Failure Mode and Effect Analysis:

 FMEA is a risk and potential failure identification methodology which is used as a tool to
identify and quantify both the probability and effect of a failure or potential problem
eventuating.
 A FMEA is used in many different applications, the most common being in a
manufacturing, process or assembly application where the analysis will try and quantify
the different failure modes of product, part or machine and the effects of these happening.
 This analysis tool can also be used in a diverse range of applications from building and
infrastructure projects to interactive customer service systems or technology.
STAGES OF FMEA:

1-Specifying Possibilities:
Functions:
 Uneven distribution of glass in most of the cavities.

Root Causes:

 Improper Loading of gob in blank

 Design of blank.
 Uneven glass temperature.

Effects:

 Formation of thin at shoulder, body or bottom areas

 Resulting of broken of bottle during inspection ,transit, ceiling and packing

2- Quantifying Risk:

 Severity of effects :

Criteria for ranking severity Effects Rank

Failure occur without warning Deadly 10

Failure occur with warning hazardous 9

Product inoperable with loss of Very serious 8

 function
Chances of detection of failure mode Rank
Product operable but with loss of Serious 7
performance.
No Known control available 10
Product
Very operable but with
remote changes loss of Moderate
of detection 9 6
Remote
comfort chances of detection 8
Very low
Product chances
operable of low
with detection
effect low 7 5
Low chances of detection
on performance. 6
Moderate chances
Noticeable effect ofbydetection
most Very low 5 4
customers
Moderatelyeffect
Noticeable high chances of detection
by average Minor 4 3
High
customerschances of detection 3
Very high chances
Noticeable of detection
effect by Very minor 2 2
Almost certain to detect
discriminating customers 1

No-effect None 1

 Occurrence of failure :

Occurrenc Failure Criteria Rank

e rate

Very high >1 in 2 Failure is almost 10

1 in 3 inevitable 9
High 1in 8 Repeated failure 8
1 in 20 7
Moderate 1 in 400 Occasional 6
1 in 2000 failures 5
Low 1 in 4
15000 Relatively few
1 in failures 3
150,0000
Remote <1 in 2
1,500,000 Failures is 1
unlikely

 Detection of failure :
Risk Priority Number (RPN):

S O D R
E C E P
P C T N
4
10 2 10*4*2=80

6
10 7

10*6*7=420

10 4 4 10*4*4=160

3- Correcting High Risk Causes

Prioritizing work:

 Manual checking of deflector alignment with blank.

 Inspection of bank design.
 Electronic control for glass tube rotation.

Detailed Actions:
 Maintain the temperature of glass.
 Frequency of manual sampling increased at hot.
  Inspection of all parameters of bank on profile projector.
 Installation Of computerize system of alignment of deflector with ban

Assigning Action Responsibilities:

 Responsibility assigned to the respective department with Targeted date

 Glass temperature maintains Computerize System for Deflector Alignment
installed.
 Sampling of bottles at hot end done by M/C Engineer
 In every hour Profile Projector for blank Inspection installed
 Check points on completion.

4- Re- evaluation of Risk:

 Recalculation of RPN.

S O D R
E C E P
P C T N
2
10 2 10*2*2=40

3
10 2 10*3*2=60

3
10 2 10*3*2=60
Product Potential Potential S Potential O Current D R Recommended Responsibiliti Actions results
function failure effects of E causes of C Control E P Actions es Action S O D R
requireme mode failure V failure C T N and target test E C E P
nt completion P C T N
date
Light Uneven Formation of 10 Uneven glass 4 Electronic 2 1 Maintain the Responsibility Glass 10 2
2 10*2
weight Distributi thin at temperature control for 0 temperature of glass Assigned to Temperatur *2=
glass bottle on of shoulder, glass * the respective e 40
glass in body or Tube 4 Frequency of department Maintain
most of bottom areas. rotation * manual sampling with Computeriz
the 2 increased at hot Targeted date. e
3
cavities. = end. System 2
For
Resulting of
8
Installation Deflector 10*3
Storage of broken of Of computerize Alignment *2=
0
liquor bottle during system of alignment Installed 60
Improper 6 Manual 7 1
inspection of deflector with
Loading of checking 0
,transit, bank Sampling
gob in blank of *
ceiling and
deflected 6
packing
alignment *
with blank 7
 = Of bottles 3 2
4 Inspection of all At hot
2 parameters of bank End done
0 on profile projector By M/C
10*3
Design of 4 Inspection 4 1 Engineer
blank of blank 0 In every *2=
design * hour 60
4 Profile
* Projector
4 For blank
= Inspection
1 installed
6
0