Beer Brewing Pfmea Aiag-Format

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

Team:
Function
Potential Failure Mode Potential Effect(s) of Failure S C
Process Element: Sterilisation
Sterilise
Equipment is
all of
not sterilised
the
equipment
and
then
rinse
with
clean
water
and
allow to
dry
[5% Indian Pale Ale

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 bitterness 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
Steriliser not fully rinsed from

equipment
Process Element: Preparing the Wort
[5% Indian Pale Ale

Beer]
Beer tastes of detergent
[5% Indian Pale Ale

Beer]
party
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale

Beer]
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 description
Excessive boiling water

added
[5% Indian Pale Ale

Beer]
Insufficient boiling water

added
[5% Indian Pale Ale

Beer]
Place
Malt &
Hops
container into
warm
water
for a
time of
>= 5
mins +5
Malt & Hops

not warmed sufficiently
Add boiling
water to
the fermentation
bucket
= 5 litres
+1
Water added
is not at boiling
point
[5% Indian Pale Ale

Beer]
[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
Add the
ingredients to
the fermentation
bucket
= 1 kg
beer
enhanc
er (sugar)
1.8kg
Malt &
Hops
Excessive quantity of sugar
scapped
[5% Indian Pale Ale
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]
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
Party goers are inebriated to early in the night
Incorrect ingredients added
[5% Indian Pale Ale

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]
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale

Beer]
party
Insufficient
quantity of
Malt & Hops
Insufficient
quantity of sugar
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is watery
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
Beer is watery
[5% Indian Pale Ale
Beer]
Insufficient alcoholic
beverages for the party goers
Sugar omitted
Wort is contamination
[5% Indian Pale Ale

Beer]
party
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
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
Mix contents
until
ingredients are
Ingredients mixing not mixed

to a soluble
state
dissolved
[5% Indian Pale Ale

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

Beer]
Beer is watery
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Fill the
fermentation
bucket
to the
correct
volume
40
pints
Insufficient
water added
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
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale

Beer]
Beer is too gaseous
[5% Indian Pale Ale

Beer]
Party goers are inebriat-
ed to early in the night

[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
malty
[5% Indian Pale Ale

Beer]
[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
9
Beer]
goers unwell
[5% Indian Pale Ale
Beer]
Beer is too gaseous
(bad)
Cover
fermentation
bucket
and
insert air-
[5% Indian Pale Ale

Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
lock
whilst
tempera-
Beer]
g. vinegary)
ture settles
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale

Beer]
8
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
Process Element: Add yeast

Mix the
Yeast omitted
yeast
into the
wort at
a specified temperature =
22 Centi-
[5% Indian Pale Ale

Beer]
party
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale

Beer]
Beer is watery
[5% Indian Pale Ale
Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
grade
5C
Yeast added
when wort is
too hot
6
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
Airlock does not bubble during the fermentation
[5% Indian Pale Ale
Beer]
yeast is killed
Yeat not
mixed to a soluble state
[5% Indian Pale Ale

Beer]
Yeast added
when wort is
too cold
[5% Indian Pale Ale

Beer]
Cover
fermentation
bucket
and
insert airlock
Airlock is not
inserted into lid
[5% Indian Pale Ale

Beer]
[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
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]

g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is contaminated
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]
[5% Indian Pale Ale
Beer]
[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
Lid is not fully

sealed /
pushed home
Process Element: Primary Fermentation

Beer is
Beer is contamiallowed
nated
to ferment for
6
days 2
[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]
[5% Indian Pale Ale

Beer]
[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)
Beer leakage
Fermentation
does not occur
(no bubbles
exit airlock)
[5% Indian Pale Ale

Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
Fermentation
process
stopped too
early
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
malty
Beer is
allowed
to ferment in
constistent tem-
Temperature
fluctuations
perature of
= 2025C
Temperature is
too high
[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
[5% Indian Pale Ale
Beer]
Beer is flat
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
[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
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale
Beer]
yeast is killed
Temperature is
too low
Process Element: Keg Fermentation

Syphon
Beer is contamithe fernated
menting
beer
into a
keg
avoiding the
sediment
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
party
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer spillage
Excess sediment decanted
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]
[5% Indian Pale Ale
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
Add
additional ingredients =
150 g
30g
Excessive quantity of sugar
[5% Indian Pale Ale

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

Beer]
[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
[5% Indian Pale Ale

Beer]
Beer is too gaseous
Incorrect ingredients added
[5% Indian Pale Ale

Beer]
[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]
[5% Indian Pale Ale

Beer]
Beer is too gaseous
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Insufficient
quantity of sugar
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
malty
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale
Beer]
Beer is flat
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
Beer is watery
Sugar omitted
Beer is
allowed
to ferment for
7
days +6
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale

Beer]
Beer is watery
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
[5% Indian Pale Ale

Beer]
g. vinegary)
[5% Indian Pale Ale
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
Beer leakage
Fermentation
process
stopped too
early

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]
[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]
[5% Indian Pale Ale
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
Beer tastes yeasty
[5% Indian Pale Ale
Beer]
4
Party goers have
'wind' the next day
Beer is
allowed
to ferment in
constistent tem-
Temperature is
too low
perature of
= 2025C
Temperature is
[5% Indian Pale Ale

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale
Beer]
[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
[5% Indian Pale Ale
4
too high
Temperature
fluctuations
Beer]
Beer is too sweet
[5% Indian Pale Ale
Beer]
[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
[5% Indian Pale Ale

Beer]
Beer is flat
[5% Indian Pale Ale

Beer]
Beer is too sweet
[5% Indian Pale Ale

Beer]
[5% Indian Pale Ale
Beer]
6
[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
FMEA
Process
Process Responsibility: Robbins, Gavin, Penkridge, FMEA Facilitator / Trainer
Key date:
Potential Cause(s) of Failure Preventive Actions
[Instructions]
Ambiguous methodology
Use of good quality

brew kit ingredients
Detection Actions
Cause
2 Instructions are
read thoroughly
before commencing brewing
Shop owner / supplier advice
[Instructions]
Metric / imperial
weights and volumes
not specified (including
U.S. imperial)
[Brewer]
Fails to sterilise container
used to carry water
[Brewer]
Does not wash hands
beforehand
[Instructions]
Insufficient detail about
Use of good quality

2 Directions are read

and re-read at
each stage of the
brewing process
Measuring devices
at Gavin's home display both imperial
& metric units
Instructions clearly
express that all
equipment needs to
be sterilised
3 none
Common sense /
hygiene
3 none
Use of good quality

2 Instructions are
read thoroughly
2
alternative ingredients
(does & don'ts)
[Steriliser]
insufficent concentration / ratios
[Home]
Poor air quality (micro
organisms present)
[Brewer]
Washes out sterilising fluid too early
[Water]
Domestic supply quality
is contaminated (micro
organisms present)
[Brewer]
Does not rinse equipment properly
[Brewer]
Forgets to rinse equipment properly

Quantity is specified
in the instructions
Instructions specify
imperial and metric
weights and volumes
Controlled environment

3 Sterilising solution
has a strong smell
3 none
express that all
equipment needs to
be sterilised
Water quality is
assured by water
board
has a strong smell
express that all
equipment needs to
be sterilised
express that all
equipment needs to
be sterilised
has a strong smell
Past experiences
with similar brew kits
that are being
drank with gusto!
2 none
has a strong smell
[Instructions]
Use of good quality

2 Instructions are
read thoroughly

[Kettle]
Thermostat failure
TPM on all devices
2 Visual inspection
[Brewer]
Impatientience / carelessness or inexperience
Past experiences
that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be downbloaded from the
internet
Use of good quality
3 none
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
[Fermentation Bucket &

lid]
Volume measurements
are illegible
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)

Measuring devices
& metric units
Products recently purchased (JIT)
Use of good quality

Measuring devices
at Gavin's home dis-

and re-read at
each stage of the
brewing process
1 Visual inspection

and re-read at
each stage of the
brewing process

lid]
Volume measurements
are illegible
[Brewer]
[Brewer]
[Brewer]
Omits a stage
play both imperial

& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
1 Visual inspection
3 none
3 none
3 subsequent stages
will be affected
(detection post
process)
[Scales]
Batteries are flat
Alternative scales
available
[Instructions]
Use of good quality

4 Scales clearly display a battery level symbol

2 Instructions are
read thoroughly
[Brewer]
Adds more sugar than
required
Ingredients and
quantities are specified in the instructions
5 Electronic scales
within accurate to
0.25g
[Instructions]
(does & don'ts)
Use of good quality

2 Instructions are
read thoroughly
[Brewer]
Incorrect type of sugar
used (e.g. brown sugar /
Muscovado)
[Scales]
Out of calibration
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)

Ingredients and
Past experiences
that are being
drank with gusto!
TPM on all devices
Digital scales used

Use of good quality
Measuring devices
2 Sugar packaging
is clearly labelled
3 1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
and re-read at
each stage of the
brewing process
[Brewer]
[Brewer]
Muscovado)
& metric units

Past experiences
that are being
drank with gusto!
with each brewing
internet
Ingredients and
3 none
2 Sugar packaging
is clearly labelled
Past experiences
that are being
drank with gusto!
[Instructions]
(does & don'ts)
Use of good quality

2 Instructions are
read thoroughly

[Brewer]
[Brewer]
Experimentation with
process (Brewer has a
'good' idea!)
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
3 none
5 none
5 none
[Instructions]
[Brewer]
Fails to rinse out Malt &
Hops container
[Brewer]
[Instructions]
with each brewing
internet
Use of good quality

Instructions include
special care points
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality
[Scales]
Batteries are flat
Alternative scales
available
[Brewer]
Ingredients and
2 Instructions are
read thoroughly
2 Visual inspection
3 none
2 Instructions are
read thoroughly

2 Sugar packaging
is clearly labelled
Muscovado)
[Scales]
Out of calibration
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
[Brewer]
[Brewer]
Omits a stage
Past experiences
that are being
drank with gusto!
TPM on all devices
Digital scales used

Use of good quality
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
3 1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
and re-read at
each stage of the
brewing process
3 none
3 subsequent stages
will be affected
(detection post
process)
[Brewer]
Fails to cover the wort
Common sense /
hygiene
3 none
[Instructions]
Use of good quality

2 Instructions are
read thoroughly
Shop owner / suppli-
er advice
lid]
Bacterial contamination
present
special care points
2 none
[Malt & Hops]

present
2 none
Use of good quality

[Scales]
present
[Brewer]
Does not wash hands
beforehand
[Home]
organisms present)
[Sugar]
present
[Brewer]
Washes out sterilising fluid too early
Basic hygiene practice

Mixed with boiling
water to ensure sterility
special care points
2 none
Common sense /
hygiene
3 none
3 none

Use of good quality
Mixed with boiling
express that all
equipment needs to
be sterilised
2 none
has a strong smell
[Brewer]
[Spoon]
present
[Malt & Hops]
Poor quality product /
batch
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points
3 none

Use of good quality
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
2 none
2 none
3 none
with each brewing
[Spoon]
Insufficient length
[Brewer]
Omits a stage
[Brewer]
Does not wash hands
beforehand
[Instructions]

internet
Past experiences
that are being
drank with gusto!
Common sense /
hygiene
Use of good quality
1 Cannot complete
and move on to
next operation
3 subsequent stages
will be affected
(detection post
process)
3 none
2 Instructions are
2
read thoroughly

[Home]
organisms present)
3 none
[Spoon]
present
special care points
2 none
[Brewer]
'good' idea!)
Past experiences
that are being
drank with gusto!
5 none

lid]
Volume measurements
with each brewing
internet
1 Visual inspection
1 Visual inspection
are illegible
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
[Brewer]

lid]
Insufficient capacity
[Instructions]
Use of good quality

Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
Use of good quality

and re-read at
each stage of the
brewing process
3 none
2 Visual inspection
2 Instructions are
read thoroughly
[Brewer]
Fails to sterilise container
used to carry water
[Brewer]
Does not wash hands
beforehand
[Home]
express that all
equipment needs to
be sterilised
Common sense /
hygiene
3 none
Controlled environ-
3 none
3 none
3 none
organisms present)
ment
[Water]
organisms present)
Water quality is
assured by water
board
2 none
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points
3 none
[Airlock]
2 Visual inspection
Airlock or fluid content is

contaminated
special care points
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing

lid]
present
2 none
3 none

lid]
Plastic fatigue (cracks /
orange peel)
[Brewer]
Omits a stage
[Thermometer]
present
[Brewer]

internet
1 Visual inspection
Past experiences
that are being
drank with gusto!
special care points
3 subsequent stages
will be affected
(detection post
process)
2 none
Past experiences
that are being
drank with gusto!
3 none
with each brewing
[Brewer]
Omits a stage
[Instructions]
internet
Past experiences
that are being
drank with gusto!
Use of good quality
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
Use of good quality

3 subsequent stages
will be affected
(detection post
process)
2 Instructions are
read thoroughly

and re-read at
each stage of the
brewing process
[Brewer]
[Thermometer]
Out of calibration
[Instructions]
[Brewer]
Omits a stage
[Brewer]
[Brewer]
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Mechanical thermometer used
Use of good quality
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
with each brewing
3 none
2 Visual inspection
2 Instructions are
read thoroughly
3 subsequent stages
will be affected
(detection post
process)
3 none
3 none
[Spoon]
present

internet
special care points
2 none
[Home]
organisms present)
3 none
[Thermometer]
present
[Brewer]
Does not wash hands
beforehand
special care points
2 none
Common sense /
hygiene
3 none
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
3 none
[Brewer]
Omits a stage

internet
Past experiences
3 subsequent stages
will be affected
3
that are being
drank with gusto!
(detection post
process)
[Airlock]
contaminated
special care points
2 Visual inspection

lid]
present
[Brewer]
Does not wash hands
beforehand
special care points
2 none
Common sense /
hygiene
3 none
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet
3 none

lid]
orange peel)
1 Visual inspection
[Airlock]
contaminated
special care points
2 Visual inspection

lid]
orange peel)
1 Visual inspection
[Home]
Shelf strength in airing
cupboard is inadequate
Office floor used

instead
1 none
[Brewer]
Uses only boiling water
when preparing the wort
Cost and time limitations
1 Primary fermentation will be impeded / airlock does

not bubble
[Water]
organisms present)
Water quality is
assured by water
board
2 none
[Water]
is contaminated (chlorine content)
[Home]
Ambient temperature is
too low / incorrect proximity to heat source
Water quality is
assured by water
board
2 Water Chlorination
can be smelt from
the tap (US
tap=faucet)
2 Climate supervisor
(wife)
Home is in a temperate climate and centrally heated

Past experiences
that are being
drank with gusto!
Lack of hot domestic water supply (discovered when

teenage son want
[Home]
too high / incorrect proximity to heat source
[Yeast]
Past best before date
Home is in the UK,

which is unlikely to
lead to excessively
high temperatures
Past experiences
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
where the cat usually sleeps!)
Use of good quality
to shower)
(wife)
teenage son want
to shower)
2 none
Past experiences
that are being
drank with gusto!
[Instructions]
Use of good quality

2 Instructions are
read thoroughly

[Brewer]
Past experiences
that are being
drank with gusto!
3 none
3 none
with each brewing
internet
[Home]
Location is close to
draughts / UV light source
Home is double
glazed
(wife)
fermentation bucket
is covered
[Instructions]
Use of good quality

2 Instructions are
read thoroughly
[Home]
Past experiences
(wife)
Lack of hot domes-
[Instructions]
[Home]

that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
Use of good quality
Past experiences
that are being
drank with gusto!
[Instructions]
Home is in the UK,

lead to excessively
high temperatures
Use of good quality
tic water supply (discovered when

teenage son want
to shower)
2 Instructions are
read thoroughly
(wife)

teenage son want
to shower)
2 Instructions are
read thoroughly
[Syphon]
present
special care points
2 none
[Home]
organisms present)
3 none
[Brewer]
Does not wash hands
Common sense /
hygiene
3 none
3 none
beforehand
[Keg]
orange peel)
1 Visual inspection
[Keg]
present
special care points
2 none
[Brewer]
Past experiences
that are being
drank with gusto!
3 none
[Syphon]
Insufficient length
[Syphon]
Multi-section product
[Keg]
[Brewer]
with each brewing
internet
Compression fit at
joint
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
1 Cannot complete
and move on to
next operation
3 Visual inspection
2 Visual inspection
3 none
3 none
[Instructions]
[Keg]
present
with each brewing
internet
Use of good quality
special care points
2 Instructions are
read thoroughly
2 none
[Scales]
present
special care points
2 none
[Sugar]
present
2 none
Use of good quality

Mixed with boiling

[Spoon]
present
[Brewer]
Does not wash hands
beforehand
[Instructions]
Metric / imperial
weights and volumes
special care points
2 none
Common sense /
hygiene
3 none
Use of good quality


and re-read at
each stage of the

U.S. imperial)
[Brewer]
[Brewer]
Adds more sugar than
required
[Instructions]
[Scales]
Out of calibration
[Scales]
Batteries are flat
[Brewer]
Muscovado)
Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
with each brewing
internet
Ingredients and
Use of good quality
TPM on all devices
Digital scales used

Alternative scales
available
Ingredients and
Past experiences
that are being
drank with gusto!
Shop owner / suppli-
brewing process
3 none
5 Electronic scales
within accurate to
0.25g
2 Instructions are
read thoroughly
3 1 standard bag of
white cane sugar
should weigh
approx. 1kg (Gold
sample)
2 Sugar packaging
is clearly labelled
er advice
[Brewer]
'good' idea!)
[Brewer]
Omits a stage
[Instructions]
Metric / imperial
weights and volumes
U.S. imperial)
[Brewer]
Past experiences
that are being
drank with gusto!
with each brewing
internet
Past experiences
that are being
drank with gusto!
Use of good quality
Measuring devices
& metric units
Past experiences
that are being
5 none
3 subsequent stages
will be affected
(detection post
process)
and re-read at
each stage of the
brewing process
3 none
3 none
[Instructions]
(does & don'ts)
[Instructions]
[Brewer]
[Keg]
present
drank with gusto!

with each brewing
internet
Use of good quality
Use of good quality
Past experiences
that are being
drank with gusto!
with each brewing
internet
special care points
2 Instructions are
read thoroughly
2 Instructions are
read thoroughly
3 none
2 none
[Keg]
orange peel)
1 Visual inspection
[Keg]
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
with each brewing
internet
Use of good quality
2 Visual inspection
[Brewer]
[Instructions]

[Brewer]
Past experiences
3 none
2 Instructions are
read thoroughly
5 none
5 none
'good' idea!)
[Yeast]
Insufficient resistance to
high alcohol content
[Home]
that are being

drank with gusto!
with each brewing
internet
Use of good quality
Past experiences
that are being
drank with gusto!
Past experiences
that are being
drank with gusto!
3 none
(wife)
teenage son want
to shower)
Home is in the UK,

lead to excessively
high temperatures
[Instructions]
Use of good quality
2
Metric / imperial
weights and volumes
U.S. imperial)
[Home]
[Instructions]
[Brewer]
[Home]
Excessive variations in
the ambient temperature

Measuring devices
& metric units
Past experiences
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
Use of good quality
Past experiences
that are being
drank with gusto!
with each brewing
internet
and re-read at
each stage of the
brewing process
(wife)
teenage son want
to shower)
2 Instructions are
read thoroughly
3 none
(wife)
Lack of hot domestic water supply (dis-
[Instructions]
Use of good quality

covered when
teenage son want
to shower)
2 Instructions are
read thoroughly
Trainer
Prepared By:
Created: 13/03/2013
tection Actions
D RPN Recommended Actions
Failure Mode
3
54
36
10 270
10 270
90
90
4 108
10 270
54
10 180 D: Beer
clarity
and
smell
are
checke
d during the
seconadary
fermentation
stage
2
48
32
42
14
10 210 D: Regular referal to the

instructions
24
12
24
12

instructions

instructions
7 189
28
42
35
70
14
63
28

instructions
16
80

instructions
10 400 D: Smell
& clarity
checks small
glass
10 400
poured
before 6
days
into
final fermentation
process
42
28

instructions
42
28
14
14
63
28

instructions
7 168
10 270
54
54
10 180
10 180
10 180
10 270
10 270
10 180
54

instructions
10 180
10 180

instructions
7 147
10 270
54
54
10 270
10 180
10 300 D: Smell
& clarity
checks small
glass
poured
before 6
days
into
final fermentation
process
12
12
24

instructions
12
54
10 270
10 270
10 270
10 270
10 180 D: Beer
clarity
and
smell
are
checke
d during the
seconadary
fermentation
stage
instructions
10 180
90

instructions
45
7 189
10 180

instructions
7 168
48
32

instructions
48
36
7 126

instructions

instructions
10 180
10 270
10 180
10 270

instructions
7 189
7 189
90
10 180
10 270

instructions
45
90
40
56
10 160 D: Beer
clarity
and
smell
are
checke
d during the
seconadary
fermentation
stage
2
32
48
48
10 160
42

instruc-
10 210
tions
24
48
48
48
48
48
10 180
10 270
10 270
10 270
45
10 180

instructions
48
16

instruc-
10 210
tions
42
10 180
10 180
10 180
10 180
10 270
28
28

instructions
35
42
63
28
12
10 350 D: Smell
& clarity
checks small
glass
poured
before 6
days
into
final fermentation
process
7 147
28
10 210
instructions
70
42

instructions
10 180
40
16

instructions
42
10 350 D: Smell
& clarity
10 350
checks small
glass
poured
before 6
days
into
final fermentation
process
10 210
42
32
32
48
48

instructions
48
48
Number: 1.1
Page:
Prepared By:
Created: 13/03/2013
Responsibility & Target Completion
Date
Modified: 20/03/2013
Action Results
Actions Taken
S O D RPN
Robbins, Gavin, Penkridge, FMEA

Facilitator / Trainer
3/22/2013
in revision
9 2 8 {144}

4/3/2013
in revision
7 3 5 {105}

6 3 5 {90}
4/3/2013
in revision

4/3/2013
in revision
9 3 5 {135}

7 3 5 {105}
4/3/2013
in revision

8 3 5 {120}
4/3/2013
in revision

8 5 6 {240}

8 5 6 {240}
3/27/2013
in revision

4/3/2013
in revision
7 3 5 {105}

4/3/2013
in revision
7 3 5 {105}

9 3 5 {135}
4/3/2013
in revision

4/3/2013
in revision
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
9 2 8 {144}
9 3 5 {135}
4/3/2013
in revision

4/3/2013
in revision
9 3 5 {135}

4/3/2013
in revision
8 3 5 {120}

8 3 5 {120}
4/3/2013
in revision

6 3 5 {90}
4/3/2013
in revision

4/3/2013
in revision
6 3 5 {90}

4/3/2013
in revision
9 3 5 {135}

4/3/2013
in revision
8 3 5 {120}

3/22/2013
in revision
8 2 8 {128}

3/15/2013
completed

D: Visual
inspection
D: Audible
sounds
of bubbles exiting the
airlock
expected within 24
hours
8 2 2
32
7 3 5 {105}
7 3 5 {105}
4/3/2013
in revision

8 3 5 {120}
4/3/2013
in revision

7 3 5 {105}
7 3 5 {105}
4/3/2013
in revision

4/3/2013
in revision
7 3 5 {105}

7 5 6 {210}
3/27/2013
in revision

7 3 5 {105}

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 5 6 {210}

3/27/2013
in revision
7 5 6 {210}

4/3/2013
in revision
8 3 5 {120}

Beer Brewing Pfmea Aiag-Format

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Item: Beer making (based on Indian Pale Ale - IPA)

Model Year(s)/Vehicle(s): Complete brewing process

[5% Indian Pale Ale

Steriliser not fully rinsed from

Process Element: Preparing the Wort

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Excessive boiling water

[5% Indian Pale Ale

Insufficient boiling water

[5% Indian Pale Ale

Malt & Hops

[5% Indian Pale Ale

[5% Indian Pale Ale

Excessive quantity of sugar

Incorrect ingredients added

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Ingredients mixing not mixed

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

ed to early in the night

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Process Element: Add yeast

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Beer aroma is poor (e.

Lid is not fully

Process Element: Primary Fermentation

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale

Process Element: Keg Fermentation

[5% Indian Pale Ale

[5% Indian Pale Ale

Excess sediment decanted

[5% Indian Pale Ale

Excessive quantity of sugar

[5% Indian Pale Ale

[5% Indian Pale Ale

[5% Indian Pale Ale