Analyzing Composite Material Manufacturing Methods Using Failure Modes Effect Analysis

Abstract

This paper presents the preliminary results of a case study of Failure Modes and Effects Analysis (FMEA) in composite manufacturing. The purpose of FMEA is to improve quality, reliability, safety, durability, and reduce product life-cycle costs. Six various methods of composite layup (both manual and automated) were identified and examined with respect to various defect types caused through the composite layup process such as porosity, fiber misalignment, excess or insufficient resin, and incomplete curing. An adaptation of FMEA for composite manufacturing was used to analyze the different defect types, and the occurrence, severity, and detectability of each type of failure in each of the composite manufacturing processes. Failure was defined as the loss of function or ability to perform a prescribed task in a given manner for which that part was designed [1]. The conclusions of this study are two-fold: design engineers can analyze the most common composite material defects in order to build robustness into the product and the methodologies used can assist process improvement for manual or automated composite manufacturing.