F M E A Number: 1.1
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): Complete brewing process Key date:   Created: 13/03/2013 Modified: 20/03/2013
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: Sterilisation
Sterilise
all of
the
equip-
ment
and
then
rinse
with
clean
water
and
allow to
dry
Equip-
ment is
not ster-
ilised
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 54              
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [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 36              
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Brewer]
Fails to sterilise
container
used to carry
water
3 Instructions
clearly
express
that all
equipment
needs to
be sterilised
none 10 270              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Brewer]
Does not wash
hands before-
hand
3 Common
sense /
hygiene
none 10 270              
[Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
5 90              
Shop own-
er / suppli-
er advice
[Steriliser]
insufficent con-
centration /
ratios
3 Quantity is
specified in
the instruc-
tions
Sterilising
solution
has a
strong smell
4 108              
Instructions
specify
imperial
and metric
weights
and vol-
umes
[Home]
Poor air quali-
ty (micro
organisms
present)
3 Controlled
environ-
ment
none 10 270              
[Brewer]
Washes out ster-
ilising fluid too
early
3 Instructions
clearly
express
that all
equipment
needs to
be sterilised
Sterilising
solution
has a
strong smell
2 54              
[Water]
Domestic sup-
ply quality is
contaminated
(micro organ-
isms present)
2 Water quali-
ty is
assured by
water board
none 10 180 D: Beer
clarity
and
smell
are
checke
d dur-
ing the
sec-
onadary
fermen-
tation
stage
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   9 2 8 {144}
22/03/2013
in revision
Steriliser
not fully
rinsed
from
equip-
ment
[5% Indian
Pale Ale Beer]
Beer tastes of
detergent
8   [Brewer]
Does not rinse
equipment
properly
3 Instructions
clearly
express
that all
equipment
needs to
be sterilised
Sterilising
solution
has a
strong smell
2 48              
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Brewer]
Forgets to rinse
equipment
properly
2 Instructions
clearly
express
that all
equipment
needs to
be sterilised
Sterilising
solution
has a
strong smell
2 32              
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Process Element: Preparing the Wort
Place
Malt &
Hops
contain-
er into
warm
water
for a
time of
>= 5
mins +5
Malt &
Hops
not
warmed
suffi-
ciently
[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 42              
[5% Indian
Pale Ale Beer]
Beer is watery
7   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   [Kettle]
Thermostat fail-
ure
2 TPM on all
devices
Visual
inspection
1 14              
[Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Add boil-
ing
water to
the fer-
menta-
tion
bucket
= 5 litres
+1
Exces-
sive boil-
ing
water
added
[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 24              
Shop own-
er / suppli-
er advice
Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[Fermentation
Bucket & lid]
Volume mea-
surements are
illegible
1 Products
recently pur-
chased (JIT)
Visual
inspection
2 12              
Insuffi-
cient
boiling
water
added
[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 24              
Shop own-
er / suppli-
er advice
Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[Fermentation
Bucket & lid]
Volume mea-
surements are
illegible
1 Products
recently pur-
chased (JIT)
Visual
inspection
2 12              
[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
Water
added
is not at
boiling
point
[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  
Add the
ingredi-
ents to
the fer-
menta-
tion
bucket
= 1 kg
beer
enhanc
er (sug-
ar)
1.8kg
Malt &
Hops
Exces-
sive
quantity
of sugar
[5% Indian
Pale Ale Beer]
Beer is too
gaseous
5   [Scales]
Batteries are flat
4 Alternative
scales avail-
able
Scales
clearly dis-
play a bat-
tery level
symbol
1 28              
[5% Indian
Pale Ale Beer]
Beer tastes
yeasty
7   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   [Brewer]
Adds more sug-
ar than required
5 Ingredients
and quanti-
ties are
specified in
the instruc-
tions
Electronic
scales with-
in accu-
rate to 0.25g
1 35              
[5% Indian
Pale Ale Beer]
Beer is too
sweet
4   [Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
5 70              
[5% Indian
Pale Ale Beer]
Party goers
are inebriat-
ed to early in
the night
6   Shop own-
er / suppli-
er advice
[Brewer]
Incorrect type
of sugar used
(e.g. brown
sugar / Muscov-
ado)
2 Ingredients
and quanti-
ties are
specified in
the instruc-
tions
Sugar pack-
aging is
clearly
labelled
1 14              
Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Shop own-
er / suppli-
er advice
[Scales]
Out of calibra-
tion
3 TPM on all
devices
1 standard
bag of
white cane
sugar
should
weigh
approx.
1kg (Gold
sample)
3 63              
Digital
scales used
[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 28              
Shop own-
er / suppli-
er advice
Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Incor-
rect
ingredi-
ents
added
[5% Indian
Pale Ale Beer]
Beer tastes
caramelly/
malty
6   [Brewer]
Incorrect type
of sugar used
(e.g. brown
sugar / Muscov-
ado)
2 Ingredients
and quanti-
ties are
specified in
the instruc-
tions
Sugar pack-
aging is
clearly
labelled
1 16              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
[5% Indian
Pale Ale Beer]
Beer is too
gaseous
5   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   [Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
5 80              
[5% Indian
Pale Ale Beer]
Beer is too
sweet
4   Shop own-
er / suppli-
er advice
[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 10 240 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 3 5 {120}
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   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 not
ready for
Gavin's 40th
birthday party
8   [Brewer]
Experimenta-
tion with
process (Brew-
er has a
'good' idea!)
5 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 400 D: Smell
& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 5 6 {240}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
27/03/2013
in revision
Insuffi-
cient
quantity
of Malt
& Hops
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
[5% Indian
Pale Ale Beer]
Beer is watery
7   Shop own-
er / suppli-
er advice
[Brewer]
Fails to rinse
out Malt &
Hops container
2 Instructions
include spe-
cial care
points
Visual
inspection
2 28              
[Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Insuffi-
cient
quantity
of sugar
[5% Indian
Pale Ale Beer]
Beer is flat
6   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
[5% Indian
Pale Ale Beer]
Beer is watery
7   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Insufficient
alcoholic bev-
erages for the
party goers
6   [Scales]
Batteries are flat
4 Alternative
scales avail-
able
Scales
clearly dis-
play a bat-
tery level
symbol
1 28              
[Brewer]
Incorrect type
of sugar used
(e.g. brown
sugar / Muscov-
ado)
2 Ingredients
and quanti-
ties are
specified in
the instruc-
tions
Sugar pack-
aging is
clearly
labelled
1 14              
Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Shop own-
er / suppli-
er advice
[Scales]
Out of calibra-
tion
3 TPM on all
devices
1 standard
bag of
white cane
sugar
should
weigh
approx.
1kg (Gold
sample)
3 63              
Digital
scales used
[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 28              
Shop own-
er / suppli-
er advice
Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Sugar
omitted
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [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              
Wort is
contami-
nation
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Brewer]
Fails to cover
the wort
3 Common
sense /
hygiene
none 10 270              
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 54              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Fermentation
Bucket & lid]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9   [Malt & Hops]
Bacterial conta-
mination
present
2 Shop own-
er / suppli-
er advice
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9   Use of
good quali-
ty brew kit
ingredients
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   Basic
hygiene
practice
Mixed with
boiling
water to
ensure sterili-
ty
[Scales]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[Brewer]
Does not wash
hands before-
hand
3 Common
sense /
hygiene
none 10 270              
[Home]
Poor air quali-
ty (micro
organisms
present)
3 Controlled
environ-
ment
none 10 270              
[Sugar]
Bacterial conta-
mination
present
2 Shop own-
er / suppli-
er advice
none 10 180              
Use of
good quali-
ty brew kit
ingredients
Mixed with
boiling
water to
ensure sterili-
ty
Basic
hygiene
practice
[Brewer]
Washes out ster-
ilising fluid too
early
3 Instructions
clearly
express
that all
equipment
needs to
be sterilised
Sterilising
solution
has a
strong smell
2 54              
[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}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[Spoon]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[Malt & Hops]
Poor quality
product / batch
2 Shop own-
er / suppli-
er advice
none 10 180              
Use of
good quali-
ty brew kit
ingredients
Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Mix con-
tents
until
ingredi-
ents are
dissolved
Ingredi-
ents mix-
ing not
mixed
to a solu-
ble state
[5% Indian
Pale Ale Beer]
Beer is flat
6   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
[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
[5% Indian
Pale Ale Beer]
Beer is watery
7   [Spoon]
Insufficient
length
1 Shop own-
er / suppli-
er advice
Cannot
complete
and move
on to next
operation
1 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)
7 147              
Wort is
contami-
nation
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Brewer]
Does not wash
hands before-
hand
3 Common
sense /
hygiene
none 10 270              
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 54              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Home]
Poor air quali-
ty (micro
organisms
present)
3 Controlled
environ-
ment
none 10 270              
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9   [Spoon]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9  
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8  
Fill the
fermen-
tation
bucket
to the
correct
volume
= 40
pints
Insuffi-
cient
water
added
[5% Indian
Pale Ale Beer]
Insufficient
alcoholic bev-
erages for the
party goers
6   [Brewer]
Experimenta-
tion with
process (Brew-
er has a
'good' idea!)
5 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 300 D: Smell
& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   6 5 6 {180}
[5% Indian
Pale Ale Beer]
Beer is too
gaseous
5   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
27/03/2013
in revision
[5% Indian
Pale Ale Beer]
Party goers
are inebriat-
ed to early in
the night
6   [Fermentation
Bucket & lid]
Volume mea-
surements are
illegible
1 Products
recently pur-
chased (JIT)
Visual
inspection
2 12              
[5% Indian
Pale Ale Beer]
Beer is too
sweet
4   [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 24              
[5% Indian
Pale Ale Beer]
Beer tastes
caramelly/
malty
6   Shop own-
er / suppli-
er advice
Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[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
[Fermentation
Bucket & lid]
Insufficient
capacity
2 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Visual
inspection
1 12              
Shop own-
er / suppli-
er advice
Wort is
contami-
nation
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 54              
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Brewer]
Fails to sterilise
container
used to carry
water
3 Instructions
clearly
express
that all
equipment
needs to
be sterilised
none 10 270              
[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   [Home]
Poor air quali-
ty (micro
organisms
present)
3 Controlled
environ-
ment
none 10 270              
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9   [Water]
Domestic sup-
ply quality is
contaminated
(micro organ-
isms present)
2 Water quali-
ty is
assured by
water board
none 10 180 D: Beer
clarity
and
smell
are
checke
d dur-
ing the
sec-
onadary
fermen-
tation
stage
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   9 2 8 {144}
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   22/03/2013
in revision
[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}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
Cover
fermen-
tation
bucket
and
insert air-
lock
whilst
tempera-
ture set-
tles
Wort is
contami-
nation
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Fermentation
Bucket & lid]
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   [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 is
cloudy/hazy
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 is not
ready for
Gavin's 40th
birthday party
8   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9   [Fermentation
Bucket & lid]
Plastic fatigue
(cracks /
orange peel)
1 Products
recently pur-
chased (JIT)
Visual
inspection
5 45              
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9   [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]
40 pints of
beer is
scapped
8   [Thermometer]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
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
Process Element: Primary Fermentation
Beer is
allowed
to fer-
ment for
= 6
days ±2
Beer is
contami-
nated
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Fermentation
Bucket & lid]
Plastic fatigue
(cracks /
orange peel)
1 Products
recently pur-
chased (JIT)
Visual
inspection
5 45              
[5% Indian
Pale Ale Beer]
Beer aroma is
poor (e.g.
vinegary)
9   [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 is
cloudy/hazy
7  
[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  
Beer
leakage
[5% Indian
Pale Ale Beer]
Insufficient
alcoholic bev-
erages for the
party goers
6   [Fermentation
Bucket & lid]
Plastic fatigue
(cracks /
orange peel)
1 Products
recently pur-
chased (JIT)
Visual
inspection
5 40              
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   [Home]
Shelf strength
in airing cup-
board is inade-
quate
1 Office floor
used instead
none 1 8              
Fermen-
tation
does
not
occur
(no bub-
bles exit
airlock)
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Brewer]
Uses only boil-
ing water
when prepar-
ing the wort
1 Cost and
time limita-
tions
Primary fer-
mentation
will be
impeded /
airlock
does not
bubble
7 56              
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   [Water]
Domestic sup-
ply quality is
contaminated
(micro organ-
isms present)
2 Water quali-
ty is
assured by
water board
none 10 160 D: Beer
clarity
and
smell
are
checke
d dur-
ing the
sec-
onadary
fermen-
tation
stage
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 2 8 {128}
22/03/2013
in revision
[Water]
Domestic sup-
ply quality is
contaminated
(chlorine con-
tent)
2 Water quali-
ty is
assured by
water board
Water Chlo-
rination
can be
smelt from
the tap (US
tap=faucet)
2 32              
[Home]
Ambient tem-
perature is too
low / incorrect
proximity to
heat source
2 Home is in
a temper-
ate climate
and central-
ly heated
Climate
supervisor
(wife)
3 48              
Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Lack of hot
domestic
water sup-
ply (discov-
ered when
teenage
son want to
shower)
Home is in
the UK,
which is
unlikely to
lead to
excessively
high tem-
peratures
[Home]
Ambient tem-
perature is too
high / incor-
rect proximity
to heat source
2 Home is in
a temper-
ate climate
and central-
ly heated
Climate
supervisor
(wife)
3 48              
Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Lack of hot
domestic
water sup-
ply (discov-
ered when
teenage
son want to
shower)
Warm floor
space in
office has
been
assigned
(location
where the
cat usually
sleeps!)
[Yeast]
Past best
before date
2 Use of
good quali-
ty brew kit
ingredients
none 10 160   Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer D: Visu-
al
inspec-
tion
8 2 2 32
Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
15/03/2013
completed
D: Audi-
ble
sounds
of bub-
bles exit-
ing the
airlock
expect-
ed with-
in 24
hours
Fermen-
tation
process
stopped
too early
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   [Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer tastes
caramelly/
malty
6   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
[5% Indian
Pale Ale Beer]
Beer tastes
yeasty
7   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 too
sweet
4  
[5% Indian
Pale Ale Beer]
Beer is too
gaseous
5  
Beer is
allowed
to fer-
ment in
constis-
tent tem-
pera-
ture of
= 20-
25C
Temper-
ature
fluctua-
tions
[5% Indian
Pale Ale Beer]
Beer is flat
6   [Home]
Location is
close to
draughts / UV
light source
1 Home is
double
glazed
Climate
supervisor
(wife)
3 24              
[5% Indian
Pale Ale Beer]
Beer is too
sweet
4   Controlled
environ-
ment
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   fermenta-
tion bucket
is covered
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   [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]
40 pints of
beer is
scapped
8   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8  
[5% Indian
Pale Ale Beer]
yeast is killed
8  
Temper-
ature is
too high
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   [Home]
Ambient tem-
perature is too
high / incor-
rect proximity
to heat source
2 Home is in
a temper-
ate climate
and central-
ly heated
Climate
supervisor
(wife)
3 48              
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Lack of hot
domestic
water sup-
ply (discov-
ered when
teenage
son want to
shower)
[5% Indian
Pale Ale Beer]
yeast is killed
8   Warm floor
space in
office has
been
assigned
(location
where the
cat usually
sleeps!)
[Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 48              
Shop own-
er / suppli-
er advice
Temper-
ature is
too low
[5% Indian
Pale Ale Beer]
Brewing
process takes
longer than
required
6   [Home]
Ambient tem-
perature is too
low / incorrect
proximity to
heat source
2 Home is in
a temper-
ate climate
and central-
ly heated
Climate
supervisor
(wife)
3 48              
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Lack of hot
domestic
water sup-
ply (discov-
ered when
teenage
son want to
shower)
[5% Indian
Pale Ale Beer]
Airlock does
not bubble
during the fer-
mentation
8   Home is in
the UK,
which is
unlikely to
lead to
excessively
high tem-
peratures
[Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 48              
Shop own-
er / suppli-
er advice
Process Element: Keg Fermentation
Syphon
the fer-
ment-
ing
beer
into a
keg
avoid-
ing the
sediment
Beer is
contami-
nated
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Syphon]
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   [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   [Keg]
Plastic fatigue
(cracks /
orange peel)
1 Products
recently pur-
chased (JIT)
Visual
inspection
5 45              
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9   [Keg]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9  
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8  
Beer
spillage
[5% Indian
Pale Ale Beer]
Insufficient
alcoholic bev-
erages for the
party goers
6   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 240 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   8 3 5 {120}
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[Syphon]
Insufficient
length
1 Shop own-
er / suppli-
er advice
Cannot
complete
and move
on to next
operation
1 8              
[Syphon]
Multi-section
product
3 Compres-
sion fit at
joint
Visual
inspection
2 48              
[Keg]
Insufficient
capacity
2 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
Visual
inspection
1 16              
Shop own-
er / suppli-
er advice
Excess
sedi-
ment
decant-
ed
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
[5% Indian
Pale Ale Beer]
Party goers
have 'wind'
the next day
4   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
Shop own-
er / suppli-
er advice
Add
addition-
al ingre-
dients =
150 g
±30g
Beer is
contami-
nated
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Keg]
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   [Scales]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   [Sugar]
Bacterial conta-
mination
present
2 Shop own-
er / suppli-
er advice
none 10 180              
[5% Indian
Pale Ale Beer]
Beer is not
ready for
Gavin's 40th
birthday party
8   Use of
good quali-
ty brew kit
ingredients
[5% Indian
Pale Ale Beer]
Beer makes
the party
goers unwell
9   Mixed with
boiling
water to
ensure sterili-
ty
[5% Indian
Pale Ale Beer]
Beer is too
gaseous (bad)
9   Basic
hygiene
practice
[5% Indian
Pale Ale Beer]
40 pints of
beer is
scapped
8   [Spoon]
Bacterial conta-
mination
present
2 Instructions
include spe-
cial care
points
none 10 180              
[Brewer]
Does not wash
hands before-
hand
3 Common
sense /
hygiene
none 10 270              
Exces-
sive
quantity
of sugar
[5% Indian
Pale Ale Beer]
Beer is too
gaseous
5   [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 28              
[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]
Beer is too
sweet
4   Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[5% Indian
Pale Ale Beer]
Party goers
are inebriat-
ed to early in
the night
6   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[5% Indian
Pale Ale Beer]
Brewing
process takes
longer than
required
6   [Brewer]
Adds more sug-
ar than required
5 Ingredients
and quanti-
ties are
specified in
the instruc-
tions
Electronic
scales with-
in accu-
rate to 0.25g
1 35              
[Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
Shop own-
er / suppli-
er advice
[Scales]
Out of calibra-
tion
3 TPM on all
devices
1 standard
bag of
white cane
sugar
should
weigh
approx.
1kg (Gold
sample)
3 63              
Digital
scales used
[Scales]
Batteries are flat
4 Alternative
scales avail-
able
Scales
clearly dis-
play a bat-
tery level
symbol
1 28              
Incor-
rect
ingredi-
ents
added
[5% Indian
Pale Ale Beer]
Beer is too
gaseous
5   [Brewer]
Incorrect type
of sugar used
(e.g. brown
sugar / Muscov-
ado)
2 Ingredients
and quanti-
ties are
specified in
the instruc-
tions
Sugar pack-
aging is
clearly
labelled
1 12              
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
[5% Indian
Pale Ale Beer]
Beer is too
sweet
4   Shop own-
er / suppli-
er advice
[5% Indian
Pale Ale Beer]
Beer tastes
caramelly/
malty
6  
[5% Indian
Pale Ale Beer]
Party goers
are inebriat-
ed to early in
the night
6  
Insuffi-
cient
quantity
of sugar
[5% Indian
Pale Ale Beer]
Beer is flat
6   [Brewer]
Experimenta-
tion with
process (Brew-
er has a
'good' idea!)
5 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 350 D: Smell
& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 5 6 {210}
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
27/03/2013
in revision
[5% Indian
Pale Ale Beer]
Beer is watery
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)
7 147              
[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 28              
Shop own-
er / suppli-
er advice
Measuring
devices at
Gavin's
home dis-
play both
imperial &
metric units
[Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[Instructions]
Insufficient
detail about
alternative
ingredients
(does & don'ts)
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
5 70              
Shop own-
er / suppli-
er advice
[Instructions]
Ambiguous
methodology
2 Use of
good quali-
ty brew kit
ingredients
Instructions
are read
thoroughly
before com-
mencing
brewing
3 42              
Shop own-
er / suppli-
er advice
Sugar
omitted
[5% Indian
Pale Ale Beer]
Beer is flat
6   [Brewer]
Impatien-
tience / care-
lessness or inex-
perience
3 Past experi-
ences with
similar
brew kits
that are
being
drank with
gusto!
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions
Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer   7 3 5 {105}
[5% Indian
Pale Ale Beer]
Beer is watery
7   Instructions
supplied
with each
brewing kit
& can be
down-
bloaded
from the
internet
03/04/2013
in revision
[5% Indian
Pale Ale Beer]
Alcohol con-
tent is not as
per product
description
6  
Beer is
allowed
to fer-
ment for
= 7
days +6
Beer is
contami-
nated
[5% Indian
Pale Ale Beer]
Beer taste has
a bitterness to it
7   [Keg]
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  
[5% Indian
Pale Ale Beer]
Beer is
cloudy/hazy
7  
[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  
Beer
leakage
[5% Indian
Pale Ale Beer]