FAILURE MODE Apparel

Quality
AND EFFECT Management

ANALYSIS
 INTRODUCTION

 Failure modes and eff ects analysis (FMEA) is a step -by-step

approach for identi fying all possible failures in a design, a
manufacturing or assembly process, or a product or service.

 “Failure modes” means the ways, or modes, in which

something might fail. Failures are any errors or
defects, especially ones that affect the customer, and can be
potenti al or actual.

 “Effects analysis” refers to studying the consequences of

those failures.
 Process FMEA , Page: 1

Process: Ecu ' Responsibility: . Project Monoge r ," Num ber:

Product: Exampie produot ' P re pa red by: , Gavin Robbins , Creatéd: 01/01/2008
, Key Date: . Milestone 1 , Modified: O3/03/2OO8
Anon Teom

Process Potential Failure Prdventive Z, Beccommended Responsible Actions

Function Failure Mc<le Failure Effect § Detection Action
Step Gause u Action a, Actions & Deadline Take.n
C

Casé Prod uoe a Deformation Total

Tfiermo-couples First off
Moulding moulded of the csse .2 Preventstive 1 16,
cose os par fail inspection
Mo intenonce
draw ing High scrap 4 Totsl First off
ins ation
Damaged tel 2 Preventative 3 4B
Ope rotor
Maintenance
.1.5. visusI
ins ction
Granulate
Controlled
moisture First off
1 environment
content is oufof inspection
within the 5ilo
tolerance
Problems wifh
Incorrect type of 2 Work First off
Instructic•ns
tooi ins otic•n
lnitioI setup
vehic ie by First off
Incorrect inspection
Manufacturing 2 1s,
temperature 1 En ineer
settings Work Operator visu il
Instructions inspection ,
lnitiaI setup '”
by
Manufacturing
Incorrect inF tion
’2’0 1 En ineer 2 16
pressure settings
worn
21 Instructions
InitiaI setup by
Msnufocturing
Incorrect cycle
En ineer
time
2Z’ worn Operator visual
W irrenty Instructions ins ation
24 returns Incoming
Incorrect type of Ins ction NONE
granulafe Work
25 Instructic•ns
First off
 INTRODUCTION

 Failures are prioriti zed according to how serious their

consequences are, how frequently they occur and how easily
they can be detected. The purpose of the FMEA is to take
actions to eliminate or reduce failures, starting with the highest-
priority ones.

 Failure modes and eff ects analysis also documents current

knowledge and acti ons about the risks of failures, for use in
conti nuous improvement. FMEA is used during design to
prevent failures. Later it‟s used for control, before and during
ongoing operati on of the process. Ideally, FMEA begins during
the earliest conceptual stages of design and conti nues
throughout the life of the product or service.
Part/Assembly Name Description System Tree ID
L-+ Laser Drive System ” Laser Drive and Positioning SYS-022
Primary °iIide Bearinq 1/4 Inch Stainless Steel Traversinq Beam Bearing 5Y°i-
023 Drive Belt X-Axis Laser Drive Belt SYS-024
Rotary Drive Motor 45LB5(IN-LBS) Peak Torque Drive Servo . SYS-025
fi Pulley 50mm Axis Drive Pulley 5YS-026
q Sy e T e Configurât”ion Table FMT FM EA - System Tree

Eh1EA Table
Item/Function Failure Rate Failure Mode Mode % Mode Failure Rate Local Effect
Next End Effect Severity Occurrence Cause(s) of Failure
Effect

Contamination

Machine
3ammed 30 20 L1etaI is not cut Marqinal Remote
Downtime

Lubrication Problem

Primary Slide
Bearing

119 Contamination
Machine
Cannot Freely Move Metal is not .Reasonably
Restricted 70 Downtime, Loss Marginal
cut or urooucc Probable
47
correctly
120 Lubrication Problem

' Cannot support or Machine Defective

Breaks 90 26 Metal is not Occasional
122 Downtime
cut
'Drive Belt 29 Could cause significant damage to the overall
system
123 e aser anno e Machine 'Extremely
0 3 metal is not cut Minor Overstressed
moved correctly Downtime ”Unlikely

124
Ino l is not cut
per
ativ
Contamination
e

Meta
Machine Marginal
Extremely
30 2
Downtime Unli' -'"

FMEA 121 of 144

 TYPES OF FMEA

 System FMEA : Aft er completi on of all equipment and

design, a method used to make the most favorable analysis and
the fl ow of sub-systems such as manufacturing and quality
assurance. FMEA system focuses on the diff erent types of
potenti al errors that cause disturbances in the system. It
examines system
interaction with other systems and sub-elements.

 Design FMEA : It is an analyti cal technique, which all possible

types of errors that may arise and also their respecti ve causes
are addressed and resolved by it. Design FMEA creates a
reference to provide additi onal informati on about design
requirements, evaluation of alternatives, and types of errors that may occur
in processing system and also their results to consider the design/
development process, and planning of the full and
eff ecti ve design and test development programs. Design FMEA is
a method of analyzing the design in order to determine the weak
points or any criti cal situati on that can do more harm
on, especially product reliability and / or safety.
 Process FMEA : It is an analyti cal technique that provides
considerati on and resoluti on of all possible problems that may
be taken into account during the creati on of the product. The
purpose of FMEA process is to take measures for identifying and correcting
weaknesses in the production process. Moreover, it
can be used to analyze manufacturing and assembly processes.

 Service FMEA : It is the method which is applied with

coordination of production quality assurance (QA) and marketing in order
to improve the customer service. It helps to analyze the defects in the
organization. It indicates that determination of
priority between the acti viti es of the organizati on and
workflow, and system and process analysis in an efficient way and
identifies and control errors on the process of carrying out plans
 WHEN TO USE FMEA?

 When a process, product or service is being designed

or redesigned, aft er quality functi on deployment.
 When an existi ng process, product or service is being
applied in a new way.
 Before developing control plans for a new or
modifi ed process.
 When improvement goals are planned for an existi ng
process, product or service.
 When analyzing failures of an existi ng process, product
or service.
 Periodically throughout the life of the process, product
or service
 HOW DOES IT WORK?

 First, List the characteristi cs of a product or service design or

the steps of a process.

 The Team then identi fi es all the ways the design or process
could fail, referred to as potenti al failure modes.

 The 3 main types of design failure modes are

materials, processes and costs.

 The 4 main types of process failure modes are too much, too
litt le, missing or wrong.
 A traditi onal FMEA quanti fi es risk. This is done by calculati ng
the Risk Priority Number (RPN) derived from 3 subjecti ve
ratings – Severity(S), Occurrence(O) and Detection(D)

 The Severity rati ng is based on how serious the impact would

be if the potenti al failure were to occur.

 The Occurrence rati ng is based on the probability of the

potenti al failure occurring.

 The Detecti on rati ng is based on how easily the potential

failure could be detected prior to occurrence.
The Risk Priority
Number is Step 1: Detect a Failure Mode

calculated by:
RPN = S x O x D Risk Priority
umbern=(RPN)
Step 2: Severity number (S
S*O*D

The smaller the

number, lesser is the
Step 4: Detection number
Step(D)
3: Probability number (O)
risk.
 PHASES OF AN FMEA

I. The pre-work : In this phase it determines the objecti ves and

the level of FMEA. During this phase criteria on the basic
concepts and special procedures for the preventi on of
unnecessary loss of ti me and cost are defi ned.
II. Systems analysis : Development and analysis of the
system, processes, and fault tree diagrams operates according
to specifi ed functi ons, areas of interacti on, stages, and their
types.
III. Review of results : potenti al types of errors are
identi fi ed, eff ects of them are evaluated, and control measures
to prevent errors are defi ned according to the analysis and
evaluation.
IV. Monitoring / Implementation : During this phase, results and
data documentation are obtained.
V. Verification
 CREATING A LIFE-CYCLE FMEA

1) Form an FMEA team that consists of representati ves from

all stages of the product‟s life cycle.
2) Identi fy all the systems, sub-systems and components and
list them in the fi rst three columns on the FMEA.
3) Make the next column a D-M- A-I-O code for the phase of the
equipment‟s life cycle in which the failure originates ( can
also add a „S‟ code for Shutdown if desired)
4) Conti nue to fi ll in the remaining columns of the FMEA
D = Design. Includes potential failures of design that surface
in a design FMEA

D-M- A-I-
M=Manufacturing. Includes the potential failures of O CODES
the components or manufacturing of standard details
that might be produced or machined in-house

A = Assembly. Includes potential failures of

assembling the equipment

I = Installation. Potential failures of installation might

be overlooked.

O = Operation. Includes all the potential failures associated

with Operators and Operations.
FMEA ANALYSIS AND
APPLICATIONS IN Case Study

KNITTING INDUSTRY
 ABSTRACT

 In this study relevant products errors were determined with

error probabiliti es, severity values, and values of
discoverability were calculated at a knitti ng company by types
of Failure Modes and Effects Analysis‟s (FMEA); process FMEA.
Correcti on steps were determined with RPN (Risk Priority
Number) values due to occurred errors. According to the
obtained results, it was determined that traces of platen, fly,
broken needle, lycra eccentric, number of hole, transverse
band, and lycra cut are the most criti cal errors. These errors
have been occurred by knitti ng machines. Furthermore,
workers' education and improvement of working conditions critical
factors on eliminating errors.
 GOALS OF FMEA

Identifying and testing to

Defining potential error / fault eliminate or minimize Avoid potential errors that may Eliminate potential types of errors
types, rates, effects and the degree Identify the critical and Sorting potential errors of occur along to the product or to take corrective actions or reduce
determinant design and process based on errors, defects, malfunctions, and
of importance changes and to ensure product process, by predefining them the possibility of formation.
characteristics severity
development
 INTRODUCTION

 The benefi ts of FMEA are:

 Enhances quality, reliability, image, security, and level of competi ti on

of the product.
 Helps to increase customer sati sfacti on.
 Reduces product development t ime and cost, and provides selecti ng
the most appropriate system and the opportunity to opti mize
processes.
 Reduce r isks by monitoring and documenti ng methods.
 These documents would be a good guide for the design of system and
process that will be developed in the future.

 The informati on obtained from the design FMEA, is used on changes in

the producti on process, material selecti on, quality control, and quality
inspecti on criteria. Hence, the method can be used as a decision
making tool. Types of errors are reviewed systemati c in order to prevent
even the smallest damage on product, process, or service.
 MATERIAL AND METHOD

 Material:  Method
ERROR CODE ERROR NAME
HT 1 Number of Hole
Two fleece HT 2 Fly
fabric, single jersey and HT 3 Broken Needle
rib fabrics measured for HT 4 Lycra Eccentric

this study because of HT 5 Traces of Platin

HT 6 Transverse Band
their widely usage in
knitting HT 7 Lycra Cut
industry, which supplied HT 8 Oil Stain

from Ethem Örme HT 9 Empty Iro Error

HT 10 Color Difference
Textile company
HT 11 Longitudinal
Lines
 Number of hole (HT1): It may cause because of yarn, or the
machine elements.
 Fly (HT2): Fly-adhesive cott on dusts from machines will cause
an error on colorless, knitt ed fabric during the knitti ng with
colored yarn.
 Broken needle (HT3): Errors that may occur on the fabric
surface in case of working with broken needle.
 Lycra Eccentric (HT4): The error is observed with the needle
does not receive during the knitti ng process because of the
rotati on of the lycra in the fabric.
 Traces of Plati n (HT5): The error is formed by the traces seen
on the fabric due to the use of worn or deformed platin.
 Transverse band (HT6): Yarn and machine are two important
factors in the formati on of this error.
 Lycra cut (HT7): Error caused by wear needles used on the
bench or feeding type of lycra.
 Oil stain (HT8): Discolorati ons on the fabric due to the use of
oil, haunti ng with water, in the machine.
 Empty iro error ( Meninger) (HT9): A type of error caused by
can‟t wind yarns on iro properly.
 Color diff erence (HT10): Using of diff erent yarn lots at the
same ti me cause that error.
 Longitudinal lines (HT11): A jump occurs due to moti onless of
tongue of needle, the loop does not occur on the needle. It
occurs an open longitudinal line on fabric.
 Identi fying the Eff ects of Error: These errors are not met positi ve by the
customer and included in the second quality class.

 Identi fi cati on of Error Reasons: These errors are occur because of raw
materials, machinery, and human.

 Applicable Control Measures

 Controlling of yarns that required for knitti ng
 Setti ng of machine due to knitti ng fabric type
 Measuring weight of knitt ed fabric aft er beginning of knitti ng
 Doing raw quality control of fabric
 Controlling of fabrics aft er dyeing

 Applicati on of Scoring: Relevant products error probabiliti es, severity

values, and values of discoverability were calculated by process FMEA
 RESULTS AND DISCUSSION

 The Possibility Of The Error

 In this study unit of measured samples that kilograms. The
number of working days in the business was 303 days in
2011 . Three month‟s data chose for this study due to business
prepared the most order in that months. Table 2 shows the
production information and the probability values according to
data from the factory. In tables 3 and 4 values of the error
severity and detectability of error type are shown.
RESULT TABLES
 RESULT AND DISCUSSION

 Identi fying of Risk Priority Number ( RPN)

 Based on the value of PRN, we can decide to start working on which
type of error for improvement. The types of errors are usually caused by
a lack of training of personnel were encountered in business. The
training should be about planning of work t ime, place and business
plan. Worker should be understand the aim and do it carefully.
Business manager must be make a point of training for that situation. Companies
engaged in training activities as required for certification of quality assurance systems
and quality assurance. However, after
receiving this document, many businesses have failed to conti nue
training acti viti es. conti nuity of approach of quality producti on can be
achieved with but the conti nuity of training acti viti es. Failure to
precise settings of looms can be defined as the cause of an error. To obtain the
required characteristics of the production is possible by made a complete and
precision looms settings. The operator, who
make loom setting, must be educated and experienced. These
improvement activities have to be mind in for zero- defect
production, elimination of errors that were encountered and customer satisfaction.
 Error Values of RPN
160 THE
DISTRIBUTIO
140 N OF ERROR
VALUES OF
120 RPN

100
RPN

80

60

40

20

0 HT HT HT HT HT HT HT HT HT HT HT
1 2 3 4 5 6 7 8 9 10 11
RPN 14 14 14 12 12 12 11 10 96 84 84
 CONCLUSION

 Traces of platin, fly, broken needle, lycra eccentric, number of hole,

transverse band, and lycra cut are determined as the
most criti cal errors. Calculati ng of RPN has indicated the
necessity of applying correcti ve and preventi ve acti ons for
each type of error. Most critical errors have been occurred by knitting
machines. Although some errors are due to
workers, the main reason of errors are depend on making the
necessary settings of equipment incompletely and hasty.

 Workers' education and improvement of working conditions

must be considered, and skilled workers should be introduced
to other workers as examples. Diff erent types of training
should be given to workers to troubleshoot errors.
 Maintenance and setti ngs up of the machines and soft wares
should be reviewed. Aft er making discussion for eliminati ng
errors primarily, we should control deformati on of needle
surface. Especially HT1 and HT3 errors occur because of
needle and machine. Clean machine and area are too
important factor for decreasing fly amount. In
addition, working time should be reorganized, and number of
break ti me should be increased, so lack of att enti on due to
fatigue can be eliminated in this way.
 RPN should be push down to have zero defect by reducing
occurrence probability.
 Widely usage of that analysis in sector should be increases
customer sati sfacti on due to increasing of quality, reliability
and competi ti veness. For this reason representati ves of the
sector should be informed.
 REFERENCES

 FMEA-Something Old, Something New - Reid, R Dan - Quality

Progress; May 2005; 38, 5; ABI/INFORM - Complete pg. 90

 An innovati ve methodology: The life cycle FMEA -

Lore, Jonathan - Quality Progress; Apr 1998; 31, 4;
ABI/INFORM - Complete pg. 144

 Case Study - FMEA ANALYSIS AND APPLICATIONS IN

KNITTING INDUSTRY - Istanbul Technical
University, Department of Textile Engineering, Istanbul, Turkey

 FailureModesandEff ectsAnalysis_FMEA_1.pdf – Insti tute for

Healthcare Improvement