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Similar to Here is a potential FMEA for withdrawing cash from an ATM machine at night:Process/Function: Withdrawing cash from ATM at night Potential Failure Mode: Cash not dispensedPotential Effects: Customer does not receive money, becomes frustratedSeverity: 8Potential Causes: Machine runs out of cash, technical issue prevents dispensing Occurrence: 4Controls: ATM replenished daily, maintenance checks, emergency number postedDetection: 2 RPN: 128Recommended Actions: Add external security camera, increase lighting around ATM, install panic button, replenish cash more frequently at high-traffic locations.Let me know if you need
Similar to Here is a potential FMEA for withdrawing cash from an ATM machine at night:Process/Function: Withdrawing cash from ATM at night Potential Failure Mode: Cash not dispensedPotential Effects: Customer does not receive money, becomes frustratedSeverity: 8Potential Causes: Machine runs out of cash, technical issue prevents dispensing Occurrence: 4Controls: ATM replenished daily, maintenance checks, emergency number postedDetection: 2 RPN: 128Recommended Actions: Add external security camera, increase lighting around ATM, install panic button, replenish cash more frequently at high-traffic locations.Let me know if you need (20)
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Here is a potential FMEA for withdrawing cash from an ATM machine at night:Process/Function: Withdrawing cash from ATM at night Potential Failure Mode: Cash not dispensedPotential Effects: Customer does not receive money, becomes frustratedSeverity: 8Potential Causes: Machine runs out of cash, technical issue prevents dispensing Occurrence: 4Controls: ATM replenished daily, maintenance checks, emergency number postedDetection: 2 RPN: 128Recommended Actions: Add external security camera, increase lighting around ATM, install panic button, replenish cash more frequently at high-traffic locations.Let me know if you need
- 1. © Simplexiti Ltd, UK www.simplexiti.com Trainer: Sachin Agrawal Sachin@simplexiti.com Lean Six Sigma Green Belt Training Improve
- 2. © www.simplexiti.com Tools For Improve Phase 2 Pugh Metrics Work Standardisation Improve Workflow 5 S FMEA Mistake Proofing Kaizen Evaluating Solutions
- 3. © www.simplexiti.com • A systematic approach used to identify potential product or process failures and their effects • Drill down to root cause and identify actions that eliminate or reduce the failure from occurring • Performed before a process, product, or service is changed or designed • Prepared by a team representing all effected areas • A living document that is to be maintained and reviewed throughout the life of the product, process, or service 3 FMEA Summary
- 4. © www.simplexiti.com • Measure – To identify process outputs (y) that cause dissatisfaction • Analyse – To identify process inputs (x) and prioritize them • Improve – To determine root cause and to assign and implement recommended actions • Control – To be maintained as a living document as part of the ongoing control plan 4 When do I use it?
- 5. © www.simplexiti.com Approach Who is involved? • Team approach is essential • Members represent all groups affected by the process • BB or GB leads the team • Process owner owns the document and is responsible for maintaining it Preparation • Scope and boundary definition • Process map, SOP’s, C&E matrix, etc. 5
- 6. © www.simplexiti.com FMEA – Each component asks a question 6 Process Function Potential Failure Mode Potential Failure Effects S E V Potential Causes O C C Current Controls D E T R P N Actions Recommended 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 What is the Process Step or Function ? What is the Effect on the Outputs/ Customer ? What are the Causes of the Failure? How Bad is the effect? How Often does the Failure Occur? What controls exist to prevent or detect the failure? How well? What can be done? What can go wrong (create dissatisfaction)? How weak is the process?
- 7. © www.simplexiti.com7 A ctio n R esults Item / Function Potential Failure Mode(s) Potential Effect(s) of Failure S e v Potential Cause(s)/ Mechanism(s ) of Failure P r o b Current Design Controls D e t R P N Recommende d Action(s) Responsibilit y & Target Completion Date Actions Taken NewSev NewOcc NewDet NewRPN Car Tyre Function: support weight of car, traction, comfort Flat tire Stops car journey, driver and passengers stranded 10 Puncture 2 Tire checks before journey. While driving, steering pulls to one side, excess noise 6 120 Carry spare tire and appropriate tools to change tire Car owner, immideate Spare tire and appropriate tools permanently carried in trunk 4 2 6 48 Phone Answer Phone Answer on or after 5th ring Customer Hangs up, become unhappy, loss of potential sales 6 Can't hear the phone 3 Ringer set to loud 5 90 Remove music from order area Duty Manager, 1st July 2014 As Recommended 5 3 2 30 6 Phone too far to reach on time 8 Fix spot for phone handset 7 336 Buy Wireless phone headset Restaurant Owner, 1st July 2014 Too expensive deffered to next quarter 5 8 7 280 6 Staf tied up in work that cannot be interrupted 4 One staff always asign to phone duty 3 72 None None None 5 4 3 60 FMEA – Example Recommended actions can come through mistake proofing
- 8. © www.simplexiti.com Activity – FMEA 8 • Do an FMEA for withdrawing cash from ATM machine in night •Work together : 10 min •Discuss the results: 5 min