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FMEA.pptx
- 1. FMEA –Failure Modeand Effect Analysis FMEA is the analysis of potential failure of a product or process that affects the function partially or completely Types of FMEA • DFMEA – Design • PFMEA – Process • Others (Concepts, Systems, Service, etc,.) Design FMEA • Design FMEA aids in the design process by identifying known and upcoming Failure modes and then ranking failures according to relative impact on the product. • Hence Design FMEA focuses on relative impact of the failure mode on the product Process FMEA • Process identifies potential process failure modes by ranking failures and helping to establish Priorities according to the relative impact on the internal or external customer. • Hence Process FMEA focuses on relative impact of the failure mode on internal or external Customer.
- 2. • Severity -Classification of failure by severity of the effects • Occurrence - How often they occur • Deduction - How easily can they deducted RPN (Risk priority number) = Severity X Occurrence X Deduction Cause Failure mode Effect Control Process Calculate RPN Re-calculate RPN Recommended action, if need. • The RPN gives us a relative risk ranking. • The higher the RPN, the higher the potential risk. • An organization may decide any RPN above a maximum target of 200 presents an unacceptable risk and must be reduced. • Severity will not change, when recalculating RPN. Define S, O, D
- 3. 1) Specifying possibilities •Functions • Possible feature modes • Root causes • Effects • Deduction / Prevention Stages of FMEA documentation 2) Quantifying Risk • Severity of effect • Occurrence of failure (probability of cause) • Deduction (effectiveness of control to prevent cause) • RPN (Risk priority number) 3) Correcting high causes • Prioritizing work • Detailing action • Assigning action responsibility • Check point on completion 4) Re-evaluating Risk • Recalculation of RPN
- 4. FAILURE MODE ANDEFFECTS ANALYSIS Item: Responsibility: FMEA number: Model: Prepared by: Page : Core Team: FMEA Date (Orig): Rev: Process Function Potential Failure Mode Potential Effect(s) of Failure S e v C l a s s Potential Cause(s)/ Mechanism(s) of Failure O c c u r Current Process Controls D e t e c R P N Recommended Action(s) Responsibility and Target Completion Date Action Results Actions Taken S e v O c c D e t R P N
- 5. FAILURE MODE ANDEFFECTS ANALYSIS Item: Drill Hole Responsibility: AAA FMEA number: 123456 Model: Current Prepared by: BBB Page : 1 of 1 Core Team: AAA (Engineering), BBB (Production), CCC (Quality) FMEA Date (Orig): 1/1/2021 Rev: 1 Process Function Potential Failure Mode Potential Effect(s) of Failure S e v C l a s s Potential Cause(s)/ Mechanis m(s) of Failure O c c u r Current Process Controls D e t e c R P N Recommended Action(s) Responsibility and Target Completion Date Action Results Actions Taken S e v O c c D e t R P N Drill Blind Hole Hole too deep Break through bottom of plate 7 Improper machine set up 3 Operator training and instructions 3 63 0 Hole not deep enough Incomplete thread form 5 Improper machine set up 3 Operator training and instructions 3 45 0 hole missing Tool life 5 Broken Drill 5 None 9 225 Install Tool Detectors BBB 3/1/2021 5 5 1 25 0 0 0 0
- 9. Benefits of FMEA •Prevent failures before they happen. • Identifies where to focus • Improves the quality, reliability, and safety of the process • Reduces process development time, cost • Documents and tracks risk reduction activities • Helps to identify critical-to-quality characteristics • Provides historical records; establishes baseline • Helps increase customer satisfaction and safety