How to audit fme as using quality objectives preliminary exercise


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An exercise for the Achieving Effective FMEAs short course

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How to audit fme as using quality objectives preliminary exercise

  1. 1. Example FMEA Audit For this presentation, a truncated portion of a fictitious Design FMEA on a Bicycle Hand Brake Subsystem will be audited This FMEA has been selectively modified with errors for evaluation of the 10 FMEA Quality Objectives. Exercise: for each of the 10 FMEA quality objectives, review the FMEA example to assess how well it achieves the FMEA Quality Objective. Make note of how well this objective was achieved. Explain. 1
  2. 2. Excerpt from Hand Brake Subsystem Design FMEA (with errors introduced for FMEA Quality Objectives evaluation) Classification Potential S Potential O Current Design Current Design D R Item / Potential Effect(s) of E Cause(s) of C Controls Controls E P Recommended Actions Function Failure Mode V C Failure Failure (Prevention) (Detection) T NHand Brake Insufficient friction Bicycle wheel does 10 Cable Binds due to 4 Design review of Bicycle system 2 80 Modify bicycle durability testingSubsystem: delivered by hand not slow down inadequate lubrication brake system durability test # 789 to include periodic brake cableProvide the correct brake subsystem when the brake or poor routing checks for bindinglevel of friction between brake pads lever is pulled External foreign 2 3 60 Modify bicycle durability testingbetween brake and wheels during potentially resulting material reduces to include foreign materialpad assembly and heavy rain in accident. friction (dust, leaves, etc.) at interfacewheel rim to safely conditions. of brake pad and wheel rimstop bicycle in therequired distance, Cable breaks 6 Cable material Bicycle system 4 240 1. Require cable DFMEA /under all operating selection based on durability test # 789 PFMEA from supplier approvedconditions. ANSI #ABC. by All-Terrain FMEA team. 2. Based on results of Cable DFMEA, develop cable strength test TRUNCATED Brake Lever breaks 1 Design review of Bicycle system 1 10 brake system durability test # 789 Selected brake pad 2 2 40 Add bench test to evaluate material does not adequate brake pad friction apply required friction to wheelHand Brake Brake system Brake system does 10 Brake cable mis- 6 Bicycle system 5 300 1. Develop new brake cableSubsystem: misadjusted by not stop bicycle in adjusted by user durability test # 789 adjustment test that identifiesBrake system is bicycle user required distance mis-adjustment problemseasy to adjust and or is erratic, 2. Revise bicycle durability testkeep in optimal potentially resulting regimen to periodically checkworking order. in accident. for brake cable, pad and lever mis-adjustment Brake pad mis- 1 Design review of Bicycle system 1 10 adjusted by user brake system durability test # 789 Brake lever mis- 1 Design review of Bicycle system 2 20 adjusted by user brake system durability test # 789 Brake becomes mis- adjusted due to failure of interface between brake cable assy, brake pad assy and/or wheel assy. 2 Excerpted from Effective FMEAs, by Carl S. Carlson, John Wiley & Sons, © 2012, all rights reserved TRUNCATED
  3. 3. Example FMEA AuditGeneral Information The FMEA team is made up of a bicycle design engineer and a bicycle test engineer, in support of a new all-terrain bicycle due to be launched soon. The FMEA was completed 4 weeks after design freeze, after testing had begun. The FMEA team prepared for the FMEA project by studying drawings and sketches for the hand brake subsystem. When the FMEA was completed, the bicycle test engineer thought the result was value added; however the bicycle design engineer thought the analysis was a waste of time. 3