and effects analysis: An integrated approach for product design and process control , 1996 .

[8]  F. Jolai,et al.  An integrated approach for risk-assessment analysis in a manufacturing process using FMEA and DES , 2011, 2011 IEEE International Conference on Quality and Reliability.

[9]  M Weda,et al.  Consistency of FMEA used in the validation of analytical procedures. , 2011, Journal of pharmaceutical and biomedical analysis.

[10]  Osman Turan,et al.  Reliability and Availability of Pod Propulsion Systems , 2006, Qual. Reliab. Eng. Int..

[11]  Waj Werner Schippers.  The process matrix, a simple tool to analyse and describe production processes , 1999 .

[12]  Zilda de Castro Silveira,et al.  Development and reduction of a fault tree for gearboxes of heavy commercial vehicles based on identification of critical components , 2008, Qual. Reliab. Eng. Int..

[13]  Jean-Yves Dantan,et al.  Conceptual process planning - an improvement approach using QFD, FMEA, and ABC methods , 2010 .

[14]  N. Bernstein.  Reliability analysis techniques for mechanical systems , 1985 .

[15]  Theodoros H Varzakas,et al.  Application of Failure Mode and Effect Analysis (FMEA), Cause and Effect Analysis, and Pareto Diagram in Conjunction with HACCP to a Corn Curl Manufacturing Plant , 2007, Critical reviews in food science and nutrition.

[16]  Paulo Augusto Cauchick Miguel,et al.  Failure mode and effects analysis (FMEA) in the context of risk management in new product development: A case study in an automotive company , 2008 .

[17]  Theodoros Varzakas,et al.  Application of failure mode and effect analysis (FMEA) and cause and effect analysis for industrial processing of common octopus (Octopus vulgaris) – Part II , 2009 .

[18]  Desheng Dash Wu,et al.  A risk analysis model in concurrent engineering product development. , 2010, Risk analysis : an official publication of the Society for Risk Analysis.

[19]  Kenji Tanaka,et al.  Fault tree diagnosis based on minimal cut sets and using repair information , 1999 .

[20]  M. Molhanec,et al.  Model based FMEA - An efficient tool for quality management of the free lead soldering , 2012, 2012 35th International Spring Seminar on Electronics Technology.

[21]  Rui Kang,et al.  Application and improvement study on FMEA in the process of military equipment maintenance , 2011, The Proceedings of 2011 9th International Conference on Reliability, Maintainability and Safety.

[22]  Pavel Mach,et al.  The ontology based FMEA of lead free soldering process , 2009, 33rd International Spring Seminar on Electronics Technology, ISSE 2010.

[23]  Marcello Braglia,et al.  Fuzzy TOPSIS approach for failure mode, effects and criticality analysis , 2003 .

[24]  Svante Hovmark,et al.  The GAPT Model: Four Approaches to the Application of Design Tools , 1994 .

[25]  Irem Y. Tumer,et al.  Failure Mode Identification Through Clustering Analysis , 2004 .

[26]  James B Battles,et al.  Sensemaking of patient safety risks and hazards. , 2006, Health services research.

[27]  Chun-Bo Liu.  Notice of RetractionAircraft fuel tank system fire disaster analysis based on FMEA and FTA , 2013, 2013 International Conference on Quality, Reliability, Risk, Maintenance, and Safety Engineering (QR2MSE).

[28]  Ioannis S. Arvanitoyannis,et al.  Application of failure mode and effect analysis and cause and effect analysis and Pareto diagram in conjunction with HACCP to a chocolate-producing industry: a case study of tentative GMO detection at pilot plant scale , 2007 .

[29]  Salman Kahrobaee,et al.  Risk-based Failure Mode and Effect Analysis for wind turbines (RB-FMEA) , 2011, 2011 North American Power Symposium.

[30]  S. R. Devadasan,et al.  Design and development of modified service failure mode and effects analysis model , 2007 .

[31]  K. Mcnally,et al.  Failure-mode and effects analysis in improving a drug distribution system. , 1997, American journal of health-system pharmacy : AJHP : official journal of the American Society of Health-System Pharmacists.

[32]  A. D. Ookalkar,et al.  Quality improvement in haemodialysis process using FMEA , 2009 .

[33]  Hong-Zhong Huang,et al.  Design FMEA for a diesel engine using two risk priority numbers , 2012, 2012 Proceedings Annual Reliability and Maintainability Symposium.

[34]  Andrea Lásková,et al.  Method for the systematical hazard identification , 2008 .

[35]  David J. Russomanno.  A function-centered framework for reasoning about system failure at multiple levels of abstraction , 1999, Expert Syst. J. Knowl. Eng..

[36]  C. A. McMahon,et al.  Integration of Process FMEA with Product and Process Design Based on Key Characteristics , 2009, DET.

[37]  Carolyn D. Heising,et al.  The Ocean Ranger Oil Rig Disaster: A Risk Analysis , 1989 .

[38]  Theodoros Varzakas,et al.  Application of failure mode and effect analysis (FMEA), cause and effect analysis and Pareto diagram in conjunction with HACCP to a potato chips manufacturing plant , 2007 .

[39]  N. W. Ozarin.  Bridging software and hardware FMEA in complex systems , 2013, 2013 Proceedings Annual Reliability and Maintainability Symposium (RAMS).

[40]  Theodoros Varzakas,et al.  Application of failure mode and effect analysis and cause and effect analysis on processing of ready to eat vegetables – part II , 2009 .

[41]  B. J. Berkley.  Application of Fmea to Nightclub Security , 1998 .

[42]  Om Prakash Yadav,et al.  A framework for capturing and analyzing the failures due to system/component interactions , 2008, Qual. Reliab. Eng. Int..

[43]  D. Palumbo.  Automating failure modes and effects analysis , 1994, Proceedings of Annual Reliability and Maintainability Symposium (RAMS).

[44]  George Pantazopoulos,et al.  Process failure modes and effects analysis (PFMEA): A structured approach for quality improvement in the metal forming industry , 2005 .

[45]  Keith Case,et al.  Modelling and reasoning for failure modes and effects analysis generation , 2004 .

[46]  Craig P. Beyers.  THE SYSTEM ENGINEERING ANALYSIS: A STRUCTURED APPROACH FOR IMPROVING SHIP MAINTENANCE , 1982 .

[47]  Michael H. Wang.  A cost-based FMEA decision tool for product quality design and management , 2011, Proceedings of 2011 IEEE International Conference on Intelligence and Security Informatics.

[48]  Daoud Ait Kadi,et al.  A STATE-OF-THE-ART REVIEW OF FMEA/FMECA , 1994 .

[49]  Robert Stone,et al.  The risk in early design method , 2009 .

[50]  Dongil Kwon,et al.  Failure analysis of a boiler tube in USC coal power plant , 2009 .

[51]  Gianni Campatelli,et al.  Reliability Improvement of a Diesel Engine Using the FMETA Approach , 2004 .

[52]  João Carlos Espíndola Ferreira,et al.  Knowledge Sharing and Reuse in Potential Failure Mode and Effects Analysis in the Manufacturing and Assembly Processes (PFMEA) Domain , 2007 .

[53]  Peter Tavner,et al.  Failure Modes and Effects Analysis (FMEA) for wind turbines. , 2010 .

[54]  Lars Grunske,et al.  Generalizable safety annotations for specification of failure patterns , 2010, Softw. Pract. Exp..

[55]  Dinesh Kumar,et al.  Modeling system behavior for risk and reliability analysis using KBARM , 2007, Qual. Reliab. Eng. Int..

[56]  Xiangyang Wang,et al.  Defining Process Design Space for Biotech Products: Case Study of Pichia pastoris Fermentation , 2008, Biotechnology progress.

[57]  J. Natrop,et al.  QUALITY ASSURANCE OF COMPUTER CONTROLLED HOT-TOOL WELDING FOR MASS PRODUCTION , 1991 .

[58]  Wei-Min Cui,et al.  Notice of RetractionFailure mode effect analysis and optimal design of the wing structure , 2013, 2013 International Conference on Quality, Reliability, Risk, Maintenance, and Safety Engineering (QR2MSE).

[59]  Barrie Dale,et al.  Failure mode and effects analysis in the U.K. motor industry: A state-of-the-art study , 1990 .

[60]  F. Fantini,et al.  Failure Analysis-assisted FMEA , 2006, Microelectron. Reliab..

[61]  S. K. Majumdar,et al.  Study on reliability modelling of a hydraulic excavator system , 1995 .

[62]  Arash Shahin,et al.  Integration of FMEA and the Kano model , 2004 .

[63]  F. Mozaffari,et al.  Implementation of FMEA to improve the reliability of GEO satellite payload , 2013, 2013 Proceedings Annual Reliability and Maintainability Symposium (RAMS).

[64]  Ioannis S. Arvanitoyannis,et al.  Application of ISO 22000 and Failure Mode and Effect Analysis (FMEA) for Industrial Processing of Salmon: A Case Study , 2008, Critical reviews in food science and nutrition.

[65]  J. Bert Keats,et al.  THE USE OF FMEA IN PROCESS QUALITY IMPROVEMENT , 1995 .

[66]  Pascale Carayon,et al.  FMEA Team Performance in Health Care: A Qualitative Analysis of Team Member Perceptions , 2009, Journal of patient safety.

[67]  H. Paul Barringer.  An Overview Of Reliability Engineering Principles , 1996 .