CHAPTER NO.

INTRODUCTION

1.1 Problem statement

(FMEA) Failure Mode Effect Analysis of Welding Defects of Beam Assembly.
To identify the Failure Modes for Beam assembly.

Introduction to FMEA
The purpose of FMEA is to analyze the design characteristics relative to the planned
manufacturing process to ensure that the resultant product meets customer needs and expectations.
When modes of failure are identified, improvement can be done by reducing the chances for
occurrence by taking some correct actions. FMEA provides an organized analysis of failure modes
of the system being defined and identifies related causes. It uses probabilities of detection and
occurrence in addition with a severity criteria to develop a risk priority number (RPN) for ranking
corrective action considerations. Used in both the design and manufacturing processes, they
substantially reduce costs by identifying product and process improvements early in the develop
process when changes are relatively easy and inexpensive to make. The result obtained found
robust, as the need for post corrective action and problems are reduced completely. This project
discuses and implementation of Process Failure mode and effect analysis for improvement in all
sub-processes involved till the completion of welding process.

FMEA Types are as follows:

1) Design FMEA
2) Process FMEA

Further it is classified according to operation/work.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 1

 Basic classification of FMEA as follows:

Concept of

FMEA

Design FMEA Process FMEA

-System -Assembly

-Subsystem -Manufacturing

-Component

Fig. no. 1.1 Classification of FMEA

The role of maintenance as an effective tool to improve plant reliability, increase profit
margin and reduce safety and environmental hazards has become increasingly important. The
perception about maintenance has shifted from being a “necessary evil” to being an effective tool
to improve processing efficiency and ultimately larger profits. The trend is part of the new
approach to processing named Smart Plants, which advances the concept that such plants anticipate
problems instead of reacting to them. One of the effective approaches to solving industrial system
failures is through proper mechanisms for failure modes identification and prioritization through
application of failure mode and effect analysis (FMEA) as a tool for reliability analysis.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 2

1.2 Objectives
• To understand the use of Failure Modes Effect Analysis (FMEA) of welding Defects of
beam assemble.
• To detect and analyze the process failure of beam assembly.
• To recommend action plan to eliminate failure causes.

1.3 Scope
 Used in the design of products and processes (manufacturing line, service procedures,
etc.) to anticipate and address potential failure modes early in the process when they are
least expensive for correction.
 Identifies the failure modes discovered during testing and update the probabilities of
occurrence based on the Reliability Growth testing data.
 It is used to evaluate critical plans to modify an existing process. Used to investigate the
credibility of existing systems/processes.

1.4 Methodology
 Step 1: First of all collect the functions of system and make a hierarchical structure. Then
divide the system into several subsystems, having number of components.
 Step 2: Now determine the failure modes of each component and its effects. Assign the
severity ranking (S) of each failure mode according to the respective effects on the
system.
 Step 3: Determine the causes of failure modes and estimate the likelihood of each failure
that can occur. Give the rating of occurrence (O) to each failure mode.
 Step 4: Make a list of approaches to detect the failures and determine the ability of
system to detect the failures prior to the failures occurring. Hence assign the detection
rating (D) of each failure mode.
 Step 5: Calculate the risk priority number (RPN) and prepare the priorities for attention.
 Step 6: Take suitable actions to enrich the performance of system.
 Step 7: Prepare FMEA report in a tabular form.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 3

 CHAPTER NO. 2

Literature review
Every asset is put into service because there is a need for a specific function or
functions, and this asset is expected to fulfill this need. Reliability focuses on asset ability to
perform this function under certain specified conditions during a stated period of time. Failure risk
analysis is critical since it reveals possible potential failures (evaluate the inherent reliability) and
predict the effect which the failures will have on the system as a whole. This is useful in order to
pin point potential areas for reliability improvement or if not possible, identify possible failures
and take action to mitigate the effects before the failure occurs. There are several techniques and
tools that can be used to improve the reliability of equipment.

This research considered FMEA as an appropriate reliability analysis tool for failure
modes identification and failure risk prioritization. This was due to its capability to identify,
prioritize and rank the sub-system failure modes together with application of the Pareto chart.
Failure risk was regarded as the sub-system failure criticality in terms of down time and the
corresponding downtime cost or the production loss caused by sub-system unavailability. For
purposes of failure risk analysis, failure cost was considered as having three cost elements;
materials cost (spare parts cost), labor cost (Man Hour Cost, MHC) and downtime time production
loss or cost, which was an hidden cost but very critical in this research. All these costs were
evaluated and their values tabulated to assets each equipment failure risk.

Various researchers have used FMEA in the analysis of industrial systems with many
interacting components either in process, design applications found that FMEA is one potential
tool with extended use in reliability engineering for the electrical and electronic components
production field as well as in complicated assemblies (aerospace and automotive industries). The
main purpose for their study was to reveal system weaknesses and thereby minimize the risk of
failure occurrence. From the above mentioned literature review.

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 No research studies have been done on milling plants or else in maintenance
management function efficiency on failure identification, failure analysis and failure risks
prioritization in the milling industry and that’s why this research finds its usefulness in the
manufacturing industry.

Failure Modes and Effects Analysis (FMEA) is a useful tool for planning and
performing preventive maintenance system in various industries. The technique for the first time
by reliability engineers was based in the 1950s to assess the safety of military systems. After that
using of this method quickly spread so that in the United States and France it used to evaluate
safety of Concord and Airbus aircraft, respectively. In 1960, safety issues in the aerospace industry
led to implementation of FMEA. The method was developed and applied in the early 1960s by
NASA because of the importance of safety and prevention of accidents in space projects. Later in
the 1980s, Germany used this method in its chemical and nuclear industries. In the second half of
the 1980s, the Ford automobile plant implemented the quality standard ISO 9000 series in the auto
industry in the United States and used this method and caused the spread and development FMEA
in the world and in the sciences especially in automotive industry.

The efficiency of this method has led that healthcare centers also use it to improve
patient safety and their emergency medical services system (Namdari. 2010). Also, this method is
widely used in electronics, chemicals and other manufacturing sectors, to identifying, prioritizing
and resolving failures, defects and potential problems (Maleki 2006; Hojjatnejad 2008). FMEA is
an efficient tool for identifying the potential failure modes and their effects in order to increase the
reliability and safety of complex systems and gathering the data that is necessary to decide about
how to manage risks. In fact, the purpose of this technique is to identify failure modes and their
effects and corrective actions to eliminate or reduce the probability of failure (redesign) and finally
the development of efficient maintenance system, to reduce the occurrence of potential scenarios.

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 CHAPTER NO. 3
FMEA PROCEDURE
3.1 FMEA Procedure

1. For each process input (start with high value inputs), determine the ways in which the input
can go wrong (failure mode).

2. For each failure mode, determine effects.

 Select a severity level for each effect.

3. Identify potential causes of each failure mode.

 Select an occurrence level for each cause.

4. List current controls for each cause.

 Select a detection level for each cause.

5. Calculate the Risk Priority Number (RPN).

6. Develop recommended actions, assign responsible persons, and take actions.

 Give priority to high RPNs.

3.2 FMEA Inputs and Outputs

Fig. 3.2. FMEA Inputs and Outputs

Inputs Output

C&E Matrix List of actions to

Process Map prevent causes or
Process History FMEA detect failure modes
Procedures History of actions
Knowledge taken
Experience

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3.3 Risk Assessment Factor
3.3.1 Severity
Probability of Severity (S): A number from 1 to 10 is selected, depending on the severity of the potential
failure mode’s effect.
• 1 = no effect
• 10 = maximum severity
Rating Description
10 Dangerously
high
9 Extremely high
8 Very high
7 High
6 Moderate
5 Low
4 Very low
3 Minor
2 Very minor
1 None
JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering)
Table no. 3.3.1 Severity
Definition
Failure could injure a customer or employee
Failure would create noncompliance with federal regulations
Failure renders the unit inoperable or unfit for use
Failure causes a high level of customer dissatisfaction
Failure results in a subsystem or partial malfunction of product
Failure creates enough of performance loss to cause the customer
to complain
Failure can be overcome with modifications to the customer’s
process or product, but there is minor performance loss.
Failure would create minor nuisance to the customer, but the
customer can overcome it without performance loss
Failure may not be really apparent to the customer, but would
have minor effects on the customer’s process or product
Failure not be noticeable to the customer& not affect the
customer’s process.
7
3.3.2 Occurrence
Probability of occurrence (O): A number from 1 to 10 is selected, depending on the likelihood of the failure
mode’s occurrence

• 1 = very unlikely to occur

• 10 = almost certain to occur
Table no. 3.3.2 Occurrence

Rating Description Definition

10 Very high failure is almost
inevitable
9 High failures occur almost as often
as not
8 High: Repeated failures
7 High failure occur often
6 Moderate high: frequently failures
5 Moderate: Occasional failures
4 Moderately low: infrequent
failures
3 Low: Relatively few failures
2 Low: Failures are few and far
between
1 Remote: Failures are unlikely
More than one occurrence per day or probability of more than 3
occurrence in 10 events
One occurrence every three to four days or a probability of 3
occurrences in 10 events
One occurrences per week or a probability of 5 occurrences in
100 events
One occurrence every month of 1 occurrence in 100 events
One occurrence every three month or 3 occurrences in 1000
events
One occurrence every six month to one year or 5 occurrences in
10000 events
One occurrence per year or 6 occurrences in 1000,000 events
One occurrence every one to three years or <6 occurrences in
100,000 events
One occurrences every three to five years
One occurrences in greater than five years

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3.3.3 Detection

Probability of detection (D): A number from 1 to 10 is selected, depending on how unlikely it is that the fault will
be detected by the system responsible (design control process, quality testing, etc.)

• 1 = nearly certain detection

• 10 = impossible to detect

Table no. 3.3.3Occurrence

Rating Det. Rate Description Definition

10 <60%
9 60%
8 65%
7 70%
6 75%
5 80%
4 85%
3 90%
2 95%
1 99.99%
Absolutely Uncertainly Product is not inspected or the defect caused
by failure is not detectable
Very Remote Product is sampled, inspected and released
based on Acceptable Quality Level sampling
plans
Remote Product is accepted based on no defectives in
a sample
Very low Product is 100% manually inspected in
process
Low Product is 100% manually inspected using
go/no-go or either mistake proving gauges.
Moderate Statistical Process Control(SPC) is used in
process and product is final inspected offline
Moderately high SPC is used and there is immediate reaction
to out-of-control condition
High An effective SPC program is in place with
process capabilities greater than 1.33
Very High All product is 100% automatically inspected
Almost certain The defect is obvious or there is 100%
automatic inspection with regular calibration
and maintenance of the equipment

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Severity

Failure Effects

 Insufficient penetration, turbulent weld pools, undercuts.

 Weld bead smaller or larger in size.
 Metal pilling up into base metal, weld bead sags.
 Porosity, blow holes, generation of cracks.
 Spatter generation, variation in bead.

Potential Causes

 High voltage or low voltage during welding.

 Gun travelling speed.
 Insufficient gas supply.
 Weak weld material.
 Filler material not matching with material.

Occurrence

Prevention

 Automatic setting in welding machine according to customer requirement, or by

parameter chart.
 Provide training to workers, gun holding position, proper angle, contact of tip and work
piece.
 Regulation of gas supply, set flow meter, clean gas holes in guns, condition of gas flow
tubes.
 Proper storage area for weld material and for filler material.
 Material specification confirming as per batch test certificate.

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Detection

 Visual inspection of weld.

 Uneven sound during welding.
 Thickness gauges.
 Generation of spatter around surface is more.
 Generation of blowholes is more.

Fish Bone / cause and effect diagram of welding defects

MAN Machine Position of part

Holding gas flow rate
Position of gun mixture of gas
Skill & current
Experience voltage
Process
failure

Position of weld base metal

Filler
Material

Method Material Atmospheric condition

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 CHAPTER NO. 4

Welding Defects modes

TYPES OF WELDING DEFECTS

The weld defects such as Lack of Penetration, Porosity, Slag Inclusion, Burn Through,
Oxide Inclusion, Lack of Fusion, Crack, Cluster Porosity, Internal Concavity, Offset, Tungsten
Inclusion etc., deteriorate the mechanical properties of the welded structures thereby increasing
the risks of fatigue, failure and disaster. Lack of Penetration is one of the weld defects that occur
as a result incomplete penetration of the weld defect through a joint. This is one of the most
unpleasant weld defects because this acts as a cause for Natural stress. When this defect is
pressurized, it may result in the failure of the entire weld metal. So this should be avoided to the
maximum possible extent. It usually appears as a dark straight line of medium width. Internal
Concavity defect arises due to the contraction of the weld metal as it cools. This defect resembles
Lack of Penetration but has irregular edges and is broader in the middle.

Cluster porosity and Porosity weld defect occur due to the presence of moisture, which
turns into gas that will be further trapped in the weld when heated. Lack of fusion weld defect
occurs when the filler metal doesn’t fuse correctly with the base metal. In a radiographic image
these defects appear as straight lines between the seam of the metal and they orient themselves in
only one direction, along the weld seam in the metal. Oxide Inclusion occurs as irregularities dark
in color since they are less intense than the adjoining materials.

Burn-Through is a weld defect which arises due to overheating that makes the weld metal
to penetrate the weld zone. When the metal is burnt so much, there is an excessive penetration and
there are deposits of the weld metal inside the base metal. They appear as large globules of metal
inside the base metal. Burn-Through appears as a dark spot, surrounded by whitish grayscale
intensities. Root Undercut weld defect take places as a result of erosion of the base metal near the
root of the weld. Tungsten Inclusion defect arises when the tungsten get entrapped in the weld.
Slag Inclusion defect occurs due to the presence of nonmetallic element in the weld metal.

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 The distinguishing characteristics of Slag inclusion defect are that, they are asymmetric,
jagged, rounded edged and may possibly be scattered throughout the image.

Voltage

The maximum and minimum of the voltage range for the machine were defined in SOP
(Standard Operating Procedure) to performed welding operation. This creates the problem of 1)
Inconsistent penetration 2) Turbulent weld pool 3) Undercut 4) Spatter generation 5) Pin hole
formation 6) Stubbing.

Gun Traveling Speed

The gun travelling speed is totally depends on the operator skill following are the causes
of High or low gun traveling speed 1) Insufficient Penetration 2) Weld Bead Smaller 3) Weld Bead
Larger By providing proper training to the worker it can help to minimized failure.

Current and Feed Rate

The maximum and minimum of the current range for the machine were defined in SOP
(Standard Operating Procedure) to performed welding operation and the feed rate is kept
accordingly. This creates the problem of 1) Slag inclusions 2) Metal Piling-up instead penetrating
into base metal 3) Weld Bead Sags 4) Spatter generation.

Although welding is a straightforward process, metal is a dynamic material, so you can

expect many twists and turns along the way. Your work pieces will expand when heated. The grain
structure may weaken and cause brittleness. And the metal’s shape may deform, causing cracks
that will spread over time and potentially break the weld.

Low-carbon (aka mild) steel is widely used for structural work, since it’s more likely to
retain its ductility when overheated than other metals. Even if you quench it in water too quickly,
but life is not so breezy for aluminum, cast iron, titanium, stainless or high-carbon steels.

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 Moreover, that cause may have nothing to do with your ability to lay down a welding bead.
Instead, the culprit may be traced to one of the following:

• Poor joint design or fit-up

• Incorrect settings or a machine deficiency

• Wrong shielding gas or flow rate

• Inadequate pre or post-heat treatment

• Using the wrong (or a defective) rod /wire

• A hot or cold ambient temperature, high humidity, or other atmospheric condition.

Cracks

No matter how small, every crack is considered a defect, and it takes just one to fail a weld
inspection. That’s because over time a crack has the potential to become the next Grand Canyon.
And unlike carpentry, you can’t just fill the gap with a little glue and sawdust. Cracks must be
ground out with a file or grinder, and then a new weld performed. Here are four common types to
watch for: hot cracking - This crack appears soon after welding, usually inside the weld, as a result
of something called hot shortness. Poor fit-up or design may be responsible, but the presence of
sulfur in the base or weld metal can likewise cause problems, as can different rates of cooling
within the weld. Often, the crack forms along the axis (center) of the joint as the two sides pull
apart. Cold crack - This doesn’t show up at first, but within a day or so of welding. It’s induced by
hydrogen absorbed into the weld via the weld puddle.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 14

Porosity

Porosity is the technical term for gas bubbles. These develop inside or on the face of welds
because metal in a molten state is highly vulnerable to impurities entering the mix. For this reason,
some form of shielding gas (or dry flux ingredients in rods) are used in most welding processes.
Porosity is usually caused by one of the following:

• The flow meter setting on the shielding gas tank is too high.

• You’re using the wrong gas mixture or rod/wire.

• The weld puddle is contaminated due to unclean metal, surface moisture or contact between
dissimilar metals.

• Your welding travel speed is too fast, not allowing enough time for the shielding gas or flux
ingredients to do their job.

• A breeze or draft is blowing the gas away from the weld puddle.

Oxygen and hydrogen are the two big enemies of welders. Oxidized surfaces - which
appear as rust, corrosion or mill scale in ferrous metals - should be removed from all weld able
areas just prior to welding (and not the day before). Remember, water is composed of two parts
hydrogen, one part oxygen. Once the hydrogen gets inside metal, it can create a condition known
as hydrogen embrittlement.

Lack of Penetration and Fusion

Depending on the joint, you may have to weld all the way down to the bottom or your
plates to achieve what’s known as Complete Joint Penetration (CJP). Most fillet welds, on the
other hand, require only Partial Joint Penetration (PJP). Either way, you’ll have to set your welding
machine so there’s sufficient voltage and current to get the job done.

A weld bead that simply rides the surface of the base metal is easy to spot because it looks
like a bullet train. Deep penetration is only achieved when there’s enough heat to melt the base
metal. For thicker metals, a beveled groove is typically cut or ground on either side of the joint to
create a wider pocket.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 15

 The welder then performs multiple passes, methodically filling the space so no gap is left
behind. Too fast a travel speed, or holding your torch too high above the joint, will limit
penetration. (Heat-sensitive metals such as aluminum and stainless steel require more fine tuning
of the machine than carbon steel. Switching the current polarity may also be necessary.)

Fusion refers to tying the borders of the weld to the base metal so that there’s no dividing
line. This requires more time and attention for groove welds with an open root, since there’s a lot
of space there to fill. Any gap will produce cracks.

To fuse the sides of a joint, a welder must pause briefly on each side while depositing the
weld metal. After pausing, you must move quickly across the center of the joint to avoid piling up
weld metal in that area. The sides of joints are prone to undercutting because metal edges melt
faster than areas where heat can be conducted away in any direction. So pausing is needed to
prevent gaps from forming. In a typical weld, a flat or slightly convex bead is deposited with good
tie-in at the toes on either side of the joint.

Undercutting

As noted earlier, failure to get good tie-in with both toes of a weld can result in
undercutting. That’s because metal melts faster at its edges than in the middle. On a T-joint, like
the one shown above, the standing plate is most often welded on its edge, where it’s more
susceptible to melt through. Since the bottom plate is welded at the middle, it makes sense to focus
more heat on it as you move along the joint. Many entry-level welders forget this basic rule of
thumb about how metal responds to heat. You can also undercut the toe on the bottom plate by not
spending enough time welding on that side of the joint. So in addition to focusing more heat on it,
be sure to manipulate your electrode laterally, pausing on each toe, so the weld puddle covers both
those edges of the joint. This is an essential skill to master, as it will come up repeatedly in almost
every type of welding assignment you undertake.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 16

Overlap

This is the opposite extreme from undercutting. Here, the weld metal flows across the base
metal at the toe without producing any fusion between the two. This may be caused by insufficient
heat to melt the base metal, and/or improper manipulation of the electrode. Make sure your torch
work angle is correct when pausing on each side; otherwise the heat won’t be directed at the toes.

Whereas too much heat causes undercut, too little creates overlap, where two separate
layers of metal are left behind along the toe. Welding to code requires thorough fusion with the
base metal.

Spatter and Other Surface Disruptions

When welding to meet code requirements, maintaining an unblemished surface on your

work plates or pipe is critical. Even a single burr left behind after grinding can interfere with a
mechanical assembly or catch another worker’s clothes or skin and cause injury. (Burrs can also
block the flow of weld metal during a welding operation.) A dent in the metal left by a wayward
arc strike could be the start of a transverse crack. So always strike your arcs inside the joint ahead
of your weld, or on the edge of your work plates, or in another area that can be ground or removed
later. Spatter describes the bits of molten metal that are sent flying up out a weld.

Misalignment

This type of geometric defect is generally caused by a setup/fit up problem, or trying to

join plates of different thickness.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 17

 CHAPTER NO. 5

Detection and Recommended actions

Control Detection

1) Voltage
a) Digital display of machine.
b) Visual inspection of weld area.
c) As per SOP(Standard Operating Procedure)

2) Gun Travelling Speed

a) Check welding area visually.
b) Uneven sound during welding.
c) Thickness gauge.

3) Current
a) Digital display of machine.
b) Formation of small holes in welding.

4) Shielding Gas
a) Visual inspection of flow meter
b) Generation of spatter around part is more.
c) Peak valley of welding surface.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 18

 5) Filler material
a) As per standard Operating Procedure.

Recommended Actions

1) Voltage
a) Voltage fluctuation should note manually data logger, it help to understanding as how it
affects the severity and RPN study.

2) Gun Travelling Speed

a) Training should be provided to the welder for gun travelling and the distance of gun
holding.

3) Current
a) Current fluctuation should note manually data logger, it help to understanding as how it
affects the severity and RPN study.

4) Shielding Gas
a) Vary the gas combination percentage and regular maintenance of gas tubes.

5) Filler material
a) Provide slow cooling.
b) Proper storage place for filler material.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 19

 Potential Potential S O Current Current D R
Failure Effect(s) E Potential C Design Design E P Recommended
Mode of Failure V Cause(s) C Controls Controls T N Action(s)

Class
(Prevent (Detectio
ion) n)
LED Bulb no light 8 hot spots on 5 ANSI LED Bulb 3 120 Implement new glass
burns out on glass due to Guideline for environmental coating to minimize
prematurely. image, over incandescent test #123 impact of touching on
custome touching bulbs bulb durability
r Revise LED Bulb
dissatisfi environmental test
ed #123 to include
periodic touching of
glass
gas leak at 2 LED Bulb 1 16
base of glass environmental
due to test #123
overheating
inadequate 8 Sneak circuit LED Bulb 7 448 Change LED Bulb base
voltage to analysis durability test to material ABC in order
LED Bulb system #456 to be less corrosive.
due to Revise LED Bulb
corrosion of durability test #456 to
base add corrosion
inducement and
checking.
Revise the interface
between bulb base and
electrical connection to
ensure positive
connection, with increased
connection force.
Bulb no light, 10 over 2 LED Bulb LED Bulb 8 160 Install additional plastic
shatters potential pressure in Design Guide durability test shield on Bulb to ensure
for injury Bulb due to #ABC #456 no injury to user if glass
to user wrong gas shatters.
Modify LED Bulb
Design Guide #ABC to
include correct bulb gas.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 20

 Conduct Design of
Experiments on LED
bulb gas to determine the
optimum gas
specification to
desensitize bulb pressure
to gas variation.
Modify LED Bulb
durability test #456 to
include induced gas
pressure build up.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 21

 CHAPTER NO. 6

Diagrams

1) Undercuts

2) Porosity

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 22

 3) Incomplete Fusion

4) Overlapping

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 23

 5) Spatter generation

6) Incomplete penetration

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 24

 CHAPTER NO. 7

CONCLUSION AND RESULTS

 Proper early failure detection methods and potential failure prediction or detection is
fundamental for effective maintenance management. This reduces the probability of
failure which leads to plant shut down and thus improving OEE. To reduce the adverse
effects of breakdown and to increase the equipment availability at a low cost, FMEA is a
key reliability analysis tool that needs to be instituted in industrial set-ups.

The FMEA benefits:

 prevention planning,
 identifies change requirements,
 cost reduction,
 decreased waste and warranty costs,
 reduce non-value added operations,
 systematic procedure,
 acknowledged procedure,
 knowledge transfer through departments,
 risk management instead of crisis management,
 Determination of failure modes.

JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 25

 REFERENCE

 Failure Modes and Effects Analysis (FMEA), Available at: http://asq.org/learn-

aboutquality/process-analysis-tools/overview/fmea.html,Accessed on: 16.01.2011.
 McDermott, R.E., Mikulak, R.J., Beauregard, M.R., The basic of FMEA, Publisher
Productivity Press, ISBN 978-1-56327-377-3, United State of America, 2008.
 A. A. Nannikar, D. N. Raut, M. Chanmanwar, S. B. Kamble and D. B. Patil, “FMEA
for Manufacturing and Assembly Process”, International Conference on Technology
and Business Management, pp. 26-28, March 2012.
 A.K. Josiah "Failure Mode Identification and Prioritization Using FMEA- A Case
Study of Corn Milling Industry.” IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE) , vol. 15, no. 2, 2018, pp. 21-28
 Vision based Identification and Classification of Weld Defects in Welding
Environments: A Review Mohd Shah Hairol Nizam*, Sulaiman Marizan, Shukor
Ahmad Zaki and Ab Rashid Mohd Zamzuri Universiti Teknikal Malaysia Melaka,
Faculty of Electrical Engineering, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka,
Malaysia; hnizam@utem.edu.my
 RiddhishThakor, Rajat Dave, TejasParsana(2015) A Case Study: A Process FMEA
Tool to Enhance Quality and Efficiency of Bearing Manufacturing Industry” Scholars
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JSPM Narhe Technical Campus, Pune ∣ BE (Mechanical Engineering) 27