F M E A Number: 1.3
Process Page:  
Item: Beer making (based on Indian Pale Ale - IPA) Process Responsibility: Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer Prepared By:  
Model Year(s)/Vehicle(s): Add yeast Key date:   Created: 13/03/2013 Modified: 13/03/2013
Team:  
Function Potential Failure Mode Potential Effect(s) of Failure S C Potential Cause(s) of Failure O Preventive Action Detection Action D RPN Recommended Actions R/D Actions Taken S O D RPN
Process Element: Add yeast
Mix the
yeast
into the
wort at
a speci-
fied tem-
pera-
ture =
22 Centi-
grade ±
5C
Yeast
omitted
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 240 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 3 5 {120}
[5% Indian
Pale Ale Beer]
Brewing
process takes
longer than
required
6   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[Brewer]
Omits a stage
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
subse-
quent
stages will
be affect-
ed (detec-
tion post
process)
7 168              
Yeast
added
when
wort is
too hot
[5% Indian
Pale Ale Beer]
Beer is watery
7   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 48              
[5% Indian
Pale Ale Beer]
Beer is flat
6   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Brewing
process takes
longer than
required
6   [Instructions]
Metric / imperi-
al weights and
volumes not
specified
(including U.S.
imperial)
2 Use of
good quali-
ty brew kit
ingredients
Directions
are read
and re-
read at
each stage
of the brew-
ing process
2 32              
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[5% Indian
Pale Ale Beer]
Airlock does
not bubble
during the fer-
mentation
8   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 240 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 3 5 {120}
[5% Indian
Pale Ale Beer]
yeast is killed
8   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[Thermometer]
Out of calibra-
tion
2 Mechani-
cal ther-
mometer
used
Visual
inspection
3 48              
Yeat not
mixed
to a solu-
ble state
[5% Indian
Pale Ale Beer]
Brewing
process takes
longer than
required
6   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 36              
Shop own-
er / suppli-
er advice
[Brewer]
Omits a stage
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
subse-
quent
stages will
be affect-
ed (detec-
tion post
process)
7 126              
[Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 180 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   6 3 5 {90}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Yeast
added
when
wort is
too cold
[5% Indian
Pale Ale Beer]
Brewing
process takes
longer than
required
6   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 180 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   6 3 5 {90}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Wort is
contami-
nation
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Spoon]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   [Home]
Poor air quali-
ty (micro
organisms
present)
3 Controlled
environ-
ment
none 10 270              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Thermometer]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Brewer]
Does not wash
hands before-
hand
3 Common
sense /
hygiene
none 10 270              
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9  
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9  
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8  
Cover
fermen-
tation
bucket
and
insert air-
lock
Airlock
is not
inserted
into lid
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 270 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   9 3 5 {135}
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Brewer]
Omits a stage
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
subse-
quent
stages will
be affect-
ed (detec-
tion post
process)
7 189              
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8  
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9  
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9  
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8  
[5% Indian
Pale Ale Beer]
Airlock does
not bubble
during the fer-
mentation
8  
Beer is
contami-
nated
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Airlock]
Airlock or fluid
content is cont-
aminated
2 Instructions
include spe-
cial care
points
Visual
inspection
5 90              
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   [Fermentation
Bucket & lid]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Brewer]
Does not wash
hands before-
hand
3 Common
sense /
hygiene
none 10 270              
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8  
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9  
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9  
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8  
Lid is not
fully
sealed /
pushed
home
[5% Indian
Pale Ale Beer]
Airlock does
not bubble
during the fer-
mentation
8   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 240 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 3 5 {120}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision