Advanced Powertrain
Control Symposium 9th July
2013
Vlkommen, welcome, hun yng, welkom, Bienvenue,
willkommen, fogadtats, benvenuto, velkommen, powitanie, bem05/07/2013
www.fmea.co.uk
1
vindo, croeso
, bienvenido, vtejte
The Effective Application of
FMEA
Who am I?
What is FMEA?
Why do FMEA?
Application of FMEA
A Structured Approach
Effective FMEA
Use Software for FMEA
Use an FMEA Facilitator
05/07/2013
www.fmea.co.uk
What is FMEA?
Contrary to popular belief FMEA is actually an acronym for a risk analysis
called Failure Modes & Effects Analysis, and not Five Men Endlessly
Arguing.
Failure Modes & Effects Analysis is an activity that brings
minds together in a collaborative and pre-emptive way in
order to avoid failure of a system!
FMEA is a systematic procedure that focuses on a system(s) in order to
uncover weaknesses, i.e. what can go wrong, what could possibly
cause it and what are the potential effects. FMEA then focuses on
these weaknesses with the objective of making them obsolete, or by
reducing the likelihood of failure (or risk of failure) though the
implementation of corrective methods, which in turn optimises the system.
05/07/2013
www.fmea.co.uk
What is FMEA?
FMEA is a living document and if used correctly records:
intellectual property
weaknesses within the system
quantified risk of system failure
mistakes made
solutions to problems
responsibility for controls methods
Failure are any potential errors or defects within a process, design,
or part, especially ones that affect the customer, environment and
law.
05/07/2013
www.fmea.co.uk
What is FMEA?
1949
1963
1965
1975
1977
1980
1986
1992
2008
05/07/2013
US Military (MIL-P-1649)
NASA
Aerospace Industry
Nuclear Industry
Ford Motor Company
DIN 25448
VDA Volume 4
Ford, Chrysler & GM
AIAG
Is universally accepted as an engineering tool
www.fmea.co.uk
Why do FMEA?
Cost reduction and increased profits
Demand for higher quality
Extended warranty periods
Product liability
Quality standard demands
Retention of knowledge
Make processes more robust
Enhanced communication within the business,
customer & suppliers
Shorter development times
Functional Safety & Reliability
05/07/2013
www.fmea.co.uk
Application of FMEA
05/07/2013
www.fmea.co.uk
Application of FMEA
There are two main schools of thought
about the methodology to use and which
is most effective?
Rose with a different name
Procedure
Document formats
Adherence to ISO / TS 16949
Basis for ISO / TS 26262
05/07/2013
www.fmea.co.uk
Application of FMEA
To get the best out of FMEA you should have:
Cross functional team
FMEA Moderator / Facilitator
Props and documentation
Structured approach
FMEA Software
Management Support!
05/07/2013
www.fmea.co.uk
A Structured Approach
05/07/2013
www.fmea.co.uk
10
Effective FMEA
Step 1: Visual representation of the scope
Inner Race Spline
Inner Race
Inner Race Track
Inner Race Sphere
Outer Race Sphere
Outer Diameter
Outer Race
Outer Race Track
Outer Race Spline
Thread
CV Joint
Windows
Cage
Cage Sphere
Hole
ABS Ring
Ball Bearing
Grease
Clip
Shield
05/07/2013
www.fmea.co.uk
11
Effective FMEA
Step 2: Runs in line with other engineering
techniques, such as Function Analysis System
Technique (FAST)
Capacitor #38
Filter noise
Accelerator input circuit
Conditions accelerator target wiper
signal
Electronic drive control
Sends a timely motor speed target to the
controllers
Monolithic integrated low dropout
voltage tracker
Mirrors input voltage to output voltage
Accelerator input circuit
Provides specified voltage stimulus for
the accelerator pedal target point
Capacitor #39
Filter noise
Diode #6
Protection
Programmed Microcontroller
Provides accelerator target stimulus
PCB circuit track
Maintain electrical continuity
Why?
Effects
05/07/2013
Mode
www.fmea.co.uk
How?
Causes
12
Effective FMEA
Focus on functions provide guidance for the
Short
analysis of failures, or step 3.
Signal stuck at ground
Signal stuck at
specified voltage
Signal is corrupted
Monolithic integrated low dropout
voltage tracker
Mirrors input voltage to output voltage
Accelerator input circuit
Conditions accelerator target wiper
signal
Electronic drive control
Sends a timely motor speed target to the
controllers
Accelerator input circuit
Provides specified voltage stimulus for
the accelerator pedal target point
Effects
05/07/2013
Open
Capacitor #38
Filter noise
Loss of Voltage
stimulus
Corrupted Voltage
stimulus
Voltage stimulus when
not required
Mode
www.fmea.co.uk
Capacitor #39
Filter noise
Diode #6
Protection
Programmed Microcontroller
Provides accelerator target stimulus
PCB circuit track
Maintain electrical continuity
Causes
13
Effective FMEA
Step 3: Efficient construction of effective possible
failure scenarios
Capacitor #38
Short
Monolithic integrated low dropout voltage
tracker
Output loss when input is high
Accelerator input circuit
Point of target wiper signal stuck at ground
Accelerator input circuit
Loss of voltage stimulus for accellerator
pedal target point
Diode #6
Shorted to ground
Diode #6
Open
Programmed Microcontroller
Output stuck low
PCB circuit track
Loss of electrical continuity
Effects
05/07/2013
Mode
www.fmea.co.uk
Causes
14
Effective FMEA
Step 4: Possible failure scenarios are displayed in
a fashion that is consistent with previous steps
Failure Effect(s)
05/07/2013
Failure Mode
www.fmea.co.uk
Failure Cause(s)
15
Effective FMEA
AIAG form can be unintentionally misleading
Effects
Mode
05/07/2013
Causes
www.fmea.co.uk
16
Effective FMEA
E=MC2
VDA form is logical
Effects
05/07/2013
Mode
www.fmea.co.uk
Causes
17
Effective FMEA
Step 4: Ensuring that only the controls that
are currently in fruition are considered
when calculating the risk
05/07/2013
www.fmea.co.uk
18
Effective FMEA
Step 4: Analysis of the data using RPN is
not just 1-1000, there are 120 values that
can result from SxOxD, which may not
reflect criticality.
05/07/2013
www.fmea.co.uk
19
Effective FMEA
Common sense shall prevail by looking at
the risk assessment results in a different
way e.g.:
Automotive
risk model
05/07/2013
www.fmea.co.uk
20
Effective FMEA
Step 5: Reduction of the risk is displayed
in a Chronological order
05/07/2013
www.fmea.co.uk
21
Effective FMEA
Create your own descriptions of the risk
factors of Severity (S), Occurrence (O) and
Detection (D):
Reflect what you do as a business
Reflect the product you make
Is there a customer mandate?
Using rule of thumb statements &
benchmark examples
Use AIAG descriptions as guidance*
05/07/2013
www.fmea.co.uk
22
Use Software for FMEA
Due to the complexities of modern products
& processes, software is essential. Many
companies use MS Excel, but dedicated
software can provide a visual
representation of:
the system analysed
interfaces between sub-systems, plus
inputs and outputs
complex relationships between the failures
05/07/2013
www.fmea.co.uk
23
Use Software for FMEA
In addition to this dedicated software allows the
FMEA to:
be filtered or colour coded according to your
own criteria
produce additional statistical data and
additional quality documentation as a
consequence
Switch easily between FMEA form layouts
handles variances
Supports delegation and tracking of corrective
measures
05/07/2013
www.fmea.co.uk
24
Use an FMEA facilitator
Experienced FMEA facilitation will ultimately
save time and make meetings more focused &
constructive.
An experienced FMEA facilitation minimises
digression into different types of FMEA.
An external FMEA facilitator may ask the stupid
questions that may have been overlooked as
they may be thinking outside of the box
An effective FMEA records intellectual capital for
the future developments (semantics)
05/07/2013
www.fmea.co.uk
25
tack ,
ksznm,
thanks , xixie , d a n k u w e l , merci , da n ke ,
grazie,
tak , d zi k u j , obrigado , diolch ,
d ku j ,
gracias,
akujem
078 999 625 53 - 01785 711 296
gavin@fmea.co.uk
Penkridge, Stafford, ST19 5TE. UK
05/07/2013
www.fmea.co.uk
26
