3. Key Concepts/Tool Road Map Phase 1 Customer and Business Requirements Definition Phase 2 Conceptual Design and Feasibility Phase 3 Preliminary Design Phase 4 Detail Design Phase 5 Pilot/ Prototype Phase 6 Product & Process Validation Phase 7 Transition Validate Business Case Define Customer Requirements Assess Technology Evaluate Concepts Functional Requirements (FR) Generate Ideas Requirement Flow Down Interface Management Y Model DOE Transfer Function Simulation Build Pilot / Prototype DOE - Function Verification Y N Implement Design Solution at Production / Service Environment Supply Chain Readiness Y N Implement Design & Process Controls N CTS Risk CTS Map FR to Design Parameters (DP) Simulation Viable? DP Noise Management DFx* Return to Phases 1 or 2 Y N N Y DFSS/Improve Process Gate 1 Gate 0 Gate 2 Gate 3 Gate 4 Gate 5 Gate 6 Gate 7 Map DP to Process Variables Improve Pilot / Prototype Waste Elimination Focus/Error Proof DFx* = Design For (Manufacturability, Assembly, Reliability, etc.) Textron Deliverables Segment Specific Deliverables Test OK? Req Met? Process capable? Design FRs 6 Capable?
12. Rating Definitions High 10 Low 1 Rating Almost certain detection Failure unlikely No effect Moderate detection probability Occasional failures Minor defect Low detection probability Moderate failures Loss of secondary function Remote or low chance of detection High repeated failures Loss of primary function Cannot detect or detection with very low probability Very high and almost inevitable Hazardous without warning Detection Occurrence Severity Almost certain detection Failure unlikely No effect Moderate detection probability Occasional failures Minor defect Low detection probability Moderate failures Loss of secondary function Remote or low chance of detection High repeated failures Loss of primary function Cannot detect or detection with very low probability Very high and almost inevitable Hazardous without warning Detection Occurrence Severity
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16. Internet E-mail Response Respond to E-mail within 48 hours PEOPLE ENVIRONMENT SUPPLIES POLICIES & PROCEDURES MEASUREMENTS PLACES Frequently Asked Questions Access Policies Service Centers Training Archives Volume Address Changes General Questions Transfers to Right Team Backlog Customer Satisfaction Cycle Time PC Delays Self Training Systems Training Internet Training Available Marketing Materials New Product Info Quality Phone Support Unit Research Facilities
17. DFMEA Example E-mail Response Determine the ways in which the Design can go wrong
18. DFMEA Example E-mail Response For each Failure Mode associated with the item, determine Effects
19. DFMEA Example E-mail Response Identify potential Causes of each Failure Mode
20. DFMEA Example E-mail Response List the Current Controls for each Cause
21. DFMEA Example E-mail Response Assign Severity, Occurrence and Detection ratings to each Cause
35. 36 key process inputs were reduced to 13. Lessons learned, however = tried to fix too much with this first FMEA. Performed a second, more focused, FMEA Manufacturing Process FMEA Example
49. Detection Criteria For Design FMEA Undetectable until catastrophic occurrence in application 9-10 The failure mode will be detected prior to a catastrophe in application 7-8 Will be detected prior to shipping out the finished product or service 5-6 Will be detected after release but prior to mass production is started 3-4 Will be detected prior to releasing for production 1-2 EXAMPLE RANK
50. 1,2 Cosmetic Error No loss in product functionality. Includes incorrect documentation 3,4 Product Performance Reduction - Temporary Through time-out or system load the problem will “go away” after a period of time 5,6 Functional Impairment / Loss The problem will not resolve itself, but a “work around” can temporarily bypass the problem area until fixed without losing operation 7,8 Functional Impairment / Loss The problem will not resolve itself and no “work around” can bypass the problem. Functionality has either been impaired or lost but the product can still be used to some extent 9,10 Product Halts / Process Taken Down / Reboot Required The product is completely hung up, all functionality has been lost and system reboot is required Severity Guidelines Software FMEA Scoring Example
51. Rate of Occurrence Scale 1 1 per 100 units- years (1/50m) 2 1 per 10 unit-years (1/5m) 3 1 per 1 unit-year (1/525k) 4 1 per 1 unit-month (1/43k) 5 1 per week (1/10k) 6 1 per day (1/1440) 7 1 per shift (1/480) 8 1 per hour (1/60) 9 1 per 10 min (1/10) 10 1+ per min (1/1) Software FMEA Scoring Example 1,2 Requirements / Design Reviews 3,4 Code Walkthroughs / Unit Testing 5,6 System Integration & Test 7,8 Installation & Start-up 9,10 Detectable only once “on line” Detection Scale
57. Configuration Management Update Roadmaps Block Change Release N.C. Zimba 1/2005 5.0 Block Change Release S. Ford et al 8/2004 3.0 Description of Change Author Date Revision
Editor's Notes
The module currently has a service example from slide 15 to 24. A product example in the appendix (slides 40 – 48) may be substituted.
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