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FMEA Training

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  • A very straight forward method of understanding FMEA.Would like to have a copy of the PPT.Appreciate if you could send to padmanathan_ramannayar@yahoo.com TQ
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  • What an excellent way to understand.Very simple and straight forward.Appreciate if you could send the PPT to padmanathan_ramannayar@yahoo.com Thanks.
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  • I am teaching TQM course. Could you share me this so that i can discuss with my students . Its well organised and simple to understand. my e-mail : venkatchitti@gmail.com.
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FMEA Introduction.ppt FMEA Introduction.ppt Presentation Transcript

  • FAILURE MODE AND EFFECTS ANALYSIS (FMEA)
    Non-commercial use only without written permission.  Any unauthorized use is prohibited.
    Author – Jason R Bower
  • Knowledge Base
    Risk Assessment
    WHAT IS FMEA?
    IT’S CRITICAL!!!!!
    Quality Control
    Continuous Improvement
  • WHAT IS FMEA?
    Analysis of potential failures
    • Classification of failures by severity of the effects, how often they occur and how easily can they be detected
    • Definition of controls to prevent failures
    • What do we need to do next?
  • FMEA HISTORY
    • Originally developed in the 1940’s for the US military
    • Utilized in the Apollo space program to minimize failures of expensive prototypes
    • Ford formally brought it into the automotive industry in the 1970’s after the Pinto “thermal events”
  • FMEA HISTORY
    • Now adopted as part of APQP (Advanced Product Quality Planning)
    • Required elements of PPAP (Production Part Approval Process)
    • Design Element #4
    • Process Element #6
    • Integrated into QS-9000 & ISO/TS 16949
  • BENEFITS OF FMEA
    • Reduces costs
    • Field failure
    • Scrap
    • Prioritizes risk
    • Engineering / manufacturing knowledge base
  • BENEFITS OF FMEA
    • Prevents failures before they happen
    • Identifies critical aspects of designs and processes
    • Identifies controls needed
    • Identifies where to focus
    • Essential to Continuous Improvement
    • Essential to Quality
  • TYPES OF FMEAS
    • Design (DFMEA)
    • Process (PFMEA)
    • Other less common (Concept, System, Service, etc.)
  • Customer Requirements
    Experience / Knowledge
    WHAT MAKES AN FMEA?
    Lessons Learned
    Plan For Improvement
  • WHERE IT ALL FITS
  • PRODUCT CYCLE
    Customer Requirements
    Design
    Production
    Satisfied Customer
  • PRODUCT CYCLE
    Customer Requirements
    THE BIG QUESTION
    What is important and how are we ensuring it’s right?
    THE BIG ANSWER
    Critical Characteristics are output from DFMEA and input to PFMEA
    Design
    Production
    Satisfied Customer
  • PRODUCT CYCLE
    DFMEA
    • What do they need?
    • What’s critical?
    • What do we know?
    • What can go wrong?
    • What happens?
    Customer Requirements
    Design
    Production
    Satisfied Customer
  • PRODUCT CYCLE
    Customer Requirements
    DFMEA
    • What have we learned?
    • How can we make it better?
    • How can we reduce cost?
    Design
    Production
    Satisfied Customer
  • PRODUCT CYCLE
    Customer Requirements
    PFMEA
    • What do they need?
    • What’s critical?
    • What do we know?
    • What can go wrong?
    • What happens?
    Design
    Production
    Satisfied Customer
  • PRODUCT CYCLE
    Customer Requirements
    Design
    Production
    PFMEA & DFMEA
    • What have we learned?
    • How can we make it better?
    • How can we reduce cost?
    Satisfied Customer
  • FMEA FORM
  • EXAMPLE FMEA
    • Identifies the individual functions of components / system / process
    • Drill down
    • Be specific
  • EXAMPLE FMEA
    • Identifies the individual potential failure modes
    • Be specific
    • Avoid simple ‘anti-function’
  • EXAMPLE FMEA
    • Identifies what happens if this failure occurs
    • Be specific
    • There can be several effects – list them all
  • EXAMPLE FMEA
    • Rates the potential effects of failure
    • Rating is 1–10 based on standard rules
    • Rating is based on the most severe effect but all should still be listed
  • EXAMPLE FMEA
    • Identifies ‘Critical Characteristics’
    • Items critical to function
    • Items flagged here should show up in Control Plan
  • EXAMPLE FMEA
    • Identifies potential causes
    • Be specific
    • Include outside influences as well as those related to design (DFMEA) / process (PFMEA)
  • EXAMPLE FMEA
    • Rates the possibility of occurrence
    • Rating is 1–10 based on standard rules
  • EXAMPLE FMEA
    • Identifies what controls are currently in place
    • Good place to reference design / process standards and best practices
    • Part of the knowledge base
  • EXAMPLE FMEA
    • Rates the likelihood of detection of failure
    • Rating is 1–10 based on standard rules
  • EXAMPLE FMEA
    • Risk Priority Number
    • Severity * Occurrence * Detection
    • Ranks the potential failure modes
    • There are limitations to this number
  • EXAMPLE FMEA
    • What can be done to reduce Severity, Occurrence and Detection ratings
    • Outline for Continuous Improvement
  • EXAMPLE FMEA
    • References Recommended Action
    • Assigns ownership and timing
  • EXAMPLE FMEA
    • What was done to reduce Severity, Occurrence and Detection ratings
    • More knowledge base information
    • Continuous Improvement Record
  • EXAMPLE FMEA
    • Rerating of Severity, Occurrence and Detection ‘Actions Taken’ have been completed
    • RPN is recalculated
  • EXAMPLE DFMEA