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