FMEA Introduction.ppt

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
Design
Production
Satisfied Customer

PRODUCT CYCLE
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?
Design
Production
Satisfied Customer

PRODUCT CYCLE
DFMEA
What have we learned?
How can we make it better?
How can we reduce cost?
Design
Production
Satisfied Customer

PRODUCT CYCLE
PFMEA
What do they need?
What’s critical?
What do we know?
What can go wrong?
What happens?
Design
Production
Satisfied Customer

PRODUCT CYCLE
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

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

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

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FMEA Introduction.ppt

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