Team: Equipment is [5% Indian Pale Ale not sterilised Beer] 40 pints of beer is scapped [5% Indian Pale Ale Beer] Beer makes the party goers unwell [5% Indian Pale Ale Beer] Beer taste has a bitter- ness to it [5% Indian Pale Ale Beer] Beer is too gaseous (bad) [5% Indian Pale Ale Beer] Beer aroma is poor (e. g. vinegary) [5% Indian Pale Ale Beer] Beer is not ready for Gavin's 40th birthday party [5% Indian Pale Ale Beer] Beer is cloudy/hazy Item: Beer making (based on Indian Pale Ale - IPA) Model Year(s)/Vehicle(s): Complete brewing process Function Potential Failure Mode Potential Effect(s) of Failure S C Process Element: Sterilisation 8 9 7 9 9 8 7 Sterilise all of the equip- ment and then rinse with clean water and allow to dry
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Transcript
Team:
Equipment is [5% Indian Pale Ale
not sterilised Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale
Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
F M E A
Process
Item: Beer making (based on Indian Pale Ale - IPA)
Model Year(s)/Vehicle(s): Complete brewing process
Function Potential Failure Mode Potential Effect(s) of Failure S C
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
ing brewing
Shop owner / suppli-
er advice
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of thenot specified (including brewing process
U.S. imperial) Shop owner / suppli-
er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Instructions clearlyFails to sterilise container express that allused to carry water equipment needs to
be sterilised
[Brewer] Common sense /Does not wash hands hygienebeforehand
[Instructions] Use of good quality Instructions areInsufficient detail about brew kit ingredients read thoroughly
F M E A
Process
Process Responsibility: Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer
Key date:
Potential Cause(s) of Failure Preventive Actions O Detection Actions
Process Element: Sterilisation
2
2
3 none
3 none
2
alternative ingredients before commenc-
(does & don'ts) Shop owner / suppli- ing brewing
er advice
[Steriliser] Quantity is specified Sterilising solutioninsufficent concentra- in the instructions has a strong smell
tion / ratios Instructions specify
imperial and metric
weights and volumes
[Home] Controlled environ-Poor air quality (micro mentorganisms present)
[Brewer] Instructions clearly Sterilising solutionWashes out sterilising flu- express that all has a strong smellid too early equipment needs to
be sterilised
[Water] Water quality isDomestic supply quality assured by wateris contaminated (micro boardorganisms present)
[Brewer] Instructions clearly Sterilising solutionDoes not rinse equip- express that all has a strong smellment properly equipment needs to
be sterilised
[Brewer] Instructions clearly Sterilising solutionForgets to rinse equip- express that all has a strong smellment properly equipment needs to
be sterilised
Past experiences
with similar brew kits
that are being
drank with gusto!
2
3
3 none
3
2 none
3
2
Process Element: Preparing the Wort
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
ing brewing
Shop owner / suppli-
er advice
[Kettle]
Thermostat failure
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of the
not specified (including Shop owner / suppli- brewing processU.S. imperial) er advice
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
that are being (detection post
drank with gusto! process)
2
1 Visual inspection
3 none
3 none
3
[Scales] Alternative scales Scales clearly dis-Batteries are flat available play a battery lev-
el symbol
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Brewer] Ingredients and Electronic scalesAdds more sugar than quantities are speci- within accurate torequired fied in the instructions 0.25g
[Instructions] Use of good quality Instructions areInsufficient detail about brew kit ingredients read thoroughlyalternative ingredients before commenc-
(does & don'ts) Shop owner / suppli- ing brewing
er advice
[Brewer] Ingredients and Sugar packagingIncorrect type of sugar quantities are speci- is clearly labelledused (e.g. brown sugar / fied in the instructions
Muscovado) Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Scales] 1 standard bag ofOut of calibration white cane sugar
should weigh
approx. 1kg (Gold
Digital scales used sample)
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of the
not specified (including Shop owner / suppli- brewing processU.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
3
4
2
2
5
2
TPM on all devices 3
2
& metric units
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Ingredients and Sugar packagingIncorrect type of sugar quantities are speci- is clearly labelledused (e.g. brown sugar / fied in the instructionsMuscovado)
Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Instructions] Use of good quality Instructions areInsufficient detail about brew kit ingredients read thoroughlyalternative ingredients before commenc-(does & don'ts) ing brewing
Shop owner / suppli-
er advice
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiencesExperimentation with with similar brew kitsprocess (Brewer has a that are being'good' idea!) drank with gusto!
2
3 none
2
2
3 none
5 none
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
ing brewing
Shop owner / suppli-
er advice
[Brewer] Instructions includeFails to rinse out Malt & special care pointsHops container
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Scales] Alternative scales Scales clearly dis-Batteries are flat available play a battery lev-
el symbol
[Brewer] Ingredients and Sugar packagingIncorrect type of sugar quantities are speci- is clearly labelledused (e.g. brown sugar / fied in the instructions
5 none
2
2 Visual inspection
3 none
2
4
2
Muscovado) Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Scales] 1 standard bag ofOut of calibration white cane sugar
should weigh
approx. 1kg (Gold
Digital scales used sample)
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of the
not specified (including Shop owner / suppli- brewing processU.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
that are being (detection post
drank with gusto! process)
[Brewer] Common sense /Fails to cover the wort hygiene
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
ing brewing
Shop owner / suppli-
2
TPM on all devices 3
2
3 none
3
3 none
2
er advice
[Fermentation Bucket & Instructions includelid] special care pointsBacterial contamination
present
[Malt & Hops] Shop owner / suppli-Bacterial contamination er advicepresent
Use of good quality
brew kit ingredients
Basic hygiene prac-
tice
Mixed with boiling
water to ensure sterili-
ty
[Scales] Instructions includeBacterial contamination special care pointspresent
[Brewer] Common sense /Does not wash hands hygienebeforehand
[Home] Controlled environ-Poor air quality (micro mentorganisms present)
[Sugar] Shop owner / suppli-Bacterial contamination er advice
present Use of good quality
brew kit ingredients
Mixed with boiling
water to ensure sterili-
ty
Basic hygiene prac-
tice
[Brewer] Instructions clearly Sterilising solutionWashes out sterilising flu- express that all has a strong smellid too early equipment needs to
be sterilised
2
2 none
2 none
2 none
3 none
3
3 none
2 none
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Spoon] Instructions includeBacterial contamination special care pointspresent
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
that are being (detection post
drank with gusto! process)
[Thermometer] Instructions includeBacterial contamination special care pointspresent
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
that are being (detection post
drank with gusto! process)
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of thenot specified (including brewing process
U.S. imperial) Shop owner / suppli-
er advice
3 none
1 Visual inspection
3
2 none
Process Element: Add yeast
3 none
3
2
2
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Thermometer] Mechanical ther-Out of calibration mometer used
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
that are being (detection post
drank with gusto! process)
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
2
3 none
2 Visual inspection
2
3
3 none
3 none
kit & can be down-
bloaded from the
internet
[Spoon] Instructions includeBacterial contamination special care pointspresent
[Home] Controlled environ-Poor air quality (micro mentorganisms present)
[Thermometer] Instructions includeBacterial contamination special care pointspresent
[Brewer] Common sense /Does not wash hands hygienebeforehand
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
3 none
2 none
3 none
2 none
3 none
3 none
3
that are being (detection post
drank with gusto! process)
[Airlock] Instructions includeAirlock or fluid content is special care pointscontaminated
[Fermentation Bucket & Instructions includelid] special care pointsBacterial contamination
present
[Brewer] Common sense /Does not wash hands hygienebeforehand
2
3
Visual inspection
2 none
3 none
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
[Home] Office floor usedShelf strength in airing insteadcupboard is inadequate
[Brewer] Cost and time limita- Primary fermenta-Uses only boiling water tions tion will be imped-when preparing the wort ed / airlock does
not bubble
[Water] Water quality isDomestic supply quality assured by wateris contaminated (micro boardorganisms present)
[Water] Water quality is Water ChlorinationDomestic supply quality assured by water can be smelt fromis contaminated (chlo- board the tap (USrine content) tap=faucet)
[Home] Home is in a temper- Climate supervisorAmbient temperature is ate climate and cen- (wife)too low / incorrect prox- trally heated
imity to heat source Past experiences Lack of hot domes-
with similar brew kits tic water supply (dis-
that are being covered when
drank with gusto! teenage son want
2 Visual inspection
1 Visual inspection
1 none
1
2 none
2
2
Home is in the UK, to shower)
which is unlikely to
lead to excessively
high temperatures
[Home] Home is in a temper- Climate supervisorAmbient temperature is ate climate and cen- (wife)too high / incorrect prox- trally heated
imity to heat source Past experiences Lack of hot domes-
with similar brew kits tic water supply (dis-
that are being covered when
drank with gusto! teenage son want
Warm floor space in to shower)
office has been
assigned (location
where the cat usual-
ly sleeps!)
[Yeast] Use of good qualityPast best before date brew kit ingredients
Past experiences
with similar brew kits
that are being
drank with gusto!
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
ing brewing
Shop owner / suppli-
er advice
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
2
2
2 none
2
3 none
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Home] Home is double Climate supervisorLocation is close to glazed (wife)draughts / UV light source
Controlled environ-
ment
fermentation bucket
is covered
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
ing brewing
Shop owner / suppli-
er advice
[Home] Home is in a temper- Climate supervisorAmbient temperature is ate climate and cen- (wife)too high / incorrect prox- trally heatedimity to heat source
Past experiences Lack of hot domes-
3 none
1
2
2
with similar brew kits tic water supply (dis-
that are being covered when
drank with gusto! teenage son want
Warm floor space in to shower)
office has been
assigned (location
where the cat usual-
ly sleeps!)
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Home] Home is in a temper- Climate supervisorAmbient temperature is ate climate and cen- (wife)too low / incorrect prox- trally heatedimity to heat source
Past experiences Lack of hot domes-
with similar brew kits tic water supply (dis-
that are being covered when
drank with gusto! teenage son want
to shower)
Home is in the UK,
which is unlikely to
lead to excessively
high temperatures
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Syphon] Instructions includeBacterial contamination special care pointspresent
[Home] Controlled environ-Poor air quality (micro mentorganisms present)
[Brewer] Common sense /Does not wash hands hygiene
[Keg] Instructions includeBacterial contamination special care pointspresent
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Syphon] Shop owner / suppli- Cannot completeInsufficient length er advice and move on to
next operation
[Syphon] Compression fit atMulti-section product joint
[Keg] Past experiencesInsufficient capacity with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
3 none
1 Visual inspection
2 none
3 none
1
3 Visual inspection
2 Visual inspection
3 none
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Keg] Instructions includeBacterial contamination special care pointspresent
[Scales] Instructions includeBacterial contamination special care pointspresent
[Sugar] Shop owner / suppli-Bacterial contamination er advicepresent
Use of good quality
brew kit ingredients
Mixed with boiling
water to ensure sterili-
ty
Basic hygiene prac-
tice
[Spoon] Instructions includeBacterial contamination special care pointspresent
[Brewer] Common sense /Does not wash hands hygienebeforehand
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of the
3 none
2
2 none
2 none
2 none
2 none
3 none
2
not specified (including Shop owner / suppli- brewing processU.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Ingredients and Electronic scalesAdds more sugar than quantities are speci- within accurate torequired fied in the instructions 0.25g
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Scales] 1 standard bag ofOut of calibration white cane sugar
should weigh
approx. 1kg (Gold
Digital scales used sample)
[Scales] Alternative scales Scales clearly dis-Batteries are flat available play a battery lev-
el symbol
[Brewer] Ingredients and Sugar packagingIncorrect type of sugar quantities are speci- is clearly labelledused (e.g. brown sugar / fied in the instructions
Muscovado) Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
2
3 none
5
2
TPM on all devices 3
4
2
er advice
[Brewer] Past experiencesExperimentation with with similar brew kitsprocess (Brewer has a that are being'good' idea!) drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences subsequent stagesOmits a stage with similar brew kits will be affected
that are being (detection post
drank with gusto! process)
[Instructions] Use of good quality Directions are readMetric / imperial brew kit ingredients and re-read atweights and volumes each stage of the
not specified (including Shop owner / suppli- brewing processU.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
2
5 none
2
3 none
3
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality Instructions areInsufficient detail about brew kit ingredients read thoroughlyalternative ingredients before commenc-
(does & don'ts) Shop owner / suppli- ing brewing
er advice
[Instructions] Use of good quality Instructions areAmbiguous methodolo- brew kit ingredients read thoroughlygy before commenc-
Shop owner / suppli- ing brewing
er advice
[Brewer] Past experiencesImpatientience / care- with similar brew kitslessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Keg] Instructions includeBacterial contamination special care pointspresent