Managing Quality

Chapter 18. Failure Mode and Effects Analysis

J. R. Aldridge and B. G. Dale

Introduction

This chapter provides an overview of the concept of failure mode and effects analysis (FMEA), and its value as a planning tool to assist with building quality into an organization's product, service and processes. The purpose of FMEA is described and the procedure for the development of both design FMEA and process FMEA is outlined. In examining the use of FMEA reference is made to the work carried out in developing the use of FMEAs at Allied Signal Auto-motive's Skelmersdale operation. This plant is a manufacturing and assembly facility producing turbochargers for the automotive industry. The company is the world's largest producer of automotive turbochargers, with a current market share of 50 per cent. The lessons learned in the use of FMEA are fully examined in the chapter.

What is Failure Mode and Effects Analysis?

The technique of FMEA was developed around 1962 in the aerospace and defence industries as a method of reliability analysis, risk analysis and risk management. It is a systematic and analytical quality planning tool for identifying, at the product, service and process design and development stages, what might potentially go wrong, either with a product (during manufacture, or during end-use by the customer), or with the provision of a service, thereby aiding fault diagnosis. The use of FMEA is a powerful aid to advanced quality planning of new products and services, and can be applied ...