fmea forms editor aiag (4th edition, e): complete brewing …€¦ · xls file · web viewfun...

F M E A

Process

Function Potential Failure Mode

Process Element: SterilisationSterilise Equipment is [5% Indian Pale Aleall of not sterilised Beer]the 40 pints of beer isequip- scappedment [5% Indian Pale Aleand Beer]then Beer makes the partyrinse goers unwellwith [5% Indian Pale Aleclean Beer]water Beer taste has a bitter-and ness to itallow to [5% Indian Pale Aledry Beer]

Beer is too gaseous(bad)[5% Indian Pale AleBeer]Beer aroma is poor (e.g. vinegary)[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]

Item: Beer making (based on Indian Pale Ale - IPA)Model Year(s)/Vehicle(s): Complete brewing processTeam:

Potential Effect(s) of Failure

Beer is cloudy/hazy

Steriliser not ful- [5% Indian Pale Alely rinsed from Beer]equipment Beer tastes of detergent

[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthday

party[5% Indian Pale AleBeer]40 pints of beer isscapped

Process Element: Preparing the WortPlace Malt & Hops [5% Indian Pale AleMalt & not warmed suf- Beer]Hops ficiently Brewing process takescontain- longer than requireder intowarmwaterfor a [5% Indian Pale Aletime of Beer]>= 5 Beer is waterymins +5 [5% Indian Pale Ale

Beer]Alcohol content is notas per product descrip-tion

Add boil- Excessive boil- [5% Indian Pale Aleing ing water Beer]water to added Brewing process takesthe fer- longer than requiredmenta-tionbucket= 5 litres

+1

Insufficient boil- [5% Indian Pale Aleing water Beer]added Brewing process takes

longer than required

Water added [5% Indian Pale Aleis not at boiling Beer]point Beer taste has a bitter-

ness to it[5% Indian Pale AleBeer]Beer aroma is poor (e.g. vinegary)

[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthday

party[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Add the Excessive quan- [5% Indian Pale Aleingredi- tity of sugar Beer]ents to Beer is too gaseousthe fer- [5% Indian Pale Alementa- Beer]tion Beer tastes yeastybucket [5% Indian Pale Ale= 1 kg Beer]beer Beer is cloudy/hazyenhanc [5% Indian Pale Aleer (sug- Beer]ar) Alcohol content is not1.8kg as per product descrip-Malt & tionHops [5% Indian Pale Ale

Beer]Beer is too sweet[5% Indian Pale AleBeer]Party goers are inebriat-ed to early in the night

Incorrect ingre- [5% Indian Pale Aledients added Beer]

Beer tastes caramelly/malty[5% Indian Pale AleBeer]Beer is cloudy/hazy

[5% Indian Pale AleBeer]Beer is too gaseous[5% Indian Pale AleBeer]Alcohol content is not

as per product descrip-tion[5% Indian Pale AleBeer]Beer is too sweet[5% Indian Pale AleBeer]Brewing process takeslonger than required[5% Indian Pale AleBeer]40 pints of beer isscapped

[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty

Insufficient [5% Indian Pale Alequantity of Beer]Malt & Hops Alcohol content is not

as per product descrip-tion[5% Indian Pale AleBeer]Beer is watery

Insufficient [5% Indian Pale Alequantity of sug- Beer]ar Beer is flat

[5% Indian Pale AleBeer]Beer is watery[5% Indian Pale AleBeer]Insufficient alcoholicbeverages for the par-ty goers

Sugar omitted [5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty

Wort is contami- [5% Indian Pale Alenation Beer]

Beer taste has a bitter-ness to it[5% Indian Pale AleBeer]Beer aroma is poor (e.g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous

(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Mix con- Ingredients mix- [5% Indian Pale Aletents ing not mixed Beer]until to a soluble Beer is flatingredi- stateents are [5% Indian Pale Ale

dissolved Beer]

Brewing process takeslonger than required

[5% Indian Pale AleBeer]Beer is watery


Beer taste has a bitter-ness to it[5% Indian Pale AleBeer]Beer aroma is poor (e.g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]

Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Fill the Insufficient [5% Indian Pale Alefermen- water added Beer]tation Insufficient alcoholicbucket beverages for the par-to the ty goerscorrectvolume40pints

[5% Indian Pale AleBeer]Beer is too gaseous

[5% Indian Pale AleBeer]Party goers are inebriat-ed to early in the night[5% Indian Pale AleBeer]Beer is too sweet[5% Indian Pale Ale

Beer]Beer tastes caramelly/malty


Beer taste has a bitter-ness to it[5% Indian Pale AleBeer]Beer aroma is poor (e.g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy

[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the party

goers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)

[5% Indian Pale AleBeer]40 pints of beer isscapped

Cover Wort is contami- [5% Indian Pale Alefermen- nation Beer]tation Beer taste has a bitter-bucket ness to itandinsert air- [5% Indian Pale Ale

lock Beer]whilst Beer aroma is poor (e.tempera- g. vinegary)

ture set- [5% Indian Pale Aletles Beer]

Beer is cloudy/hazy

[5% Indian Pale Ale

Beer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Process Element: Add yeastMix the Yeast omitted [5% Indian Pale Aleyeast Beer]into the Beer is not ready forwort at Gavin's 40th birthdaya speci- partyfied tem- [5% Indian Pale Alepera- Beer]ture = Brewing process takes22 Centi- longer than required

grade ±5C

Yeast added [5% Indian Pale Alewhen wort is Beer]too hot Beer is watery

[5% Indian Pale AleBeer]Beer is flat[5% Indian Pale AleBeer]

Brewing process takeslonger than required[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion[5% Indian Pale AleBeer]40 pints of beer isscapped[5% Indian Pale AleBeer]Airlock does not bub-ble during the fermen-tation[5% Indian Pale AleBeer]yeast is killed

Yeat not [5% Indian Pale Alemixed to a solu- Beer]ble state Brewing process takes


Yeast added [5% Indian Pale Alewhen wort is Beer]too cold Brewing process takes



Beer taste has a bitter-ness to it[5% Indian Pale AleBeer]Beer aroma is poor (e.g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Cover Airlock is not [5% Indian Pale Alefermen- inserted into lid Beer]

tation Beer taste has a bitter-bucket ness to itand [5% Indian Pale Aleinsert air- Beer]

lock Beer aroma is poor (e.g. vinegary)

[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped[5% Indian Pale AleBeer]Airlock does not bub-ble during the fermen-tation

Beer is contami- [5% Indian Pale Alenated Beer]

Beer taste has a bitter-ness to it[5% Indian Pale AleBeer]Beer aroma is poor (e.

g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Lid is not fully [5% Indian Pale Alesealed / Beer]pushed home Airlock does not bub-

ble during the fermen-tation

Process Element: Primary FermentationBeer is Beer is contami- [5% Indian Pale Aleallowed nated Beer]to fer- Beer taste has a bitter-ment for ness to it

6 [5% Indian Pale Aledays ±2 Beer]

Beer aroma is poor (e.g. vinegary)

[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Beer leakage [5% Indian Pale AleBeer]Insufficient alcoholicbeverages for the par-ty goers[5% Indian Pale AleBeer]40 pints of beer isscapped

Fermentation [5% Indian Pale Aledoes not occur Beer](no bubbles Beer is not ready forexit airlock) Gavin's 40th birthday

party[5% Indian Pale AleBeer]40 pints of beer isscapped

Fermentation [5% Indian Pale Aleprocess Beer]stopped too Alcohol content is notearly as per product descrip-

tion[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer tastes caramelly/malty[5% Indian Pale AleBeer]Beer tastes yeasty[5% Indian Pale AleBeer]Beer is too sweet[5% Indian Pale AleBeer]Beer is too gaseous

Beer is Temperature [5% Indian Pale Aleallowed fluctuations Beer]to fer- Beer is flatment in [5% Indian Pale Aleconstis- Beer]tent tem- Beer is too sweet

pera- [5% Indian Pale Aleture of Beer]

= 20- Beer taste has a bitter-25C ness to it

[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion[5% Indian Pale AleBeer]40 pints of beer isscapped[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]yeast is killed

Temperature is [5% Indian Pale Aletoo high Beer]

Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]40 pints of beer isscapped[5% Indian Pale AleBeer]yeast is killed

Temperature is [5% Indian Pale Aletoo low Beer]

Brewing process takeslonger than required[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Airlock does not bub-ble during the fermen-tation

Process Element: Keg FermentationSyphon Beer is contami- [5% Indian Pale Alethe fer- nated Beer]ment- Beer taste has a bitter-ing ness to itbeer [5% Indian Pale Aleinto a Beer]keg Beer aroma is poor (e.avoid- g. vinegary)ing the [5% Indian Pale Alesediment Beer]

Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]

Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Beer spillage [5% Indian Pale AleBeer]Insufficient alcoholicbeverages for the par-ty goers[5% Indian Pale AleBeer]40 pints of beer isscapped

Excess sedi- [5% Indian Pale Alement decanted Beer]

Beer is cloudy/hazy

[5% Indian Pale AleBeer]Party goers have'wind' the next day

Add Beer is contami- [5% Indian Pale Aleaddition- nated Beer]al ingre- Beer taste has a bitter-dients = ness to it150 g [5% Indian Pale Ale±30g Beer]

Beer aroma is poor (e.g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Excessive quan- [5% Indian Pale Aletity of sugar Beer]

Beer is too gaseous[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-

tion[5% Indian Pale AleBeer]Beer is too sweet

[5% Indian Pale AleBeer]Party goers are inebriat-ed to early in the night[5% Indian Pale AleBeer]Beer is cloudy/hazy

[5% Indian Pale AleBeer]Brewing process takeslonger than required

Incorrect ingre- [5% Indian Pale Aledients added Beer]

Beer is too gaseous[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion[5% Indian Pale Ale

Beer]Beer is too sweet[5% Indian Pale AleBeer]Beer tastes caramelly/malty[5% Indian Pale AleBeer]Party goers are inebriat-ed to early in the night

Insufficient [5% Indian Pale Alequantity of sug- Beer]ar Beer is flat

[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion[5% Indian Pale AleBeer]Beer is watery

Sugar omitted [5% Indian Pale AleBeer]Beer is flat

[5% Indian Pale AleBeer]Beer is watery

[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion

Beer is Beer is contami- [5% Indian Pale Aleallowed nated Beer]to fer- Beer taste has a bitter-ment for ness to it

7 [5% Indian Pale Aledays +6 Beer]

Beer aroma is poor (e.

g. vinegary)[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]Beer makes the partygoers unwell[5% Indian Pale AleBeer]Beer is too gaseous(bad)[5% Indian Pale AleBeer]40 pints of beer isscapped

Beer leakage [5% Indian Pale AleBeer]Insufficient alcoholicbeverages for the par-ty goers[5% Indian Pale AleBeer]40 pints of beer isscapped

Fermentation [5% Indian Pale Aleprocess Beer]stopped too Beer is cloudy/hazyearly

[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-

tion[5% Indian Pale AleBeer]Beer is too sweet[5% Indian Pale AleBeer]Beer tastes yeasty[5% Indian Pale AleBeer]Party goers have'wind' the next day

Beer is Temperature is [5% Indian Pale Aleallowed too low Beer]to fer- Beer is cloudy/hazyment in [5% Indian Pale Aleconstis- Beer]tent tem- Alcohol content is not

pera- as per product descrip-

ture of tion= 20- [5% Indian Pale Ale25C Beer]

Beer is too sweet[5% Indian Pale AleBeer]Beer tastes yeasty[5% Indian Pale AleBeer]Party goers have'wind' the next day

Temperature is [5% Indian Pale Aletoo high Beer]

Beer is too sweet[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion[5% Indian Pale AleBeer]40 pints of beer isscapped[5% Indian Pale AleBeer]Beer is cloudy/hazy[5% Indian Pale AleBeer]yeast is killed

Temperature [5% Indian Pale Alefluctuations Beer]

Beer is flat

[5% Indian Pale AleBeer]Beer is too sweet

[5% Indian Pale AleBeer]Beer taste has a bitter-ness to it[5% Indian Pale AleBeer]Alcohol content is notas per product descrip-tion[5% Indian Pale AleBeer]40 pints of beer isscapped[5% Indian Pale AleBeer]Beer is not ready forGavin's 40th birthdayparty[5% Indian Pale AleBeer]yeast is killed

F M E A

Process

S C Preventive Actions O

Process Element: Sterilisation8 [Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredientsgy

9 Shop owner / suppli-er advice

7 [Instructions] Use of good quality 2Metric / imperial brew kit ingredientsweights and volumesnot specified (including

9 U.S. imperial) Shop owner / suppli-er advice

9 Measuring devicesat Gavin's home dis-play both imperial& metric units

8 [Brewer] Instructions clearly 3Fails to sterilise container express that allused to carry water equipment needs to

be sterilised

7 [Brewer] Common sense / 3Does not wash hands hygiene

Process Responsibility: Robbins, Gavin, Penkridge, FMEA Facilitator / TrainerKey date:

Potential Cause(s) of Failure

7

beforehand

3

[Instructions] Use of good quality 2Insufficient detail about brew kit ingredientsalternative ingredients(does & don'ts) Shop owner / suppli-

er advice[Steriliser] Quantity is specified 3insufficent concentra- in the instructionstion / ratios Instructions specify

imperial and metricweights and volumes

[Home] Controlled environ- 3Poor air quality (micro mentorganisms present)[Brewer] Instructions clearly 3Washes out sterilising flu- express that allid too early equipment needs to

be sterilised[Water] Water quality is 2Domestic supply quality assured by wateris contaminated (micro boardorganisms present)

8 [Brewer] Instructions clearly 3Does not rinse equip- express that allment properly equipment needs to

be sterilised8 [Brewer] Instructions clearly 2

Forgets to rinse equip- express that allment properly equipment needs to

be sterilised

8 2

8 Past experienceswith similar brew kitsthat are beingdrank with gusto!

Process Element: Preparing the Wort6 [Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredientsgy


6 [Kettle] TPM on all devices 2Thermostat failure

[Brewer] Past experiences 3Impatientience / care- with similar brew kitslessness or inexperience that are being

drank with gusto!Instructions suppliedwith each brewingkit & can be down-bloaded from theinternet

6 [Instructions] Use of good quality 2Metric / imperial brew kit ingredientsweights and volumesnot specified (including Shop owner / suppli-U.S. imperial) er advice

Measuring devicesat Gavin's home dis-play both imperial

& metric units[Fermentation Bucket & Products recently pur- 1lid] chased (JIT)

6

Volume measurements

1

are illegible6 [Instructions] Use of good quality 2

Metric / imperial brew kit ingredientsweights and volumesnot specified (including Shop owner / suppli-U.S. imperial) er advice

Measuring devicesat Gavin's home dis-play both imperial& metric units

[Fermentation Bucket & Products recently pur- 1lid] chased (JIT)Volume measurementsare illegible[Brewer] Past experiences 3Impatientience / care- with similar brew kitslessness or inexperience that are being


7 [Brewer] Past experiences 3Impatientience / care- with similar brew kitslessness or inexperience that are being

drank with gusto!9 Instructions supplied

with each brewingkit & can be down-bloaded from theinternet

7 [Brewer] Past experiences 3Omits a stage with similar brew kits

that are being8 drank with gusto!

8

3

9

9

8

5 [Scales] Alternative scales 4Batteries are flat available

7 [Instructions] Use of good quality 2Ambiguous methodolo- brew kit ingredientsgy


6 [Brewer] Ingredients and 5Adds more sugar than quantities are speci-required

4 [Instructions] Use of good quality 2Insufficient detail about brew kit ingredientsalternative ingredients

6 (does & don'ts) Shop owner / suppli-er advice

[Brewer] Ingredients and 2Incorrect type of sugar quantities are speci-used (e.g. brown sugar /Muscovado) Past experiences

with similar brew kitsthat are beingdrank with gusto!

fied in the instructions


6

Shop owner / suppli-

2

er advice[Scales] TPM on all devices 3Out of calibration

Digital scales used[Instructions] Use of good quality 2Metric / imperial brew kit ingredientsweights and volumesnot specified (including Shop owner / suppli-U.S. imperial) er advice




6 [Brewer] Ingredients and 2Incorrect type of sugar quantities are speci-used (e.g. brown sugar /Muscovado)



6 [Instructions] Use of good quality 2Insufficient detail about brew kit ingredientsalternative ingredients


6

(does & don'ts)

2





8 [Brewer] Past experiences 5Experimentation with with similar brew kitsprocess (Brewer has a that are being'good' idea!) drank with gusto!

Instructions suppliedwith each brewingkit & can be down-bloaded from theinternet



[Brewer] Instructions include 2Fails to rinse out Malt & special care points

7

Hops container

2





6 [Scales] Alternative scales 4Batteries are flat available

[Brewer] Ingredients and 2Incorrect type of sugar quantities are speci-used (e.g. brown sugar /Muscovado) Past experiences

with similar brew kitsthat are beingdrank with gusto!Shop owner / suppli-er advice

[Scales] TPM on all devices 3Out of calibration

Digital scales used[Instructions] Use of good quality 2Metric / imperial brew kit ingredientsweights and volumesnot specified (including Shop owner / suppli-U.S. imperial) er advice

Measuring devices


6

at Gavin's home dis-

2

play both imperial& metric units




that are beingdrank with gusto!

7 [Brewer] Common sense / 3Fails to cover the wort hygiene



8 [Fermentation Bucket & Instructions include 2lid] special care pointsBacterial contaminationpresent

9 [Malt & Hops] Shop owner / suppli- 2Bacterial contamination er advicepresent

9 Use of good qualitybrew kit ingredients

9

2

8 Basic hygiene prac-ticeMixed with boiling

ty[Scales] Instructions include 2Bacterial contamination special care pointspresent[Brewer] Common sense / 3Does not wash hands hygienebeforehand[Home] Controlled environ- 3Poor air quality (micro mentorganisms present)[Sugar] Shop owner / suppli- 2Bacterial contamination er advicepresent Use of good quality

brew kit ingredientsMixed with boiling

tyBasic hygiene prac-tice

[Brewer] Instructions clearly 3Washes out sterilising flu- express that allid too early equipment needs to

be sterilised[Brewer] Past experiences 3Impatientience / care- with similar brew kitslessness or inexperience that are being


[Spoon] Instructions include 2Bacterial contamination special care points

water to ensure sterili-


8

present

2

[Malt & Hops] Shop owner / suppli- 2Poor quality product / er advicebatch Use of good quality

brew kit ingredientsPast experienceswith similar brew kitsthat are beingdrank with gusto!



with each brewing

kit & can be down-bloaded from theinternet

7 [Spoon] Shop owner / suppli- 1Insufficient length er advice

[Brewer] Past experiences 3Omits a stage with similar brew kits


7 [Brewer] Common sense / 3Does not wash hands hygienebeforehand



8 [Home] Controlled environ- 3Poor air quality (micro ment

8

organisms present)

3

9 [Spoon] Instructions include 2Bacterial contamination special care pointspresent

9

8


5 Instructions suppliedwith each brewingkit & can be down-bloaded from theinternet

6 [Fermentation Bucket & Products recently pur- 1lid] chased (JIT)Volume measurementsare illegible

4 [Instructions] Use of good quality 2Metric / imperial brew kit ingredientsweights and volumes

6 not specified (including Shop owner / suppli-

6U.S. imperial) er advice

2




[Fermentation Bucket & Past experiences 2lid] with similar brew kitsInsufficient capacity that are being

drank with gusto!Shop owner / suppli-er advice



7 [Brewer] Instructions clearly 3Fails to sterilise container express that allused to carry water equipment needs to

be sterilised8 [Brewer] Common sense / 3

Does not wash hands hygienebeforehand

9 [Home] Controlled environ- 3Poor air quality (micro mentorganisms present)

9 3

9 [Water] Water quality is 2Domestic supply quality assured by wateris contaminated (micro boardorganisms present)

8



7 [Fermentation Bucket & Instructions include 2lid] special care pointsBacterial contaminationpresent

9 [Airlock] Instructions include 2

Airlock or fluid content is special care pointscontaminated



8with each brewing

3


9 [Fermentation Bucket & Products recently pur- 1lid] chased (JIT)Plastic fatigue (cracks /orange peel)



8 [Thermometer] Instructions include 2Bacterial contamination special care pointspresent

Process Element: Add yeast8 [Brewer] Past experiences 3

Impatientience / care- with similar brew kitslessness or inexperience that are being

drank with gusto!

6 Instructions suppliedwith each brewingkit & can be down-bloaded from the

internet[Brewer] Past experiences 3Omits a stage with similar brew kits




6 [Instructions] Use of good quality 2Metric / imperial brew kit ingredients

6

weights and volumes

2

not specified (including6 U.S. imperial) Shop owner / suppli-

er advice



drank with gusto!


[Thermometer] Mechanical ther- 2Out of calibration mometer used


Shop owner / suppli-er advice

[Brewer] Past experiences 3Omits a stage with similar brew kits



drank with gusto!Instructions suppliedwith each brewingkit & can be down-bloaded from the

6

internet

3



7 [Spoon] Instructions include 2Bacterial contamination special care pointspresent


7 [Thermometer] Instructions include 2Bacterial contamination special care pointspresent


9

9

8

7 [Brewer] Past experiences 3Impatientience / care- with similar brew kits

7

lessness or inexperience that are being

3


with each brewing



that are being8 drank with gusto!

9

9

8

8

7 [Airlock] Instructions include 2Airlock or fluid content is special care pointscontaminated

9 [Fermentation Bucket & Instructions include 2lid] special care pointsBacterial contamination

9

present

2


8

9

9

8



Process Element: Primary Fermentation7 [Fermentation Bucket & Products recently pur- 1

lid] chased (JIT)Plastic fatigue (cracks /orange peel)

9 [Airlock] Instructions include 2Airlock or fluid content is special care pointscontaminated

7

2

8

9

9

8

6 [Fermentation Bucket & Products recently pur- 1lid] chased (JIT)Plastic fatigue (cracks /orange peel)

8 [Home] Office floor used 1Shelf strength in airing insteadcupboard is inadequate

8 [Brewer] Cost and time limita- 1Uses only boiling water tionswhen preparing the wort

8 [Water] Water quality is 2Domestic supply quality assured by wateris contaminated (micro boardorganisms present)

8 2

[Water] Water quality is 2Domestic supply quality assured by wateris contaminated (chlo- boardrine content)[Home] Home is in a temper- 2Ambient temperature is ate climate and cen-too low / incorrect prox- trally heatedimity to heat source Past experiences

with similar brew kitsthat are beingdrank with gusto!Home is in the UK,which is unlikely tolead to excessivelyhigh temperatures

[Home] Home is in a temper- 2Ambient temperature is ate climate and cen-too high / incorrect prox- trally heatedimity to heat source Past experiences

with similar brew kitsthat are beingdrank with gusto!Warm floor space inoffice has beenassigned (locationwhere the cat usual-ly sleeps!)

[Yeast] Use of good quality 2Past best before date brew kit ingredients

Past experiences

8

with similar brew kits

2






with each brewingkit & can be down-

4 bloaded from theinternet

5

6 [Home] Home is double 1Location is close to glazeddraughts / UV light source

4 Controlled environ-ment

7 fermentation bucketis covered

7

1



8

8

8 [Home] Home is in a temper- 2Ambient temperature is ate climate and cen-too high / incorrect prox- trally heatedimity to heat source


8 Warm floor space inoffice has beenassigned (locationwhere the cat usual-ly sleeps!)

[Instructions] Use of good quality 2Ambiguous methodolo- brew kit ingredientsgy


6 [Home] Home is in a temper- 2Ambient temperature is ate climate and cen-

6

too low / incorrect prox- trally heated

2

imity to heat source8 Past experiences

with similar brew kitsthat are beingdrank with gusto!

8 Home is in the UK,which is unlikely tolead to excessivelyhigh temperatures



Process Element: Keg Fermentation7 [Syphon] Instructions include 2

Bacterial contamination special care pointspresent


7 [Brewer] Common sense / 3Does not wash hands hygiene

beforehand8 [Keg] Products recently pur- 1

Plastic fatigue (cracks / chased (JIT)orange peel)

9 [Keg] Instructions include 2Bacterial contamination special care pointspresent

9

9

2

8


drank with gusto!


[Syphon] Shop owner / suppli- 1Insufficient length er advice

[Syphon] Compression fit at 3Multi-section product joint[Keg] Past experiences 2Insufficient capacity with similar brew kits

that are beingdrank with gusto!Shop owner / suppli-er advice





4


2

er advice7 [Keg] Instructions include 2

Bacterial contamination special care pointspresent

9 [Scales] Instructions include 2Bacterial contamination special care pointspresent

7 [Sugar] Shop owner / suppli- 2Bacterial contamination er advicepresent

8 Use of good qualitybrew kit ingredients

9 Mixed with boiling

ty

9 Basic hygiene prac-tice

8 [Spoon] Instructions include 2Bacterial contamination special care pointspresent[Brewer] Common sense / 3Does not wash hands hygienebeforehand


6 not specified (including Shop owner / suppli-U.S. imperial) er advice


6

2





6 [Brewer] Ingredients and 5Adds more sugar than quantities are speci-required[Instructions] Use of good quality 2Ambiguous methodolo- brew kit ingredientsgy


[Scales] TPM on all devices 3Out of calibration

Digital scales used[Scales] Alternative scales 4Batteries are flat available

5 [Brewer] Ingredients and 2Incorrect type of sugar quantities are speci-used (e.g. brown sugar /

6 Muscovado) Past experienceswith similar brew kitsthat are beingdrank with gusto!

4 Shop owner / suppli-



4er advice

2

6

6





[Instructions] Use of good quality 2Metric / imperial brew kit ingredientsweights and volumesnot specified (including Shop owner / suppli-U.S. imperial) er advice


7



[Instructions] Use of good quality 2Insufficient detail about brew kit ingredientsalternative ingredients(does & don'ts) Shop owner / suppli-

er advice[Instructions] Use of good quality 2Ambiguous methodolo- brew kit ingredientsgy




with each brewingkit & can be down-bloaded from the

6 internet

7 [Keg] Instructions include 2Bacterial contamination special care pointspresent

9

9

2

7

8

9

9

8

6 [Keg] Products recently pur- 1Plastic fatigue (cracks / chased (JIT)orange peel)

8 [Keg] Past experiences 2Insufficient capacity with similar brew kits

that are beingdrank with gusto!Shop owner / suppli-er advice



with each brewingkit & can be down-bloaded from the

6

internet

3




Instructions suppliedwith each brewingkit & can be down-bloaded from theinternet

[Yeast] Shop owner / suppli- 3Insufficient resistance to er advicehigh alcohol content Use of good quality

brew kit ingredientsPast experienceswith similar brew kitsthat are beingdrank with gusto!

7 [Home] Home is in a temper- 2Ambient temperature is ate climate and cen-too low / incorrect prox- trally heated

6 imity to heat source Past experienceswith similar brew kitsthat are being

drank with gusto!

6

2

4 Home is in the UK,which is unlikely tolead to excessively

7 high temperatures

4


6 not specified (including Shop owner / suppli-U.S. imperial) er advice


7 [Home] Home is in a temper- 2Ambient temperature is ate climate and cen-too high / incorrect prox- trally heated

8 imity to heat source Past experienceswith similar brew kitsthat are beingdrank with gusto!Warm floor space inoffice has beenassigned (locationwhere the cat usual-ly sleeps!)



8

er advice

2




7 [Home] Home is in a temper- 2Excessive variations in ate climate and cen-the ambient temperature trally heated

6



8

F M E A

Process

Detection Actions D RPN Recommended ActionsCause Failure Mode

Process Element: SterilisationInstructions are 3 54read thoroughlybefore commenc-ing brewing

Directions are read 2 36and re-read ateach stage of thebrewing process

none 10 270

none 10 270

Process Responsibility: Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer Prepared By: Created: 13/03/2013

none 10 270

Instructions are 5 90read thoroughlybefore commenc-ing brewing

Sterilising solution 4 108has a strong smell

none 10 270


none 10 180 D: Beerclarityandsmellarechecked dur-ing thesec-onadaryfermen-tationstage



2 32

Process Element: Preparing the WortInstructions are 3 42read thoroughlybefore commenc-ing brewing

Visual inspection 1 14

none 10 210 D: Regu-lar refer-al to theinstruc-tions








subsequent stages 7 189will be affected(detection postprocess)

7 189

Scales clearly dis- 1 28play a battery lev-el symbolInstructions are 3 42read thoroughlybefore commenc-ing brewing

Electronic scales 1 35within accurate to0.25g


Sugar packaging 1 14is clearly labelled

1 14

1 standard bag of 3 63white cane sugarshould weighapprox. 1kg (Goldsample)Directions are read 2 28and re-read ateach stage of thebrewing process


Sugar packaging 1 16is clearly labelled

Instructions are 5 80read thoroughlybefore commenc-

ing brewing

5 80


none 10 400 D: Smell& claritychecks -smallglasspouredbefore 6daysintofinal fer-menta-tionprocess






Scales clearly dis- 1 28play a battery lev-el symbolSugar packaging 1 14is clearly labelled

1 standard bag of 3 63white cane sugarshould weighapprox. 1kg (Goldsample)Directions are read 2 28and re-read ateach stage of thebrewing process

2 28



none 10 270


none 10 180

none 10 180

none 10 180

none 10 180

none 10 270

none 10 270

none 10 180



none 10 180

none 10 180

none 10 180


Cannot complete 1 7and move on tonext operation subsequent stages 7 147will be affected(detection postprocess)none 10 270


none 10 270

none 10 270

none 10 180




2 24




none 10 270

none 10 270

none 10 270

none 10 270

none 10 180 D: Beerclarityandsmellarechecked dur-ing thesec-onadaryfermen-tationstage


none 10 180



none 10 270


subsequent stages 7 189will be affected(detection postprocess)none 10 180

Process Element: Add yeastnone 10 240 D: Regu-

lar refer-al to theinstruc-tions

subsequent stages 7 168will be affected(detection postprocess)Instructions are 3 48read thoroughlybefore commenc-ing brewing

Directions are read 2 32and re-read at

each stage of the

2 32

brewing process




subsequent stages 7 126will be affected(detection postprocess)none 10 180 D: Regu-

lar refer-al to theinstruc-tions

none 10 180


none 10 180

none 10 270

none 10 180

none 10 270

none 10 270 D: Regu-lar refer-

none 10 270

al to theinstruc-tions



none 10 180

none 10 180

none 10 270


Process Element: Primary FermentationVisual inspection 5 45




none 1 8

Primary fermenta- 7 56tion will be imped-ed / airlock doesnot bubble

none 10 160 D: Beerclarityandsmellarechecke

none 10 160

d dur-ing thesec-onadaryfermen-tationstage

Water Chlorination 2 32can be smelt fromthe tap (UStap=faucet)Climate supervisor 3 48(wife)

Lack of hot domes-tic water supply (dis-covered whenteenage son wantto shower)

Climate supervisor 3 48(wife)


none 10 160

none 10 160




3 24






3 48



Process Element: Keg Fermentationnone 10 180

none 10 270

none 10 270


none 10 180

none 10 180


Cannot complete 1 8and move on tonext operation Visual inspection 2 48



Instructions are 3 42read thoroughlybefore commenc-

ing brewing

3 42

none 10 180

none 10 180

none 10 180

none 10 180

none 10 270


2 28


Electronic scales 1 35within accurate to0.25gInstructions are 3 42read thoroughlybefore commenc-ing brewing

1 standard bag of 3 63white cane sugarshould weighapprox. 1kg (Goldsample)Scales clearly dis- 1 28play a battery lev-el symbolSugar packaging 1 12is clearly labelled

1 12


subsequent stages 7 147will be affected(detection postprocess)Directions are read 2 28and re-read ateach stage of thebrewing process





none 10 180

none 10 210



none 10 210


Lack of hot domes-tic water supply (dis-covered when

teenage son want

to shower)

3 42





3 48



Lack of hot domes-tic water supply (dis-covered whenteenage son wantto shower)Instructions are 3 48read thoroughlybefore commenc-ing brewing

F M E A

Process

Action ResultsActions Taken S O D RPN

Process Element: Sterilisation

Number: 1.1

Page:

Prepared By: Created: 13/03/2013 Modified: 20/03/2013

Responsibility & Target Completion Date

9 2 8

3/22/2013in revision

Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer

{144}

Process Element: Preparing the Wort

7 3 5

4/3/2013in revision


{105}

6 3 5 {90}

4/3/2013in revision

9 3 5

4/3/2013in revision



{135}

7 3 5

4/3/2013in revision


{105}

8 3 5

4/3/2013in revision

8 5 6



{120}


{240}

7 3 5

4/3/2013in revision


{105}

9 3 5

4/3/2013in revision


{135}

7 3 5

4/3/2013

in revision


{105}

6 5 6



{180}

6 3 5 {90}

4/3/2013in revision


9 2 8


9 3 5

4/3/2013in revision

9 3 5

4/3/2013


{144}


{135}


{135}

in revision

9 3 5

Process Element: Add yeast8 3 5

4/3/2013in revision

{135}


{120}

8 3 5

4/3/2013in revision

6 3 5 {90}

4/3/2013in revision


{120}


6 3 5 {90}

6 3 5 {90}

4/3/2013in revision

9 3 5



{135}

9 3 5

4/3/2013in revision


{135}

8 3 5

4/3/2013in revision

Process Element: Primary Fermentation


{120}

8 2 8Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer

{128}

8 2 8


D: Visu- 8 2 2 32alinspec-tion

3/15/2013 D: Audi-


{128}


completed ble

8 2 2 32

soundsof bub-bles exit-ing theairlockexpect-ed with-in 24hours

7 3 5

4/3/2013in revision


{105}

Process Element: Keg Fermentation

8 3 5

4/3/2013in revision

7 3 5

4/3/2013in revision


{120}


{105}

7 3 5

4/3/2013in revision


{105}

7 5 6



{210}

7 3 5

4/3/2013in revision

7 3 5

4/3/2013in revision


{105}


{105}

7 3 5

4/3/2013in revision


{105}

7 3 5

7 5 6


{105}


{210}

8 3 5

4/3/2013in revision


{120}

fmea forms editor aiag (4th edition, e): complete brewing …€¦ · xls file · web viewfun...

Documents