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PFMEA refresher training for the beginners to help them
- 1. General Confidential Property ofSchneider Electric PFMEA Refresher Training – Chennai
- 2. General Confidential Property ofSchneider Electric | • FMEA (failure mode and effects analysis) is a step-by-step approach for collecting knowledge about possible points of failure in a design, manufacturing process, product or service • Failure mode and effects analysis is the process of reviewing as many components, assemblies, and subsystems as possible to identify potential failure modes in a system and their causes and effects • FMEA is a risk management tool. By systematically analyzing failure modes and their outcomes, organizations can identify and prioritize risks FMEA ? • Process failure mode and effects analysis (PFMEA) is part of the larger failure mode and effects analysis (FMEA) family. PFMEA is a risk management tool that assesses potential failures of a process. PFMEA identifies possible failure points in a process, documents their causes, and effects, suggests corrective actions and action to mitigate risks, and reduces the likelihood of those causes and effects
- 3. General Process Failure Modeand Effect Analysis Confidential Property of Schneider Electric Process Failure Mode and Effect Analysis is a tool used commonly by methods and quality engineers to identify , assess, prevent or reduce the risks in a process. PFMEA Example Quality Basics Global Supply Chain Process/ Function Sub-Process / Sub-Function Potential Failure Mode Pot. Local Effect Pot. Next Effect Potential End Effect S e v Potential Causes O c c Current Preventive Controls PY Current Detection Controls JD D e t R P N Recommended Action Responsibl e Target Date Status Action Results S e v ' O c c ' D e t ' R P N ' PY/JD Coverag e Printing route card + individual Label Select "Order Waitng" and "Manual" Wrong selection Cannot print the route card N/A N/A 1 Miss process 7 None N Cannot continue to the next step Y 1 7 None Y Printing route card + individual Label Select Reference Running Wrong reference Wrong product made Excess product N/A 1 Miss process 7 None N Visual by Captain CELL N 10 70 None N Printing route card + individual Label Input Quantity Running Over Quantity Excess product N/A N/A 1 Miss process 7 None N Visual by Captain CELL N 10 70 None N Printing route card + individual Label Input Quantity Running Less Quantity Product incomplete N/A N/A 1 Miss process 7 None N Visual by Captain CELL N 10 70 None N Printing route card + individual Label Put chop for sampling batch Missing chop Batch not tested Risk non conform product escape Risk ro product performance 4 Miss process 1 To print 100% inspection remark automatically in route card N Visual by Captain CELL with visualization on monitor N 10 40 None N Printing route card + individual Label PCBA Selection Wrong use PCBA N/A No output Product functional 7 Miss process 7 None N Go nogo check N 4 196 To create system for scan PCBA and link to route card Lano Q1 2017 Closed 4 1 10 40 N What is a RISK ? It is the possibility of making a mistake along the process which can affect the customer It is assessed by identifying the potential failure modes in each process step It is critically defined by the product of Severity (S) x Occurrence (O) It is prioritized thru Risk Priority Number (RPN) which is the product of Severity (S) x Occurrence (O) x Detection (D) Actions are required for RPNs more than 112 or Severity of 9 or 10 regardless of “O” and “D” rating to reduce the risks. Why is it important? It helps us identify potential defects and prevent them before they even reach our customers What must you do? Always follow the controls defined in Process Control Plans and CTQ’s in OWS/JBS
- 4. General Process Flow Diagram ConfidentialProperty of Schneider Electric Process flow diagram (PFD) is a picture of separate steps of a process in a sequential order. Elements that may be included are: sequence of actions, decisions that must be made, time involved at each step and/or process measurements. Standard Flowchart Symbols PROCESS Any kind of processing function TERMINATOR Start or End of process flow DECISION A decision or switching type function CONNECTOR LINES Used to describe the logic flow between symbols. Arrowheads are used when the flow is to the left or up ON-PAGE REFERENCE Cross-reference within the same page of the flowchart OFF-PAGE REFERENCE Cross-reference to another page of the flow chart Quality Basics Global Supply Chain
- 5. General Process Control Plan ConfidentialProperty of Schneider Electric Process Control Plan (PCP) is a method for documenting the functional elements of quality control in a manufacturing process that are to be implemented in order to assure that quality standards are met for a particular product. It is built from the Product Quality Control Plan and PFMEA analysis. Quality Basics Global Supply Chain 1. Process Identification - records all the process steps linked to the process flow diagram Plant: SENSOR Process Control Plan Process: Product: XS156 Index Date 6-May-17 28-Jul-17 Cutting and soldering diameter 08 Temperature Solder 375 - 385 °C Temp Calibration Critical Manual Thermocouple 1 per Shift LI Form 2020106 - 102 00 Soldering Cell 1 Adjust the temperature, change the iron tip or call technician Orientation of Coil Coil must in the right orientation Major Poka Yoke Jig 100% 100% Operator Scrap Orientation of LED LED must bend to the right position Major Visual Jig 100% 100% Operator Scrap OWS: 72247 Continuity (Functional -- > Go No Go Test) Product is able to detect object and LED able to switch ON and OFF Major Jidoka Go No Go Tester 100% 100% Operator Scrap OWS: 72247 Temperature +70 degree +1/-3 Major Manual Thermocouple 1 every 6 months Metrology Adjust the temperature, or call technician Duration 1 Hour Major Manual Stop watch 100% 100% Operator Route Card call supervisor OWS: 72247 Objet Created by Verified by Comments Add MRKP from PQCP for Waterproof flow Lano Lano Manufacturing Process identification Specification Measurements Sampling Strategy Action and Documention Change QRD number ( & modify content) on first filling and Secmer due to Low pressure issue Frequency Who/What Measures Where recorded Reaction Plan (Decision Rule) Instruction Limits Mandatory Requirements for Key Process Intrinsic Criticity Type of inspection or control Mean/Tool Dummy Sample Size Step Operation Machine / Station / Tool Type: Manual Automatic Semi-automatic Product Parameter Process Parameter 4 Cutting and soldering diameter 08 Cutting and soldering diameter 08 Manual Oven 4. Action and Documentation- finally what should happen when the step goes out of control 4 KEY ELEMENTS OF PCP 2. Specification Measurements- a detailed description of what has to be Controlled 3. Sampling Strategy- how the step will be controlled Why is it important? It defines the process controls in place and their criticality to detect and prevent occurrence of defects along the process What must you do? Consistently follow the controls defined in Process Control Plans
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Editor's Notes
- #4 Process Failure Mode and Effect Analysis is a tool used commonly by methods and quality engineers to identify , assess, prevent or reduce the risks in a process. A Risk is the possibility of making a mistake along the process which can affect the customer It is assessed by identifying the potential failure modes or possible defects in each process step. It is critically defined by the product of Severity multiplied by Occurrence It is measured thru Risk Priority Number (RPN) which is the product of Severity (S) Multiply Occurrence (O) Multiply Detection (D) Actions are required for RPNs more than 112 or Severity of 9 or 10 regardless of “O” and “D” rating to reduce the risks. PFMEA helps us identify potential defects and prevent them before they even reach our customers. A cross function team composed of Quality, Methods, Maintenance Engineers, Technical Antenna and Production Supervisors are involved in the preparation of PFMEA. As an operator, you must always follow the controls defined in your Process Control Plan and CTQs in your OWS & JBS
- #5 Process Flow diagram is a picture of separate steps of a process in a sequential order. Elements that may be included are: sequence of actions, decisions that must be made, time involved at each step and/or process measurements. It is composed of different symbols to represent each step type. A rectangle represents the process or any kind of processing function An oval is a terminator that represents the start or end of process flow A connector line is used to describe the logic flow between symbols with arrowheads that are used to show the flow direction A circle is an on-page reference within the same page of the flowchart A diamond represent a decision or switching type function normally answerable by yes or no or pass or fail A pentagon is an “off page” reference to cross-reference the flowchart in another page You may refer to the process flow diagram to know the complete manufacturing steps of your product.
- #6 Process Control Plan (PCP) is a method for documenting the functional elements of quality control in a manufacturing process that are to be implemented in order to assure that quality standards are met for a particular product. It is build from the Product Quality Control Plan or PQCP and PFMEA analysis. It is divided into 4 sections such as : 1. Process Identification - records all the process steps linked to the process flow diagram 2. Specification Measurements- a detailed description of what has to be Controlled 3. Sampling Strategy- how the step will be controlled 4. Action and Documentation- finally what should happen when the step goes out A PCP defines the process controls in place and their criticality to detect and prevent occurrence of defects along the process. Examples are torque value verification ,use of special jigs or SPC application. As an operator you must consistently follow the controls defined in your process control plans without deviation.
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