beer brewing pfmea aiag-format

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

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

http://www.fmea.co.uk/

Steriliser not ful- [5% Indian Pale Ale

ly rinsed from Beer]

equipment Beer tastes of detergent

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

7

8

8

8

Process Element: Preparing the Wort

Malt & Hops [5% Indian Pale Ale

not warmed suf- Beer]

ficiently Brewing process takes

longer than required

[5% Indian Pale Ale

Beer]

Beer is watery

[5% Indian Pale Ale

Beer]

Alcohol content is not

as per product descrip-

tion

Excessive boil- [5% Indian Pale Ale

ing water Beer]

added Brewing process takes


Insufficient boil- [5% Indian Pale Ale

ing water Beer]

added Brewing process takes


6

7

6

6

6

Place

Malt &

Hops

contain-

er into

warm

water

for a

time of

>= 5

mins +5

Add boil-

ing

water to

the fer-

menta-

tion

bucket

= 5 litres

+1

Water added [5% Indian Pale Ale

is not at boiling Beer]

point Beer taste has a bitter-

ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

6

7

9

7

8

9

9

8

scapped

Excessive quan- [5% Indian Pale Ale

tity of sugar Beer]

Beer is too gaseous

[5% Indian Pale Ale

Beer]

Beer tastes yeasty

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]

Party goers are inebriat-

ed to early in the night

8

5

4

7

7

6

6

Add the

ingredi-

ents to

the fer-

menta-

tion

bucket

= 1 kg

beer

enhanc

er (sug-

ar)

1.8kg

Malt &

Hops

Incorrect ingre- [5% Indian Pale Ale

dients added Beer]

Beer tastes caramelly/

malty

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]

Beer is too gaseous

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]

Brewing process takes


[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



party

6

6

6

7

5

4

6

8

8

Insufficient [5% Indian Pale Ale

quantity of Beer]

Malt & Hops Alcohol content is not


tion

[5% Indian Pale Ale

Beer]

Beer is watery


quantity of sug- Beer]

ar Beer is flat

[5% Indian Pale Ale

Beer]

Beer is watery

[5% Indian Pale Ale

Beer]

Insufficient alcoholic

beverages for the par-

ty goers

8

6

7

6

7

6

[5% Indian Pale Ale

Beer]



party

Wort is contami- [5% Indian Pale Ale

nation Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

6

Sugar omitted 8

7

9

7

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

7

8

9

9

8

Ingredients mix- [5% Indian Pale Ale

ing not mixed Beer]

to a soluble Beer is flat

state

[5% Indian Pale Ale

Beer]



[5% Indian Pale Ale

Beer]

Beer is watery


nation Beer]


ness to it

[5% Indian Pale Ale

8

6

6

7

7

9

Mix con-

tents

until

ingredi-

ents are

dissolved

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped


water added Beer]



ty goers

[5% Indian Pale Ale

Beer]

Beer is too gaseous

[5% Indian Pale Ale

Beer]


9

7

8

9

9

8

6

5

6

Fill the

fermen-

tation

bucket

to the

correct

volume

40

pints


[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]


malty


nation Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

6

4

6

7

9

7

8

9

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped


nation Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]

8

9

9

7

9

7

8

Cover

fermen-

tation

bucket

and

insert air-

lock

whilst

tempera-

ture set-

tles



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]



Yeast added [5% Indian Pale Ale

when wort is Beer]

too hot Beer is watery

[5% Indian Pale Ale

Beer]

Beer is flat

[5% Indian Pale Ale

Beer]



[5% Indian Pale Ale

Beer]

8

9

9

8

Process Element: Add yeast

Yeast omitted 8

6

7

6

6

6

Mix the

yeast

into the

wort at

a speci-

fied tem-

pera-

ture =

22 Centi-

grade ±

5C



tion

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]

Airlock does not bub-

ble during the fermen-

tation

[5% Indian Pale Ale

Beer]

yeast is killed

Yeat not [5% Indian Pale Ale

mixed to a solu- Beer]

ble state Brewing process takes


Yeast added [5% Indian Pale Ale

when wort is Beer]

too cold Brewing process takes


6

8

8

8

6

6


nation Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

Airlock is not [5% Indian Pale Ale

inserted into lid Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

6

7

9

7

8

9

9

8

7

9

7

Cover

fermen-

tation

bucket

and

insert air-

lock

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



tation

Beer is contami- [5% Indian Pale Ale

nated Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

7

7

8

9

9

8

8

9

7

8

9

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

Lid is not fully [5% Indian Pale Ale

sealed / Beer]

pushed home Airlock does not bub-


tation


nated Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

9

8

8

Process Element: Primary Fermentation

7

9

7

8

9

9

Beer is

allowed

to fer-

ment for

6

days ±2

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



ty goers

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

Fermentation [5% Indian Pale Ale

does not occur Beer]

(no bubbles Beer is not ready for

exit airlock) Gavin's 40th birthday

party

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

8

Beer leakage 6

8

8

8


process Beer]

stopped too Alcohol content is not

early as per product descrip-

tion

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]


malty

8

6

7

6

[5% Indian Pale Ale

Beer]

Beer tastes yeasty

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]

Beer is too gaseous

Temperature [5% Indian Pale Ale

fluctuations Beer]

Beer is flat

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]


ness to it

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]

yeast is killed

Temperature is [5% Indian Pale Ale

too high Beer]



party

[5% Indian Pale Ale

7

4

5

6

6

4

7

8

8

8

8

8

Beer is

allowed

to fer-

ment in

constis-

tent tem-

pera-

ture of

= 20-

25C

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]

yeast is killed


too low Beer]



[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]



tation


nated Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

8

8

6

8

8

9

7

Syphon

the fer-

ment-

ing

beer

Process Element: Keg Fermentation

7

into a

keg

avoid-

ing the

sediment

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



ty goers

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

Excess sedi- [5% Indian Pale Ale

ment decanted Beer]

Beer is cloudy/hazy

7

8

9

9

8

Beer spillage 6

8

7

[5% Indian Pale Ale

Beer]

Party goers have

'wind' the next day


nated Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

Excessive quan- [5% Indian Pale Ale

tity of sugar Beer]

Beer is too gaseous

4

7

9

7

8

9

9

8

5

Add

addition-

al ingre-

dients =

150 g

±30g

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]



[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



Incorrect ingre- [5% Indian Pale Ale

dients added Beer]

Beer is too gaseous

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

6

4

6

7

6

5

6

4

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]


malty

[5% Indian Pale Ale

Beer]




quantity of sug- Beer]

ar Beer is flat

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

Beer is watery

4

6

6

6

6

7

[5% Indian Pale Ale

Beer]

Beer is flat

[5% Indian Pale Ale

Beer]

Beer is watery

[5% Indian Pale Ale

Beer]



tion


nated Beer]


ness to it

[5% Indian Pale Ale

Beer]


g. vinegary)

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]

Sugar omitted 6

7

7

6

7

9

7

8

Beer is

allowed

to fer-

ment for

7

days +6



party

[5% Indian Pale Ale

Beer]


goers unwell

[5% Indian Pale Ale

Beer]

Beer is too gaseous

(bad)

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



ty goers

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped


process Beer]

stopped too Beer is cloudy/hazy

early

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]

Beer tastes yeasty

[5% Indian Pale Ale

Beer]

9

8

8

9

Beer leakage 6

8

7

6

4

7

4

Party goers have

'wind' the next day


too low Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]

Beer tastes yeasty

[5% Indian Pale Ale

Beer]

Party goers have

'wind' the next day


4

4

7

4

6

4

7

Beer is

allowed

to fer-

ment in

constis-

tent tem-

pera-

ture of

= 20-

25C

too high Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]



tion

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]

yeast is killed

Temperature [5% Indian Pale Ale

fluctuations Beer]

Beer is flat

[5% Indian Pale Ale

Beer]

Beer is too sweet

[5% Indian Pale Ale

Beer]


ness to it

[5% Indian Pale Ale

Beer]

4

6

8

7

8

6

4

7

6



tion

[5% Indian Pale Ale

Beer]

40 pints of beer is

scapped

[5% Indian Pale Ale

Beer]



party

[5% Indian Pale Ale

Beer]

yeast is killed

6

8

8

8

Cause

[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


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



ing brewing


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

Measuring devices


play both imperial

& metric units

[Fermentation Bucket & Products recently pur-lid] chased (JIT)Volume measurements

are illegible



Measuring devices


2

TPM on all devices 2 Visual inspection

3 none

2

1 Visual inspection

2

play both imperial

& metric units


are illegible


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet


drank with gusto!


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


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-


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


that are being

drank with gusto!


er advice

[Scales] 1 standard bag ofOut of calibration white cane sugar

should weigh

approx. 1kg (Gold

Digital scales used sample)



Measuring devices


play both imperial

3

4

2

2

5

2

TPM on all devices 3

2

& metric units


drank with gusto!


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


that are being

drank with gusto!


er advice

[Instructions] Use of good quality Instructions areInsufficient detail about brew kit ingredients read thoroughlyalternative ingredients before commenc-(does & don'ts) ing brewing


er advice


drank with gusto!


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


with each brewing

kit & can be down-

bloaded from the

internet


ing brewing


er advice

[Brewer] Instructions includeFails to rinse out Malt & special care pointsHops container


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet



er advice


el symbol


5 none

2

2 Visual inspection

3 none

2

4

2



that are being

drank with gusto!


er advice


should weigh

approx. 1kg (Gold




Measuring devices


play both imperial

& metric units


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet




[Brewer] Common sense /Fails to cover the wort hygiene


ing brewing


2


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



[Sugar] Shop owner / suppli-Bacterial contamination er advice

present Use of good quality


Mixed with boiling


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


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet

[Spoon] Instructions includeBacterial contamination special care pointspresent

[Malt & Hops] Shop owner / suppli-Poor quality product / er advice

batch Use of good quality


Past experiences


that are being

drank with gusto!


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet

[Spoon] Shop owner / suppli- Cannot completeInsufficient length er advice and move on to

next operation





[Instructions] Use of good quality Instructions are

3 none

2 none

2 none

3 none

1

3

3 none

2

Ambiguous methodolo- brew kit ingredients read thoroughlygy before commenc-

ing brewing


er advice





with each brewing

kit & can be down-

bloaded from the

internet


2

3 none

2 none

5 none

1 Visual inspection

are illegible



Measuring devices


play both imperial

& metric units


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet

[Fermentation Bucket & Past experienceslid] with similar brew kitsInsufficient capacity that are being

drank with gusto!


er advice


ing brewing


er advice

[Brewer] Instructions clearlyFails to sterilise container express that allused to carry water equipment needs to

be sterilised


[Home] Controlled environ-

1 Visual inspection

2

3 none

2 Visual inspection

2

3 none

3 none

3 none

Poor air quality (micro mentorganisms present)



drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet


present

[Airlock] Instructions include

Airlock or fluid content is special care pointscontaminated


drank with gusto!


with each brewing

3 none

3 none

2 none

2 none

2 Visual inspection

3 none

kit & can be down-

bloaded from the

internet

[Fermentation Bucket & Products recently pur-lid] chased (JIT)Plastic fatigue (cracks /

orange peel)




[Thermometer] Instructions includeBacterial contamination special care pointspresent


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet






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


3 none

3

2

2

Measuring devices


play both imperial

& metric units


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet

[Thermometer] Mechanical ther-Out of calibration mometer used



er advice





drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet


drank with gusto!


with each brewing

2

3 none

2 Visual inspection

2

3

3 none

3 none

kit & can be down-

bloaded from the

internet



[Thermometer] Instructions includeBacterial contamination special care pointspresent



drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet


3 none

2 none

3 none

2 none

3 none

3 none

3



[Airlock] Instructions includeAirlock or fluid content is special care pointscontaminated


present


2

3

Visual inspection

2 none

3 none


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet


orange peel)

[Airlock] Instructions includeAirlock or fluid content is special care pointscontaminated

3 none

3 none


1 Visual inspection

2 Visual inspection


orange peel)

[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 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





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


that are being

drank with gusto!


ing brewing


er advice


drank with gusto!

2

2

2 none

2

3 none


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


ing brewing


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





office has been

assigned (location


ly sleeps!)



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-




to shower)

Home is in the UK,


lead to excessively

high temperatures



er advice

[Syphon] Instructions includeBacterial contamination special care pointspresent


[Brewer] Common sense /Does not wash hands hygiene

2

2

2

2

none

3 none

3 none


2

beforehand

[Keg] Products recently pur-Plastic fatigue (cracks / chased (JIT)orange peel)

[Keg] Instructions includeBacterial contamination special care pointspresent


drank with gusto!


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!


er advice


drank with gusto!

3 none

1 Visual inspection

2 none

3 none

1

3 Visual inspection

2 Visual inspection

3 none


with each brewing

kit & can be down-

bloaded from the

internet



er advice


[Scales] Instructions includeBacterial contamination special care pointspresent

[Sugar] Shop owner / suppli-Bacterial contamination er advicepresent

Use of good quality


Mixed with boiling


ty

Basic hygiene prac-

tice




3 none

2

2 none

2 none

2 none

2 none

3 none

2


Measuring devices


play both imperial

& metric units


drank with gusto!


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



er advice


should weigh

approx. 1kg (Gold



el symbol




that are being

drank with gusto!


2

3 none

5

2


4

2

er advice



with each brewing

kit & can be down-

bloaded from the

internet






Measuring devices


play both imperial

& metric units


2

5 none

2

3 none

3

drank with gusto!


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-


er advice



er advice


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet


3 none

2

2

3 none

2 none

[Keg] Products recently pur-Plastic fatigue (cracks / chased (JIT)orange peel)

[Keg] Past experiencesInsufficient capacity with similar brew kits

that are being

drank with gusto!


er advice


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet



er advice

[Brewer] Past experiencesExperimentation with with similar brew kits

2 none

1 Visual inspection

2 Visual inspection

3 none

2

5 none

process (Brewer has a that are being'good' idea!) drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet

[Yeast] Shop owner / suppli-Insufficient resistance to er advice

high alcohol content Use of good quality


Past experiences


that are being

drank with gusto!

[Home] Home is in a temper- Climate supervisorAmbient temperature is ate climate and cen- (wife)too low / incorrect prox- trally heated





to shower)

Home is in the UK,


lead to excessively

high temperatures

[Instructions] Use of good quality Directions are read

5 none

3 none

2

2

Metric / imperial brew kit ingredients and re-read atweights and volumes each stage of the


Measuring devices


play both imperial

& metric units

[Home] Home is in a temper- Climate supervisorAmbient temperature is ate climate and cen- (wife)too high / incorrect prox- trally heated






office has been

assigned (location


ly sleeps!)



er advice


drank with gusto!


with each brewing

kit & can be down-

bloaded from the

internet

[Home] Home is in a temper- Climate supervisorExcessive variations in ate climate and cen- (wife)the ambient temperature trally heated

Lack of hot domes-

tic water supply (dis-

2

2

2

3 none

2

covered when

teenage son want

to shower)


ing brewing


er advice

2

2

Failure Mode

F M E A

Process

Process Responsibility: Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer

Key date: Created: 13/03/2013

Detection Actions D RPN Recommended Actions


2

3 54

36

10 270

10 270

5 90

Prepared By:

D: Beer

clarity

and

smell

are

checke

d dur-

ing the

sec-

onadary

fermen-

tation

stage

5 90

4 108

10 270

2 54

10 180

2 48

2 32


D: Regu-

lar refer-

al to the

instruc-

tions

3 42

1 14

10 210

2 24

2 12

2 24

D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

2 24

2 12

10 180

10 270

7 189

7 189

1 28

3 42

1 35

5 70

1 14

3 63

2 28

D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

D: Smell

& clarity

checks -

small

glass

2 28

10 210

1 16

5 80

10 240

10 400

poured

before 6

days

into

final fer-

menta-

tion

process

D: Regu-

lar refer-

al to the

instruc-

tions

10 400

3 42

2 28

10 210

3 42

1 28

1 14

D: Regu-

lar refer-

al to the

instruc-

tions

1 14

3 63

2 28

10 210

7 168

10 270

3 54

3 54

10 180

10 180

10 180

10 270

10 270

10 180

2 54

D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

10 270

10 180

10 180

10 210

1 7

7 147

10 270

3 54

D: Smell

& clarity

checks -

small

glass

poured

before 6

days

into

final fer-

menta-

tion

process

3 54

10 270

10 180

10 300

2 12

D: Regu-

lar refer-

al to the

instruc-

tions

2 12

2 24

10 180

1 12

3 54

10 270

10 270

10 270

D: Beer

clarity

and

smell

are

checke

d dur-

ing the

sec-

onadary

fermen-

tation

stage

D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

10 270

10

10 270

180

10 180

5 90

10 270

D: Regu-

lar refer-

al to the

instruc-

tions

10 270

5 45

7 189

10


180

10 240

7 168

3 48

2 32

D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

2 32

10 240

3 48

3 36

7 126

10 180

10 180

D: Regu-

lar refer-

al to the

instruc-

tions

10 180

10 180

10 270

10 180

10 270

10 270

7 189

7 189

5 90

10 180

10 270

D: Regu-

lar refer-

al to the

instruc-

tions

10 270

10


5 45

240

5 90

D: Beer

clarity

and

smell

are

checke

d dur-

ing the

sec-

onadary

fermen-

tation

stage

5 90

5 40

1 8

7 56

10 160

2 32

3 48

D: Regu-

lar refer-

al to the

instruc-

3 48

3 48

10 160

3 42

10 210

tions

10 210

3 24

483

3 48

3 48

3 48

3 48

10 180

3 48

10 270

10 270


D: Regu-

lar refer-

al to the

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

10 270

5 45

10 180

10 240

1 8

2 48

1 16

10 210

tions

10 210

3 42

10 180

10 180

10 180

10 180

10 270

2 28

D: Regu-

lar refer-

al to the

instruc-

tions

2 28

10 210

1 35

3 42

3 63

1 28

1 12

D: Smell

& clarity

checks -

small

glass

poured

before 6

days

into

final fer-

menta-

tion

process

D: Regu-

lar refer-

al to the

1 12

10 350

7 147

2 28

10 210

instruc-

tions

D: Regu-

lar refer-

al to the

instruc-

tions

10 210

5 70

3 42

10 210

10 180

D: Regu-

lar refer-

al to the

instruc-

tions

D: Smell

& clarity

10 180

5 40

1 16

10 210

3 42

10 350

checks -

small

glass

poured

before 6

days

into

final fer-

menta-

tion

process

10 350

10 210

3 42

2 32

D: Regu-

lar refer-

al to the

instruc-

tions

2 32

3 48

3 48

10

3 48

240

3 48

3 48

Actions Taken S O D RPN

F M E A

Process

Created: 13/03/2013

Responsibility & Target Completion

Date

Action Results


Number: 1.1

Page:

Prepared By:

Modified: 20/03/2013

3/22/2013

in revision

Robbins, Gavin, Penkridge, FMEA

Facilitator / Trainer

9 2 8 {144}


4/3/2013

in revision



7 3 5 {105}

4/3/2013

in revision

4/3/2013

in revision



6 3 5 {90}



9 3 5 {135}

4/3/2013

in revision

4/3/2013

in revision



{105}7 3 5



8 3 5 {120}



8 5 6 {240}

3/27/2013

in revision

4/3/2013

in revision



8 5 6 {240}



7 3 5 {105}

4/3/2013

in revision



7 3 5 {105}

4/3/2013

in revision

4/3/2013

in revision



9 3 5 {135}



7 3 5 {105}

3/27/2013

in revision



6 5 6 {180}

4/3/2013

in revision



6 3 5 {90}

3/22/2013

in revision

4/3/2013

in revision

4/3/2013

in revision

2 8 {144}



9



9

3 5 {135}



9 3 5 {135}

4/3/2013

in revision

9 3 5 {135}




8 3 5 {120}

4/3/2013

in revision

4/3/2013

in revision

4/3/2013

in revision



8 3 5 {120}



6 3 5 {90}



6 3 5 {90}

4/3/2013

in revision

6 3 5 {90}



9 3 5 {135}

4/3/2013

in revision



8 3 5 {120}


3/22/2013

in revision



8 2 8 {128}

D: Visu-

al

inspec-

tion

3/15/2013 D: Audi-

completed ble

sounds

of bub-

bles exit-

ing the

airlock

expect-

ed with-

in 24

hours



8 2 2 32



7 3 5 {105}

4/3/2013

in revision

7 3 5 {105}

4/3/2013

in revision



8 3 5 {120}



7 3 5 {105}

4/3/2013

in revision

7 3 5 {105}

4/3/2013

in revision



7 3 5 {105}

3/27/2013

in revision

{210}Robbins, Gavin, Penkridge, FMEA


7 5 6



7 3 5 {105}

4/3/2013

in revision

4/3/2013

in revision



7 3 5 {105}



7 3 5 {105}

4/3/2013

in revision



7 3 5 {105}



7 5 6 {210}

3/27/2013

in revision



7 5 6 {210}

4/3/2013

in revision



{120}8 3 5

beer brewing pfmea aiag-format

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