Failure mode effect analysis

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Failure mode effect analysis

  1. 1. FMEA
  2. 2. Introduction to FMEA • Failure Mode and Effects Analysis, FMEA is: • A systematic method of identifying and investigating potential design or process weaknesses. • A means to evaluate and manage product risks. • A means of evolving organizational knowledge. • Developed in the aerospace industry in the mid 1960’s • Also sometimes referred to as Failure Mode Effect and Criticality Analysis, FMECA
  3. 3. Purpose • Recognise and evaluate the potential failure modes and causes associated with the design andmanufacture of a product or design and operation of any process. • Identify actions which could eliminate or reduce the chance of the potential failure occurring. • Document the analysis and changes made.
  4. 4. Application of FMEA in Six Sigma In Design for Six Sigma - (Design FMEA) : • to identify potential failure modes • to identify potential causes of failure • to eliminate/minimise the potential failure modes within the Design process
  5. 5. In Transactional/Operational Six Sigma (Process FMEA) : • to analyse the existing processes (identify possible x’s) • to improve the process (elimination/reduction of failure modes) • to select new process alternatives • to develop control plans
  6. 6. 10 Keys To FMEA Success • Support by top & middle management • Motivated team members • Cross functional representation on the team • Treat as “before the event” not “after the fact” • Generate company specific rating scales • Treat as a living document-reflect latest revisions • Execute recommended actions • Integration into your development process • Generate & use a library of generic FMEA’s • Follow the spirit, not the form
  7. 7. Common Mistakes • Applied too late • Poor team working, wrong team members or no team • Over dependence upon the numbers • Inconsistency in numbers • Solving all problems in meetings
  8. 8. Application of FMEA in DMAIC • Analyse: To analyse the existing processes and identify possible x’s (causes of failure) • Improve: To improve the process (elimination/reduction of failure modes) To select new process alternatives • Control: To develop control plans It is only necessary to conduct PFMEA on the modified/changed areas of the process

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