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 S
Failure
Process Element: Sterilisation
Sterilise Equipment is [5% Indian Pale Ale 8
all of not sterilised Beer]
the 40 pints of beer is
equip- scapped
ment [5% Indian Pale Ale 9
and Beer]
then Beer makes the party
rinse goers unwell
with [5% Indian Pale Ale 7
clean Beer]
water Beer taste has a bitter-
and ness to it
allow to [5% Indian Pale Ale 9
dry Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 7
Beer]
 7

Beer is cloudy/hazy

Steriliser not ful- [5% Indian Pale Ale 8

ly rinsed from Beer]
equipment Beer tastes of detergent

[5% Indian Pale Ale 8

Beer]
Beer is not ready for
Gavin's 40th birthday
party
 [5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Process Element: Preparing the Wort
Place Malt & Hops [5% Indian Pale Ale 6
Malt & not warmed suf- Beer]
Hops ficiently Brewing process takes
contain- longer than required
er into
warm
water
for a [5% Indian Pale Ale 7
time of Beer]
>= 5 Beer is watery
mins +5 [5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion

Add boil- Excessive boil- [5% Indian Pale Ale 6

ing ing water Beer]
water to added Brewing process takes
the fer- longer than required
menta-
tion
bucket
= 5 litres

+1
Insufficient boil- [5% Indian Pale Ale 6
ing water Beer]
added Brewing process takes
longer than required

Water added [5% Indian Pale Ale 7

is not at boiling Beer]
point Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)

[5% Indian Pale Ale 7

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
 9

Beer makes the party

goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Add the Excessive quan- [5% Indian Pale Ale 5
ingredi- tity of sugar Beer]
ents to Beer is too gaseous
the fer- [5% Indian Pale Ale 7
menta- Beer]
tion Beer tastes yeasty
bucket [5% Indian Pale Ale 7
= 1 kg Beer]
beer Beer is cloudy/hazy
enhanc [5% Indian Pale Ale 6
er (sug- Beer]
ar) Alcohol content is not
1.8kg as per product descrip-
Malt & tion
Hops [5% Indian Pale Ale 4
Beer]
Beer is too sweet
[5% Indian Pale Ale 6
Beer]
Party goers are inebriat-
ed to early in the night
Incorrect ingre- [5% Indian Pale Ale 6
dients added Beer]
Beer tastes caramelly/
malty
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy

[5% Indian Pale Ale 5

Beer]
Beer is too gaseous
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 4
Beer]
Beer is too sweet
[5% Indian Pale Ale 6
Beer]
 6

Brewing process takes

longer than required
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped

[5% Indian Pale Ale 8

Beer]
Beer is not ready for
Gavin's 40th birthday
party

Insufficient [5% Indian Pale Ale 6

quantity of Beer]
Malt & Hops Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 7
Beer]
Beer is watery
Insufficient [5% Indian Pale Ale 6
quantity of sug- Beer]
ar Beer is flat
[5% Indian Pale Ale 7
Beer]
Beer is watery
[5% Indian Pale Ale 6
Beer]
Insufficient alcoholic
beverages for the par-
ty goers
Sugar omitted [5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
Wort is contami- [5% Indian Pale Ale 7
nation Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Mix con- Ingredients mix- [5% Indian Pale Ale 6
tents ing not mixed Beer]
until to a soluble Beer is flat
ingredi- state
ents are [5% Indian Pale Ale 6

dissolved Beer]

Brewing process takes

longer than required

[5% Indian Pale Ale 7

Beer]
Beer is watery

Wort is contami- [5% Indian Pale Ale 7

nation Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
 8

scapped
Fill the Insufficient [5% Indian Pale Ale 6
fermen- water added Beer]
tation Insufficient alcoholic
bucket beverages for the par-
to the ty goers
correct
volume
40
pints

[5% Indian Pale Ale 5

Beer]
Beer is too gaseous

[5% Indian Pale Ale 6

Beer]
Party goers are inebriat-
ed to early in the night
[5% Indian Pale Ale 4
Beer]
Beer is too sweet
[5% Indian Pale Ale 6
Beer]
Beer tastes caramelly/
malty
Wort is contami- [5% Indian Pale Ale 7
nation Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy

[5% Indian Pale Ale 8

Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)

[5% Indian Pale Ale 8

Beer]
40 pints of beer is
 8

scapped

Cover Wort is contami- [5% Indian Pale Ale 7

fermen- nation Beer]
tation Beer taste has a bitter-
bucket ness to it
and
insert air- [5% Indian Pale Ale 9

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

ture set- [5% Indian Pale Ale 7

tles Beer]
Beer is cloudy/hazy

[5% Indian Pale Ale 8

Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Process Element: Add yeast
Mix the Yeast omitted [5% Indian Pale Ale 8
yeast Beer]
into the Beer is not ready for
wort at Gavin's 40th birthday
a speci- party
fied tem- [5% Indian Pale Ale 6
pera- Beer]
ture = Brewing process takes
22 Centi- longer than required

grade ±
5C

Yeast added [5% Indian Pale Ale 7

when wort is Beer]
too hot Beer is watery
[5% Indian Pale Ale 6
Beer]
Beer is flat
[5% Indian Pale Ale 6
Beer]
Brewing process takes
longer than required
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale 8
Beer]
Airlock does not bub-
ble during the fermen-
tation
[5% Indian Pale Ale 8
Beer]
 8

yeast is killed

Yeat not [5% Indian Pale Ale 6

mixed to a solu- Beer]
ble state Brewing process takes
longer than required

Yeast added [5% Indian Pale Ale 6

when wort is Beer]
too cold Brewing process takes
longer than required

Wort is contami- [5% Indian Pale Ale 7

nation Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Cover Airlock is not [5% Indian Pale Ale 7
fermen- inserted into lid Beer]
tation Beer taste has a bitter-
bucket ness to it
and [5% Indian Pale Ale 9
insert air- Beer]

lock Beer aroma is poor (e.

g. vinegary)

[5% Indian Pale Ale 7

Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
 [5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale 8
Beer]
Airlock does not bub-
ble during the fermen-
tation
Beer is contami- [5% Indian Pale Ale 7
nated Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 9
Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
 Lid is not fully [5% Indian Pale Ale 8
sealed / Beer]
pushed home Airlock does not bub-
ble during the fermen-
tation

Process Element: Primary Fermentation

Beer is Beer is contami- [5% Indian Pale Ale 7
allowed nated Beer]
to fer- Beer taste has a bitter-
ment for ness to it

6 [5% Indian Pale Ale 9

days ±2 Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Beer leakage [5% Indian Pale Ale 6
Beer]
Beer leakage 6

Insufficient alcoholic
beverages for the par-
ty goers
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Fermentation [5% Indian Pale Ale 8
does not occur Beer]
(no bubbles Beer is not ready for
exit airlock) Gavin's 40th birthday
party
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Fermentation [5% Indian Pale Ale 6
process Beer]
stopped too Alcohol content is not
early as per product descrip-
tion
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 6
Beer]
Beer tastes caramelly/
malty
[5% Indian Pale Ale 7
Beer]
 7

Beer tastes yeasty

[5% Indian Pale Ale 4
Beer]
Beer is too sweet
[5% Indian Pale Ale 5
Beer]
Beer is too gaseous
Beer is Temperature [5% Indian Pale Ale 6
allowed fluctuations Beer]
to fer- Beer is flat
ment in [5% Indian Pale Ale 4
constis- Beer]
tent tem- Beer is too sweet

pera- [5% Indian Pale Ale 7

ture of Beer]
= 20- Beer taste has a bitter-
25C ness to it
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 8
Beer]
yeast is killed
Temperature is [5% Indian Pale Ale 8
too high Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 8
 8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale 8
Beer]
yeast is killed

Temperature is [5% Indian Pale Ale 6

too low Beer]
Brewing process takes
longer than required
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 8
Beer]
Airlock does not bub-
ble during the fermen-
tation

Process Element: Keg Fermentation

Syphon Beer is contami- [5% Indian Pale Ale 7
the fer- nated Beer]
ment- Beer taste has a bitter-
ing ness to it
beer [5% Indian Pale Ale 9
into a Beer]
keg Beer aroma is poor (e.
avoid- g. vinegary)
ing the [5% Indian Pale Ale 7
 7
sediment Beer]

Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Beer spillage [5% Indian Pale Ale 6
Beer]
Insufficient alcoholic
beverages for the par-
ty goers
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
 Excess sedi- [5% Indian Pale Ale 7
ment decanted Beer]
Beer is cloudy/hazy

[5% Indian Pale Ale 4

Beer]
Party goers have
'wind' the next day

Add Beer is contami- [5% Indian Pale Ale 7

addition- nated Beer]
al ingre- Beer taste has a bitter-
dients = ness to it
150 g [5% Indian Pale Ale 9
±30g Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
 8

scapped

Excessive quan- [5% Indian Pale Ale 5

tity of sugar Beer]
Beer is too gaseous
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 4
Beer]
Beer is too sweet

[5% Indian Pale Ale 6

Beer]
Party goers are inebriat-
ed to early in the night
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy

[5% Indian Pale Ale 6

Beer]
Brewing process takes
longer than required

Incorrect ingre- [5% Indian Pale Ale 5

 5
dients added Beer]
Beer is too gaseous
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 4
Beer]
Beer is too sweet
[5% Indian Pale Ale 6
Beer]
Beer tastes caramelly/
malty
[5% Indian Pale Ale 6
Beer]
Party goers are inebriat-
ed to early in the night
Insufficient [5% Indian Pale Ale 6
quantity of sug- Beer]
ar Beer is flat

[5% Indian Pale Ale 6

Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 7
Beer]
Beer is watery
 Sugar omitted [5% Indian Pale Ale 6
Beer]
Beer is flat

[5% Indian Pale Ale 7

Beer]
Beer is watery

[5% Indian Pale Ale 6

Beer]
Alcohol content is not
as per product descrip-
tion
Beer is Beer is contami- [5% Indian Pale Ale 7
allowed nated Beer]
 7

to fer- Beer taste has a bitter-

ment for ness to it

7 [5% Indian Pale Ale 9

days +6 Beer]
Beer aroma is poor (e.
g. vinegary)
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 9
Beer]
Beer makes the party
goers unwell
[5% Indian Pale Ale 9
Beer]
Beer is too gaseous
(bad)
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
Beer leakage [5% Indian Pale Ale 6
Beer]
Insufficient alcoholic
beverages for the par-
ty goers
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped

Fermentation [5% Indian Pale Ale 7

process Beer]
stopped too Beer is cloudy/hazy
 7

early
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 4
Beer]
Beer is too sweet
[5% Indian Pale Ale 7
Beer]
Beer tastes yeasty
[5% Indian Pale Ale 4
Beer]
Party goers have
'wind' the next day

Beer is Temperature is [5% Indian Pale Ale 7

allowed too low Beer]
to fer- Beer is cloudy/hazy
ment in [5% Indian Pale Ale 6
 6
constis- Beer]
tent tem- Alcohol content is not

pera- as per product descrip-

ture of tion
= 20- [5% Indian Pale Ale 4
25C Beer]
Beer is too sweet
[5% Indian Pale Ale 7
Beer]
Beer tastes yeasty
[5% Indian Pale Ale 4
Beer]
Party goers have
'wind' the next day
Temperature is [5% Indian Pale Ale 4
too high Beer]
Beer is too sweet
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale 7
Beer]
Beer is cloudy/hazy
[5% Indian Pale Ale 8
Beer]
yeast is killed
Temperature [5% Indian Pale Ale 6
fluctuations Beer]
Beer is flat

[5% Indian Pale Ale 4

Beer]
Beer is too sweet

[5% Indian Pale Ale 7

Beer]
Beer taste has a bitter-
ness to it
[5% Indian Pale Ale 6
Beer]
Alcohol content is not
as per product descrip-
tion
[5% Indian Pale Ale 8
Beer]
40 pints of beer is
scapped
[5% Indian Pale Ale 8
Beer]
Beer is not ready for
Gavin's 40th birthday
party
[5% Indian Pale Ale 8
Beer]
yeast is killed
 FMEA

Process

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

Key date:  

C Potential Cause(s) of Preventive Actions O

Failure

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Instructions] Use of good quality 2

Metric / imperial
weights and volumes
not specified (including
U.S. imperial)
brew kit ingredients
Shop owner / suppli-
er advice

[Brewer]
Fails to sterilise container
used to carry water
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
Instructions clearly 3
express that all
equipment needs to
be sterilised

[Brewer] Common sense / 3

Does not wash hands hygiene
 3

beforehand
[Instructions]
Insufficient detail about
alternative ingredients
(does & don'ts)
[Steriliser]
insufficent concentra-
tion / ratios
[Home]
Poor air quality (micro
organisms present)
[Brewer]
Washes out sterilising flu-
id too early
[Water]
Domestic supply quality
is contaminated (micro
organisms present)
Use of good quality 2
brew kit ingredients
Shop owner / suppli-
er advice
Quantity is specified 3
in the instructions
Instructions specify
imperial and metric
weights and volumes
Controlled environ- 3
ment
Instructions clearly 3
express that all
equipment needs to
be sterilised
Water quality is 2
assured by water
board

[Brewer] Instructions clearly 3

Does not rinse equip- express that all
ment properly equipment needs to
be sterilised
[Brewer] Instructions clearly 2
Forgets to rinse equip- express that all
ment properly equipment needs to
be sterilised
 2

Past experiences
with similar brew kits
that are being
drank with gusto!

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Kettle] TPM on all devices 2

Thermostat failure

[Brewer] Past experiences 3

Impatientience / care- with similar brew kits
lessness 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 2
Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial

& metric units

[Fermentation Bucket & Products recently pur- 1
lid] chased (JIT)
Volume measurements
are illegible
[Instructions] Use of good quality 2
Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Fermentation Bucket & Products recently pur- 1
lid] chased (JIT)
Volume measurements
are illegible
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!
[Scales] Alternative scales 4
Batteries are flat available

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice

[Brewer] Ingredients and 5

Adds more sugar than quantities are speci-
required fied in the
instructions

[Instructions] Use of good quality 2

Insufficient detail about brew kit ingredients
alternative ingredients
(does & don'ts) Shop owner / suppli-
er advice
[Brewer] Ingredients and 2
Incorrect type of sugar quantities are speci-
used (e.g. brown sugar / fied in the
Muscovado) instructions
Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Scales] TPM on all devices 3
Out of calibration
 TPM on all devices 3

Digital scales used

[Instructions] Use of good quality 2
Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Ingredients and 2
Incorrect type of sugar quantities are speci-
used (e.g. brown sugar / fied in the
Muscovado) instructions
Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice

[Instructions] Use of good quality 2

Insufficient detail about brew kit ingredients
alternative ingredients
(does & don'ts)

Shop owner / suppli-

er advice

[Brewer] Past experiences 3

Impatientience / care- with similar brew kits
 3

lessness or inexperience that are being

drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences 5
Experimentation with with similar brew kits
process (Brewer has a that are being
'good' idea!) drank with gusto!

Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice
[Brewer] Instructions include 2
Fails to rinse out Malt & special care points
Hops container
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness 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 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice

[Scales] Alternative scales 4

Batteries are flat available

[Brewer] Ingredients and 2

Incorrect type of sugar quantities are speci-
used (e.g. brown sugar / fied in the
Muscovado) instructions
Past experiences
with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Scales] TPM on all devices 3
Out of calibration

Digital scales used

[Instructions] Use of good quality 2
Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
 bloaded from the
internet
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!

[Brewer] Common sense / 3

Fails to cover the wort hygiene

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Fermentation Bucket & Instructions include 2

lid] special care points
Bacterial contamination
present

[Malt & Hops] Shop owner / suppli- 2

Bacterial contamination er advice
present

Use of good quality

brew kit ingredients

Basic hygiene prac-

tice
Mixed with boiling
water to ensure
ty
[Scales] Instructions include 2
Bacterial contamination special care points
present
[Brewer] Common sense / 3
Does not wash hands hygiene
 3

beforehand
[Home] Controlled environ- 3
Poor air quality (micro ment
organisms present)
[Sugar] Shop owner / suppli- 2
Bacterial contamination er advice
present Use of good quality
brew kit ingredients
Mixed with boiling
water to ensure
ty
Basic hygiene prac-
tice
[Brewer] Instructions clearly 3
Washes out sterilising flu- express that all
id too early equipment needs to
be sterilised
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Spoon] Instructions include 2
Bacterial contamination special care points
present
[Malt & Hops] Shop owner / suppli- 2
Poor quality product / er advice
batch Use of good quality
brew kit ingredients
Past experiences
with similar brew kits
that are being
drank with gusto!
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
 3

Instructions supplied

with each brewing

kit & can be down-

bloaded from the
internet
[Spoon] Shop owner / suppli- 1
Insufficient length er advice

[Brewer] Past experiences 3

Omits a stage with similar brew kits
that are being
drank with gusto!
[Brewer] Common sense / 3
Does not wash hands hygiene
beforehand

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Home] Controlled environ- 3

Poor air quality (micro ment
organisms present)

[Spoon] Instructions include 2

Bacterial contamination special care points
present
[Brewer] Past experiences 5
Experimentation with with similar brew kits
process (Brewer has a that are being
'good' idea!) drank with gusto!

Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Fermentation Bucket & Products recently pur- 1
lid] chased (JIT)
Volume measurements
are illegible
[Instructions] Use of good quality 2
Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Fermentation Bucket & Past experiences 2
 2
lid] with similar brew kits
Insufficient capacity that are being
drank with gusto!
Shop owner / suppli-
er advice
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Brewer] Instructions clearly 3

Fails to sterilise container express that all
used to carry water equipment needs to
be sterilised
[Brewer] Common sense / 3
Does not wash hands hygiene
beforehand

[Home] Controlled environ- 3

Poor air quality (micro ment
organisms present)

[Water] Water quality is 2

Domestic supply quality assured by water
is contaminated (micro board
organisms present)

[Brewer] Past experiences 3


Impatientience / care-
lessness or inexperience
[Fermentation Bucket &
lid]
Bacterial contamination
present
3
with similar brew kits
that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
Instructions include 2
special care points

[Airlock] Instructions include 2

Airlock or fluid content is special care points

contaminated

[Brewer] Past experiences 3

Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Fermentation Bucket & Products recently pur- 1
lid] chased (JIT)
Plastic fatigue (cracks /
orange peel)
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!
[Thermometer] Instructions include 2
Bacterial contamination special care points
present
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!

Instructions supplied
with each brewing
kit & can be down-
bloaded from the

internet
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice

[Instructions] Use of good quality 2

Metric / imperial brew kit ingredients
weights and volumes
not specified (including
U.S. imperial) Shop owner / suppli-
er advice

Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!

Instructions supplied
with each brewing
 kit & can be down-
bloaded from the
internet
[Thermometer] Mechanical ther- 2
Out of calibration mometer used
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Spoon] Instructions include 2
Bacterial contamination special care points
present

[Home] Controlled environ- 3

Poor air quality (micro ment
organisms present)

[Thermometer] Instructions include 2

 2
Bacterial contamination special care points
present
[Brewer] Common sense / 3
Does not wash hands hygiene
beforehand

[Brewer] Past experiences 3

Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing

kit & can be down-

bloaded from the
internet
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!
[Airlock] Instructions include 2
Airlock or fluid content is special care points
contaminated

[Fermentation Bucket & Instructions include 2

lid] special care points
Bacterial contamination
present
[Brewer] Common sense / 3
Does not wash hands hygiene
beforehand
[Brewer]
Impatientience / care-
lessness or inexperience
[Fermentation Bucket &
lid]
Plastic fatigue (cracks /
orange peel)
[Airlock]
Airlock or fluid content is
contaminated
[Fermentation Bucket &
lid]
Past experiences 3
with similar brew kits
that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
Products recently pur- 1
chased (JIT)
Instructions include 2
special care points
Products recently pur- 1
chased (JIT)
 1

Plastic fatigue (cracks /

orange peel)

[Home] Office floor used 1

Shelf strength in airing instead
cupboard is inadequate

[Brewer] Cost and time limita- 1

Uses only boiling water tions
when preparing the wort

[Water] Water quality is 2

Domestic supply quality assured by water
is contaminated (micro board
organisms present)

[Water] Water quality is 2

Domestic supply quality assured by water
is contaminated (chlo- board
rine content)
[Home] Home is in a temper- 2
Ambient temperature is ate climate and cen-
too low / incorrect prox- trally heated
imity to heat source Past experiences
with similar brew kits
that are being
drank with gusto!
Home is in the UK,
which is unlikely to
lead to excessively
high temperatures
[Home] Home is in a temper- 2
Ambient temperature is ate climate and cen-
too high / incorrect prox- trally heated
imity to heat source Past experiences
with similar brew kits
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
where the cat usual-
ly sleeps!)
[Yeast] Use of good quality 2
Past best before date brew kit ingredients

Past experiences
with similar brew kits
that are being
drank with gusto!

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Brewer] Past experiences 3

Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
 kit & can be down-
bloaded from the
internet

[Home] Home is double 1

Location is close to glazed
draughts / UV light source
Controlled environ-
ment

fermentation bucket
is covered

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice

[Home] Home is in a temper- 2

Ambient temperature is ate climate and cen-
too high / incorrect prox- trally heated
imity to heat source

Past experiences
 with similar brew kits
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
where the cat usual-
ly sleeps!)
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice
[Home] Home is in a temper- 2
Ambient temperature is ate climate and cen-
too low / incorrect prox- trally heated
imity to heat source
Past experiences
with similar brew kits
that are being
drank with gusto!

Home is in the UK,

which is unlikely to
lead to excessively
high temperatures
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice

[Syphon] Instructions include 2

Bacterial contamination special care points
present

[Home] Controlled environ- 3

Poor air quality (micro ment
organisms present)

[Brewer] Common sense / 3

 3
Does not wash hands hygiene

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

[Keg] Instructions include 2

Bacterial contamination special care points
present

[Brewer] Past experiences 3

Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!

Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Syphon] Shop owner / suppli- 1
Insufficient length er advice

[Syphon] Compression fit at 3

Multi-section product joint
[Keg] Past experiences 2
Insufficient capacity with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness 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 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice
[Keg] Instructions include 2
Bacterial contamination special care points
present

[Scales] Instructions include 2

Bacterial contamination special care points
present

[Sugar] Shop owner / suppli- 2

Bacterial contamination er advice
present
Use of good quality
brew kit ingredients

Mixed with boiling

water to ensure
sterili-
ty

Basic hygiene prac-

tice

[Spoon] Instructions include 2

Bacterial contamination special care points
present
[Brewer] Common sense / 3
Does not wash hands hygiene
beforehand
[Instructions] Use of good quality 2
Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice

Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Ingredients and 5
Adds more sugar than quantities are speci-
required fied in the
[Instructions] instructions
Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice
[Scales] TPM on all devices 3
Out of calibration

Digital scales used

[Scales] Alternative scales 4
Batteries are flat available

[Brewer] Ingredients and 2

 2
Incorrect type of sugar quantities are speci-
used (e.g. brown sugar / fied in the
Muscovado) instructions
Past experiences
with similar brew kits
that are being
drank with gusto!

Shop owner / suppli-

er advice

[Brewer] Past experiences 5

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

Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Brewer] Past experiences 3
Omits a stage with similar brew kits
that are being
drank with gusto!
[Instructions] Use of good quality 2
Metric / imperial brew kit ingredients
 2

weights and volumes

not specified (including Shop owner / suppli-
U.S. imperial) er advice
Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness 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 2
Insufficient detail about brew kit ingredients
alternative ingredients
(does & don'ts) Shop owner / suppli-
er advice
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet

[Keg] Instructions include 2

Bacterial contamination special care points
 2

present

[Keg] Products recently pur- 1

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

[Keg] Past experiences 2

Insufficient capacity with similar brew kits
that are being
drank with gusto!
Shop owner / suppli-
er advice
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
 3

drank with gusto!

Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
gy
Shop owner / suppli-
er advice

[Brewer] Past experiences 5

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

Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Yeast] Shop owner / suppli- 3
Insufficient resistance to er advice
high alcohol content Use of good quality
brew kit ingredients
Past experiences
with similar brew kits
that are being
drank with gusto!
[Home] Home is in a temper- 2
Ambient temperature is ate climate and cen-
too low / incorrect prox- trally heated
imity to heat source Past experiences
 2

with similar brew kits

that are being

drank with gusto!

Home is in the UK,

which is unlikely to
lead to excessively
high temperatures

[Instructions] Use of good quality 2

Metric / imperial brew kit ingredients
weights and volumes
not specified (including Shop owner / suppli-
U.S. imperial) er advice

Measuring devices
at Gavin's home dis-
play both imperial
& metric units
[Home] Home is in a temper- 2
Ambient temperature is ate climate and cen-
too high / incorrect prox- trally heated
imity to heat source Past experiences
with similar brew kits
that are being
drank with gusto!
Warm floor space in
office has been
assigned (location
where the cat usual-
ly sleeps!)
[Instructions] Use of good quality 2
Ambiguous methodolo- brew kit ingredients
 2

gy
Shop owner / suppli-
er advice
[Brewer] Past experiences 3
Impatientience / care- with similar brew kits
lessness or inexperience that are being
drank with gusto!
Instructions supplied
with each brewing
kit & can be down-
bloaded from the
internet
[Home] Home is in a temper- 2
Excessive variations in ate climate and cen-
the ambient temperature trally heated

[Instructions] Use of good quality 2

Ambiguous methodolo- brew kit ingredients
gy

Shop owner / suppli-

er advice
 FMEA

Process

dge, FMEA Facilitator / Trainer P

Detection Actions D RPN Recommended Actions

Cause Failure Mode

Instructions are 3 54
read thoroughly
before commenc-
ing brewing

Directions are read 2 36

and re-read at
each stage of the
brewing process

none 10 270

none 10 270
none 10 270

Instructions are 5 90
read thoroughly
before commenc-
ing brewing

Sterilising solution 4 108

has a strong smell

none 10 270

Sterilising solution 2 54
has a strong smell

none 10 180 D: Beer

clarity
and
smell
are
checke
d dur-
ing the
sec-
onadary
fermen-
tation
stage

Sterilising solution 2 48
has a strong smell

Sterilising solution 2 32
has a strong smell
 2 32

Instructions are 3 42
read thoroughly
before commenc-
ing brewing

Visual inspection 1 14

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions

Directions are read 2 24

and re-read at
each stage of the
brewing process

Visual inspection 2 12
Directions are read 2 24
and re-read at
each stage of the
brewing process

Visual inspection 2 12

none 10 180 D: Regu-

lar refer-
al to the
instruc-
tions

none 10 270 D: Regu-

lar refer-
al to the
instruc-
tions

subsequent stages 7 189

will be affected
(detection post
process)
Scales clearly dis- 1 28
play a battery lev-
el symbol
Instructions are 3 42
read thoroughly
before commenc-
ing brewing

Electronic scales 1 35
within accurate to
0.25g

Instructions are 5 70
read thoroughly
before commenc-
ing brewing

Sugar packaging 1 14
is clearly labelled

1 standard bag of 3 63
white cane sugar
should weigh
 3 63

approx. 1kg (Gold

sample)
Directions are read 2 28
and re-read at
each stage of the
brewing process

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions

Sugar packaging 1 16
is clearly labelled

Instructions are 5 80
read thoroughly
before commenc-
ing brewing

none 10 240 D: Regu-

lar refer-
none 10 240

al to the
instruc-
tions

none 10 400 D: Smell

& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process

Instructions are 3 42
read thoroughly
before commenc-
ing brewing

Visual inspection 2 28

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions
Instructions are 3 42
read thoroughly
before commenc-
ing brewing

Scales clearly dis- 1 28

play a battery lev-
el symbol
Sugar packaging 1 14
is clearly labelled

1 standard bag of 3 63
white cane sugar
should weigh
approx. 1kg (Gold
sample)
Directions are read 2 28
and re-read at
each stage of the
brewing process

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions
subsequent stages 7 168
will be affected
(detection post
process)

none 10 270

Instructions are 3 54
read thoroughly
before commenc-
ing brewing

none 10 180

none 10 180

none 10 180

none 10 270
none 10 270

none 10 270

none 10 180

Sterilising solution 2 54
has a strong smell

none 10 270 D: Regu-

lar refer-
al to the
instruc-
tions

none 10 180

none 10 180

none 10 210 D: Regu-

lar refer-
al to the
instruc-
none 10 210

tions

Cannot complete 1 7
and move on to
next operation
subsequent stages 7 147
will be affected
(detection post
process)
none 10 270

Instructions are 3 54
read thoroughly
before commenc-
ing brewing

none 10 270

none 10 180
none 10 300 D: Smell
& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process

Visual inspection 2 12

Directions are read 2 24

and re-read at
each stage of the
brewing process

none 10 180 D: Regu-

lar refer-
al to the
instruc-
tions

Visual inspection 1 12
Visual inspection 1 12

Instructions are 3 54
read thoroughly
before commenc-
ing brewing

none 10 270

none 10 270

none 10 270

none 10 180 D: Beer

clarity
and
smell
are
checke
d dur-
ing the
sec-
onadary
fermen-
tation
stage

none 10 270 D: Regu-

none 10 270
lar refer-
al to the
instruc-
tions

none 10 180

Visual inspection 5 90

none 10 270 D: Regu-

lar refer-
al to the
instruc-
tions

Visual inspection 5 45

subsequent stages 7 189

will be affected
(detection post
process)
none 10 180
none 10 240 D: Regu-
lar refer-
al to the
instruc-
tions

subsequent stages 7 168

will be affected
(detection post
process)
Instructions are 3 48
read thoroughly
before commenc-
ing brewing

Directions are read 2 32

and re-read at
each stage of the
brewing process

none 10 240 D: Regu-

lar refer-
al to the
instruc-
tions
Visual inspection 3 48

Instructions are 3 36
read thoroughly
before commenc-
ing brewing

subsequent stages 7 126

will be affected
(detection post
process)
none 10 180 D: Regu-
lar refer-
al to the
instruc-
tions

none 10 180 D: Regu-

lar refer-
al to the
instruc-
tions

none 10 180

none 10 270

none 10 180
none 10 180

none 10 270

none 10 270 D: Regu-

lar refer-
al to the
instruc-
tions

subsequent stages 7 189

will be affected
(detection post
process)
Visual inspection 5 90

none 10 180

none 10 270
none 10 240 D: Regu-
lar refer-
al to the
instruc-
tions

Visual inspection 5 45

Visual inspection 5 90

Visual inspection 5 40
Visual inspection 5 40

none 1 8

Primary fermenta- 7 56
tion will be imped-
ed / airlock does
not bubble

none 10 160 D: Beer

clarity
and
smell
are
checke
d dur-
ing the
sec-
onadary
fermen-
tation
stage

Water Chlorination 2 32
can be smelt from
the tap (US
tap=faucet)
Climate supervisor 3 48
(wife)

Lack of hot domes-

tic water supply (dis-
covered when
teenage son want
to shower)
Climate supervisor 3 48
(wife)

Lack of hot domes-

tic water supply (dis-
covered when
teenage son want
to shower)

none 10 160

Instructions are 3 42
read thoroughly
before commenc-
ing brewing

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions
Climate supervisor 3 24
(wife)

Instructions are 3 48
read thoroughly
before commenc-
ing brewing

Climate supervisor 3 48
(wife)

Lack of hot domes-

tic water supply (dis-
covered when
teenage son want
to shower)

Instructions are 3 48
read thoroughly
before commenc-
ing brewing

Climate supervisor 3 48
(wife)

Lack of hot domes-

tic water supply (dis-
covered when
teenage son want
to shower)

Instructions are 3 48
read thoroughly
before commenc-
ing brewing

none 10 180

none 10 270

none 10 270
none 10 270

Visual inspection 5 45

none 10 180

none 10 240 D: Regu-

lar refer-
al to the
instruc-
tions

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

Visual inspection 1 16
none 10 210 D: Regu-
lar refer-
al to the
instruc-
tions

Instructions are 3 42
read thoroughly
before commenc-
ing brewing

none 10 180

none 10 180

none 10 180

none 10 180
none 10 270

Directions are read 2 28

and re-read at
each stage of the
brewing process

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions

Electronic scales 1 35
within accurate to
0.25g
Instructions are 3 42
read thoroughly
before commenc-
ing brewing

1 standard bag of 3 63
white cane sugar
should weigh
approx. 1kg (Gold
sample)
Scales clearly dis- 1 28
play a battery lev-
el symbol
Sugar packaging 1 12
 1 12
is clearly labelled

none 10 350 D: Smell

& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process

subsequent stages 7 147

will be affected
(detection post
process)
Directions are read 2 28
and re-read at
 2 28

each stage of the

brewing process

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions

Instructions are 5 70
read thoroughly
before commenc-
ing brewing

Instructions are 3 42
read thoroughly
before commenc-
ing brewing

none 10 210 D: Regu-

lar refer-
al to the
instruc-
tions

none 10 180
none 10 180

Visual inspection 5 40

Visual inspection 1 16

none 10 210 D: Regu-

lar refer-
al to the
none 10 210

instruc-
tions

Instructions are 3 42
read thoroughly
before commenc-
ing brewing

none 10 350 D: Smell

& clarity
checks -
small
glass
poured
before 6
days
into
final fer-
menta-
tion
process

none 10 210

Climate supervisor 3 42
(wife)

Lack of hot domes-

 3 42

tic water supply (dis-

covered when

teenage son want

to shower)

Directions are read 2 32

and re-read at
each stage of the
brewing process

Climate supervisor 3 48
(wife)

Lack of hot domes-

tic water supply (dis-
covered when
teenage son want
to shower)

Instructions are 3 48
read thoroughly
 3 48

before commenc-
ing brewing

none 10 240 D: Regu-

lar refer-
al to the
instruc-
tions

Climate supervisor 3 48
(wife)

Lack of hot domes-

tic water supply (dis-
covered when
teenage son want
to shower)
Instructions are 3 48
read thoroughly
before commenc-
ing brewing
 Number: 1.1

Page:  

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

Responsibility & Target Completion Action Results

Date Actions Taken S O D RPN
Robbins, Gavin, Penkridge, FMEA 9 2 8 {144
Facilitator / Trainer }

3/22/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 6 3 5 {90}
Facilitator / Trainer

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 9 3 5 {135

Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 8 3 5 {120

Facilitator / Trainer }
Robbins, Gavin, Penkridge, FMEA 8 3 5 {120
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 8 5 6 {240

Facilitator / Trainer }

3/27/2013
in revision

Robbins, Gavin, Penkridge, FMEA 7 3 5 {105

Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 9 3 5 {135
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 7 3 5 {105

Facilitator / Trainer }
 7 3 5 {105
}

4/3/2013

in revision
Robbins, Gavin, Penkridge, FMEA 6 5 6 {180
Facilitator / Trainer }

3/27/2013
in revision

Robbins, Gavin, Penkridge, FMEA 6 3 5 {90}

Facilitator / Trainer

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 9 2 8 {144
Facilitator / Trainer }

3/22/2013
in revision
Robbins, Gavin, Penkridge, FMEA 9 3 5 {135
Facilitator / Trainer }
Robbins, Gavin, Penkridge, FMEA 9 3 5 {135
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 9 3 5 {135

Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 8 3 5 {120
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 8 3 5 {120

Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 6 3 5 {90}
Facilitator / Trainer

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 6 3 5 {90}

Facilitator / Trainer

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 9 3 5 {135
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 8 3 5 {120
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 8 2 8 {128
Facilitator / Trainer }

3/22/2013
in revision
Robbins, Gavin, Penkridge, FMEA D: Visu- 8 2 2 32
Facilitator / Trainer al
inspec-
tion
3/15/2013 D: Audi-
completed ble
sounds
of bub-
bles exit-
ing the
airlock
expect-
ed with-
in 24
hours

Robbins, Gavin, Penkridge, FMEA 7 3 5 {105

Facilitator / Trainer }

4/3/2013
in revision
}
Robbins, Gavin, Penkridge, FMEA 8 3 5 {120
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 5 6 {210
Facilitator / Trainer }

3/27/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 7 3 5 {105

Facilitator / Trainer }

4/3/2013
in revision
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }
Robbins, Gavin, Penkridge, FMEA 7 3 5 {105
Facilitator / Trainer }

4/3/2013
in revision

Robbins, Gavin, Penkridge, FMEA 7 5 6 {210

Facilitator / Trainer }

3/27/2013
in revision
Robbins, Gavin, Penkridge, FMEA 8 3 5 {120
Facilitator / Trainer }

4/3/2013
in revision