7 steps of Process Failure Mode and Effects Analysis (PFMEA)

7 steps of Process Failure Mode and Effects Analysis (PFMEA) is applied in an effort to stop failures. Known by another name, Process Failure Mode and Effect Analysis, it is a tool used by manufacturing and process engineers to find and evaluate possible process problems.

Purpose

Teams can plan and create process safeguards through PFMEA that will lessen or eliminate the likelihood of costly repairs, reworks, operational downtime, and accidents.

PFMEA is conducted when the following occurs in the automobile organization:

• New changes are implemented on existing processes

• New technologies, equipments, or processes steps are being introduced

• Implementing a process to a new products, or department

How to Conduct PFMEA in 7 Steps

7 steps of Process Failure Mode and Effects Analysis (PFMEA) :

1- Process review

2- Identify potential failure modes

3- List potential failure modes effects and assign severity score

4- Determine potential cuases and assign occurrence rating

5-  Determine current process controls Assign Detecting Rate

6- Calculate RPN and create actions

7- Re-Calculate RPN

Steps 1: Process review

Selecting the evaluation’s focus is a crucial initial step in the 7 steps of Process Failure Mode and Effects Analysis (PFMEA). Is it an operational procedure? A procedure for services? or a method of manufacture? After you’ve decided which topic you want to concentrate on, go over the related steps and ascertain the goals of each one. For better visualization, one of the easiest methods to do this is to place it on a flowchart.

Step 2: Identify Potential Failure Modes

Step 2 of 7 steps of Process Failure Mode and Effects Analysis (PFMEA) What might go wrong in this step? Situations that could cause the process to diverge from the desired result are known as potential failure modes. For instance, pallet conveyors are frequently used in manufacturing companies to move products during the production process. As the boxes or bottles go along the conveyor, they could trip, fall, or sustain damage. This could be a process failure mode.

Step 3: List Potential Failure Effects & Assign Severity Score

What might happen if the probable failure that has been detected takes place? Think about how it will affect the environment, the facilities, the consumers, the employees (e.g., injuries), and even the process itself. List each one as thoroughly as you can, as there can be more than one. After that, assign a severity rating, with 1 representing the lowest and 10 representing the highest. The seriousness of the effects determines the ranking of severity.

Step 4: Determine Potential Causes & Assign Occurrence Rating

What might set off the possible mode of failure? Ascertain the trigger(s) and/or potential causes of the failure mode effect. Using the same scenario as in step 2, for instance. How might an employee get hurt if the failure mode that was detected causes it? Is it because the machinery malfunctioned or were the employees not wearing the proper PPE? After that’s established, rate each occurrence appropriately, with 1 being the lowest and 10 being the highest. The frequency at which the trigger or cause is expected to occur determines the occurrence rating.

Step 5: Determine Current Process Controls & Assign Detection Rating

Existing controls aimed at detecting or preventing the failure mode? Process phases should ideally have safety measures in place. List all relevant controls and rate each one from 1 (lowest detection) to 10 (highest detection). The ease with which the failure mode can be identified with the current controls determines the detection rating.

Step 6: Calculate RPN & Create Actions

A process is assessed, given a score on a range of 1 to 10, and then multiplied by each other in order to calculate RPN. Teams can prioritize risks and develop corrective actions by using the Risk Priority Number (RPN). In the event that the failure mode produces a high RPN, an improvement or corrective action plan is developed. The action plan comprises a comprehensive guide or checklist of actions to be performed, designated persons to carry them out, and a deadline for completion.

Failure Modes and Effects Analysis (PFMEA) Risk Priority Number – RPN

Severity x Occurrence x Detection = RPN

Severity– Assesses the impact of the failure mode (the error in the process), with 1 representing the least safety concern and 10 representing the most dangerous safety concern.

Occurrence- Occurrence” is a ranking number associated with the likelihood that the failure mode and its associated cause will be present in the item being analyzed.

Detection– The detection ranking considers the likelihood of detection of the failure mode/cause, according to defined criteria. Detection is a relative ranking within the scope of the specific FMEA and is determined without regard to the severity or likelihood of occurrence.

Step 7: Re-Calculate RPN

The impact of the action plan should be measured by recalculating the RPN and reevaluating the PFMEA.

Also you can learn about What is FMEA

Where is PFMEA Used?

Many different industries that prioritize the effectiveness, safety, and dependability of goods and machinery use PFMEA. The automobile, manufacturing, and defense industries are among of these sectors.

Example of a PFMEA

By carrying out a PFMEA, you will evaluate a process to identify possible problems and determine preventative measures. This holds true for any procedure that your company may use, including those that are currently in use and those that you are considering putting into place.

For instance, you may have recently developed a new procedure that you think will increase warehouse production. Reviewing this process and identifying any potential points of failure (i.e., identifying its failure modes) is the first step in conducting a PFMEA. Subsequently, you would evaluate the gravity of these failures’ possible consequences, identify their probable origins, and determine the probability that you could detect these failures before they happen. These scores for severity, occurrence, and detection allow you to compute the RPN, which provides you with priority data. The information you have regarding the priority then enables you to create and carry out an action plan to prevent these possible setbacks.

To ensure that the RPN remains as low as feasible, you can set aside some time to regularly perform PFMEAs in the future, even after the new procedure and action plan have been implemented.

What are the Benefits of PFMEA?

Whenever suitable, performing a PFMEA can have several advantages. Among them are:

• You may design a process that produces well-managed goods and equipment while also being safe for all parties involved by employing PFMEA. This results in happier clients and staff as well as fewer time and money wasted on unforeseen labor.

• The capacity to recognize possible setbacks. You may adjust your operations to reduce risk and boost dependability with this knowledge.

• Greater understanding of the remedial measures that will optimize your processes. This is accomplished by continuously computing RPN, which gives you a concrete understanding of which failure types require the greatest attention.

What are the Disadvantages of PFMEA

PFMEAs are a terrific approach to evaluate your processes and make sure you’re minimizing risks, but they might take a while to complete. It is a multi-step process that incorporates brainstorming, trial and error, and numerous phases to ensure that asset management is not a one-and-done deal. Be certain that PFMEA is the best course of action for your particular process before beginning the PFMEA procedure. If not, you can still make sure you’re avoiding potential failures by using alternative, quicker analytical techniques.