Handbook on FMECA
A Simple But Powerful Risk Assessment Tool
By: Paul J. Zepf, P.Eng., CPP

Table of Contents

PREFACE

Chapter 1
1.0 Introduction
1.1 How to Evaluate Risk?
1.1.0 Definition of Risk

Chapter 2
2.0 Purpose of FMECA
2.1 What is FMECA?
2.1.0 Why Do a FMECA?
2.2 FMECA and Quality
2.3 When to Use FMECA
2.4 Types or Levels of FMECA
2.4.1 System Level FMECA
2.4.2 Design Level FMECA
2.4.3 Process Level FMECA
2.5 How to Get Ready to Do a FMECA?
2.5.1 FMECA is a Team of Group Effort
2.5.2 What Needs to Be Done and Determined Before Starting
2.6 Assumptions
2.7 Intent of This Handbook
2.8 Who is The Customer?
2.9 Preparatory Steps to Perform Prior to Doing a FMECA
2.10 Method of Attack
2.11 Tools to Identify Planned Downtime Issues
2.12 Tools to Identify Unplanned Downtime Issues
2.13 Outline of Steps to Follow to Accomplish a FMECA
2.13.1 Outline of Steps to Accomplish “Design Safety In” FMECA
2.14 Outline of Steps to Do a Failure Mode, Effect & Corrective Analysis
2.14.1 TASK A: Prepare to Do the Analysis
2.14.2 TASK B: Identify the Failure Mode Effect Analysis (FMEA)
2.14.3 Putting It All Together
2.14.4 TASK C: Establish Criticality Index (Risk Priority Number – RPN)
2.14.5 Examples of the Type of Actions and/or Recommendations
2.14.6 TASK D: Documentation and Future Reference
2.15 Outline of Steps to Accomplish “Design Safety In” FMECA
2.15.1 TASK E: Identify Typical Behavior in Response to Each Failure Mode Cause
2.15.2 TASK F: Rank the Severity of the Behavior
2.15.3 TASK G: Develop Recommendations for Each Behavior
2.16 Summary of the Main FMECA Execution Steps
2.17 Analysis of Failure Patterns

Appendix A of FMECA
Definition, Forms and Instructions
Biography of Paul J. Zepf, P.Eng. CPP
Bibliography