Failure mode:
Failure mode:
INGREDIENTS NOT FRESH / SPOILED
INGREDIENTS NOT FRESH / SPOILED
Effect:
Effect:
Health Code Violation / Customer
Health Code Violation / Customer
becomes ill
becomes ill
E
En
nv
viirro
on
nm
me
en
ntt
M
Ma
an
n
Method
Method
M
Me
ea
as
su
urre
em
me
en
ntt
M
Ma
ac
ch
hiin
ne
e
Material
Material
not stored at proper
not stored at proper
temperature
temperature
cause
cause
cause
cause
expired shelf life
expired shelf life
left out of storage
left out of storage
too long
too long
Cause
Cause
Cause
Cause
cause
cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
cause
cause
cause
cause
cause
cause
B
Failure mode:
INGREDIENTS CONTAMINATED DURING PREPARATION
Effect:
Health Code Violation / Customer
becomes ill
Environment
Man
Method
Measurement
Machine
Material
Temperature of
prep area
rodents
employee
came to work
sick
food preparation area
not disinfected properly
employee did not wash
hands prior to entering
work area
Cause
washing machine has no
detergent or disinfectant
utensiles (knives)
not disinfected
Cause
Cause
Cause
Washing machine not at
high enough temperature
Cause
Cause
Cause
Employee did not
wash hands after
using bathroom
employee not using
protective gear (hairnet, face
mask)
Failure mode:
PIZZA UNDERCOOKED
Effect:
Health Code Violation / Customer
becomes ill
Environment
Man
Method
Measurement
Machine
Material
cause
cause
cause
cause
Cause
Cause
Cause
oven temperature
too low
Cause
Cause
Cause
Cause
Cause
Cause
Cause
pizza not left in oven
long enough
cause
POTENTIAL FAILURE MODES AND EFFECTS WORKSHEET
FMEAType LevelofDetail
FMEA Number ---> Pizza FMEA-03
AllPizzas EricCartman Prepared by ---> Eric Cartman
Pizza Creation Other relevant information ---> None Original Date ---> May 29, 2007 June 30, 2008 Core Team --->
Processactivity ActionsTaken
wrong ingredients
7 method 2 OJT 7 98
7 man 5 OJT none 10 350
7 material 2 7 98 7 man 2 7 98 9
expired shelf life method
3 7 189 9 5 9 405 9 method 5 5 225 9 method 3 8 216 9 man 5 OJT 5 225 9 man 7
OJT / sign on wall none
10 630 sink installed 7/08 9 5 5 225 9 machine 3 5 135 9 machine 3 5 135 Product / Service Identifier --->
Design or Process Responsibility --->
Telephone #: 585-555-1212
Email address:
Process being analyzed --->
FMEA Revision Date --->
Eric Cartman (Operations Manager), Kenny (South Park Store Manager), Marge Simpson (Springfield Store Manager), Stan Marsh (pizza creation associate), Kyle Br ovlowski (BPI associate), Mr. Garrison (purchasing and inventory manager), Mr. Hand (pizza creation associate), Chef (BPI M anager)
Potential Failure Mode
Potential Effect(s) of Failure S e v T y p e Potential Cause(s) / Mechanism(s) of Failure Fishbone Cause Category O c c Current Process Controls -Prevention Current Process Controls - Detection D e t R P N Recommended Actions Responsibility & Target Completion Date S e v O c c D e t R P N Preparation of pizza customer dissatisfaction
ingredients not clearly identified monthly inventory audits error by pizza creation associate ingredients not available
weekly ordering of ingredients and FIFO system
monthly inventory audits not enough of any
ingredient
weekly ordering of ingredients and FIFO system monthly inventory audits ingredients not fresh / spoiled health code violation / customer becomes ill
weekly ordering of ingredients and FIFO system
monthly inventory audits
not stored at proper temperature environm ent cooler set at 34F by store manager monthly inventory audits left out of storage too
long
end of shift checklist requires all food to be put back in cooler
store manager monitors procedural adherence of employees 12-8pm ingredients contaminated during preparation health code violation / customer becomes ill
food preparation area not disinfected properly
outsourced cleaning service required to disinfect preparation areas each night
random internal audits of cleaning service
employee not using protective gear (hairnet, face mask)
store manager monitors procedural adherence of employees 12-8pm
employee did not wash hands after using bathroom Install a sink at kitchen entarnce Homer Simpson 9/08 utensiles (knives,
etc.) not washed / disinfected
knives washed after each shift in automated machine with disinfectant at 170F
shift start checklist requires all utensiles to washed
washing machine has no detergent or disinfectant
low detergent and disinfectant indicator machine has enough capacity for 2 shifts of detergent
shift start checklist requires verification of detergent and disinfectant
System
Process
Component /
POTENTIAL FAILURE MODES AND EFFECTS WORKSHEET
FMEAType LevelofDetail
FMEA Number ---> Pizza FMEA-03
AllPizzas EricCartman Prepared by ---> Eric Cartman
Pizza Creation Other relevant information ---> None Original Date ---> May 29, 2007 June 30, 2008 Core Team --->
Processactivity ActionsTaken
Product / Service Identifier --->
Design or Process Responsibility --->
Telephone #: 585-555-1212
Email address:
Process being analyzed --->
FMEA Revision Date --->
Eric Cartman (Operations Manager), Kenny (South Park Store Manager), Marge Simpson (Springfield Store Manager), Stan Marsh (pizza creation associate), Kyle Brovlowski (BPI associate), Mr. Garrison (purchasing and inventory manager), Mr. Hand (pizza creation associate), Chef (BPI Manager)
Potential Failure Mode
Potential Effect(s) of Failure S e v T y p e Potential Cause(s) / Mechanism(s) of Failure Fishbone Cause Category O c c Current Process Controls -Prevention Current Process Controls - Detection D e t R P N Recommended Actions Responsibility & Target Completion Date S e v O c c D e t R P N
System
Process
Component /
Design FMEA
Process FMEA
Process Step
9
machine
6
none
10 540
Baking of pizza pizza overcooked
7
machine
3 5 105
7 man 5 OJT none 10 350
Washing machine not at high enough temperature outsourced maintenance checks machine temperature each month customer dissatisfaction
oven temperature too high
oven set at constant temperature of 525F
shift start checklist requires verification of oven temperature
pizza left in oven too long
