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FailureModeandEffectAnalysisSecondEditionRevisedandExpandedAlsoavailablefromASQQualityPress:CustomerDrivenHealthcare:QFDforProcessImprovementandCostReductionEdChaplinandJohnTerninkoImprovingYourMeasurementofCustomerSatisfaction:AGuidetoCreating,Conducting,Analyzing,andReportingCustomerSatisfactionMeasurementProgramsTerryG.VavraDevelopingNewServices:IncorporatingtheVoiceoftheCustomerintoStrategicServiceDevelopmentCarolineFisherandJamesSchuttaPrinciplesandPracticesofOrganizationalPerformanceExcellenceThomasJ.CartinQualityFunctionDeployment:LinkingaCompanywithItsCustomersRonaldG.DayBreakingtheConstraintstoWorld-ClassPerformanceH.WilliamDettmerGoldratt’sTheoryofConstraints:ASystemsApproachtoContinuousImprovementH.WilliamDettmerTorequestacomplimentarycatalogofASQQualityPresspublications,call800-248-1946,orvisitourWebsiteat©2003byASQAllrightsreserved.Published2003PrintedintheUnitedStatesofAmerica1211100908070605040354321LibraryofCongressCataloging-in-PublicationDataStamatis,D.H.,1947–Failuremodeandeffectanalysis:FMEAfromtheorytoexecution/D.H.Stamatis.—2nded.p.cm.Includesbibliographicalreferencesandindex.ISBN0-87389-598-31.Reliability(Engineering)2.Qualitycontrol.I.Title.TS176.S75172003620’.00452--dc212003005126Nopartofthisbookmaybereproducedinanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofthepublisher.Publisher:WilliamA.TonyAcquisitionsEditor:AnnemiekeKoudstaalProjectEditor:PaulO’MaraProductionAdministrator:GretchenTrautmanSpecialMarketingRepresentative:RobinBarryASQMission:TheAmericanSocietyforQualityadvancesindividual,organizational,andcommunityexcellenceworldwidethroughlearning,qualityimprovement,andknowledgeexchange.AttentionBookstores,Wholesalers,SchoolsandCorporations:ASQQualityPressbooks,videotapes,audiotapes,andsoftwareareavailableatquantitydiscountswithbulkpurchasesforbusiness,educational,orinstructionaluse.Forinformation,pleasecontactASQQualityPressat800-248-1946,orwritetoASQQualityPress,P.O.Box3005,Milwaukee,WI53201-3005.ToplaceordersortorequestafreecopyoftheASQQualityPressPublicationsCatalog,includingASQmembershipinformation,call800-248-1946.VisitourWebsiteat://qualitypress.asq.org@asq.org600N.PlankintonAvenueMilwaukee,Wisconsin53203TomywonderfulwifeCarlaJeanne,daughterChristine,andsonsCary,Stephen,andTimothyTableofContentsCDContents............................xListofFMEASamplesFoundinAppendixDonCD......xiListofFigures&FiguresonCD................xiiListofTables&TablesonCD..................xvPreface.............................xviiAcknowledgements.......................xxiIntroduction..........................xxiiiChapter1LegalApproachtoLiability............1ALegalApproachtoLiability................1WhatIsProductLiability?..................3WhatIsaProduct?......................8TheDefectRequirement...................10TheLegalProcess......................16LegalReferences......................20References..........................20Chapter2FMEA:AGeneralOverview...........21CriticalorSignificantCharacteristicsorKeyIndicators..22TheFourTypesofFMEAs.................40RelationshipsofFMEAandOtherTools..........45WhoIsResponsibleandControlstheFMEA?.......66QuantitativeTechniques...................68QualitativeTechniques...................76References..........................81viiChapter3TheLanguageoftheFMEA...........83VocabularyoftheFMEA..................83References..........................91Chapter4TeamsandTeamMechanicsofFMEA.....93WhatIsaTeam?.......................93WhyUseaTeam?......................95AboutConsensus......................96TeamProcessCheck.....................98HandlingofDifficultIndividuals..............99ProblemSolving......................100PlanningtheMeeting....................102In-ProcessMeetingManagement.............103AvoidingCommonMeetingPitfalls............104UtilizingtheMeeting-ManagementGuidelines......105References.........................106Chapter5SystemFMEA..................107Step-by-StepSystemFMEAAnalysis...........111RecommendedTeam....................127References.........................127Chapter6DesignFMEA..................129Step-by-StepDesignFMEAAnalysis...........133RecommendedTeam....................151References.........................153Chapter7ProcessFMEA..................155Step-by-StepProcessFMEAAnalysis...........160RecommendedTeam....................182References.........................182Chapter8ServiceFMEA..................185Step-by-StepServiceFMEAAnalysis...........192RecommendedTeam....................207References.........................208Chapter9MachineFMEA.................211SummaryStepsofConductingt