FMEA Introduction.ppt

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FMEA Introduction.ppt

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

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