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Six Sigma DMAIC Process - Improve Phase - Failure Mode Effect Analysis (FMEA)

FMEA identifies all the probable failure modes for the product or process. It prioritizes the failure modes for focused attention by using a scoring model based on Severity (S), Occurrence (O) and Detect ability (D).

RPN = S*O*D

Based on the above suitable action plans can be created to contain the risk. It is used as a living document and could be a good foundation for building robustness.

Definition of Terms:
  • Failure Mode – The way in which a specific process input fails
  • Effect – The impact the failure has on the Critical Quality Parameter
  • Cause – The source of variation that caused the process to fail
  • Current controls – Systemized devices in place to prevent or detect the failure
  • Severity – Importance of an effect on critical quality parameter (1-Not severe; 10 – very severe)
  • Occurrence – Frequency with which a cause occurs (1-Not likely; 10-Very likely)
  • Detection – Ability of current control to detect the cause before creating a failure mode (1-likely to detect; 10-not likely to detect)
  • RPN is an acronym for Risk Priority Number. It is calculated by multiplying the Severity, Occurrence and Detectability.

Failure Mode Effect Analysis (FMEA) - 1



Failure Mode Effect Analysis (FMEA) - 2




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Table of Contents


What is Six Sigma?
What is Quality?
What is the Hidden Factory?
Six Sigma Process Excellence Disciplines
History of Six Sigma
How does Six Sigma work?
What is Sigma and Why is it Six Sigma?
What is the Focus of Six Sigma?
How does Six Sigma DMAIC Process work?
Six Sigma Roles and Responsibilities
Six Sigma vs Business Process Reengineering
What is Statistics?
What is Descriptive Statistics?
What is Inferential Statistics?
Accuracy vs Precision

Six Sigma DMAIC Process - Introduction to Define Phase
Six Sigma DMAIC Process - Introduction to Measure Phase
Six Sigma DMAIC Process - Introduction to Analyze Phase
Six Sigma DMAIC Process - Introduction to Improve Phase
Six Sigma DMAIC Process - Introduction to Control Phase
Six Sigma DMAIC Process - A Real World Example

DMAIC Define - Capturing Voice of Customer (VOC)
DMAIC Define - KANO Analysis
DMAIC Define - CTQ Drilldown Tree
DMAIC Define - Six Sigma Project Charter
DMAIC Define - Change Acceleration Process (CAP)
DMAIC Define - Process Mapping / SIPOC
DMAIC Define - Process Mapping / Flow Charting
DMAIC Measure - Identify Possible Project Y's
DMAIC Measure - Types of Data
DMAIC Measure - Variation / Discrete vs Continuous Thinking
DMAIC Measure - Data Collection Strategy - Sampling
DMAIC Measure - Measurement System
DMAIC Measure - Process Capability

DMAIC Analyze - As Is Process Map
DMAIC Analyze - Data Door Analysis
DMAIC Analyze - Control Impact Matrix
DMAIC Analyze - Why Analysis
DMAIC Analyze - Hypothesis Testing
DMAIC Analyze - Analysis Examples

DMAIC Improve - Solution Parameter
DMAIC Improve - Generate Possible Solution
DMAIC Improve - Screen Against Musts and Wants
DMAIC Improve - Conduct Cost-Benefit Analysis
DMAIC Improve - Failure Mode Effect Analysis (FMEA)
DMAIC Improve - Pilot Solution Implementation
DMAIC Improve - Validate Measurement System
DMAIC Improve - New Process Capability / Mapping

DMAIC Control - Statistical Process Control
DMAIC Control - What is a Process Control?
DMAIC Control - What are Control Charts?
DMAIC Control - SPC - Out of Control
DMAIC Control - Leading Indicator vs Lagging Indicator
DMAIC Control - Control Chart Selection
DMAIC Control - Risk Assessment and Mistake proofing - Poka Yoke
DMAIC Control - Control and Implementation Plans
DMAIC Control - Review and Sign-off

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