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FMEA Webinar Core Tools PDF
FMEA Webinar Core Tools PDF
Mark A. Morris
ASQ Automotive Division Webinar
mark@MandMconsulting.com
www.MandMconsulting.com
Purpose of this Course
C Action Results
Process Potential O
Step
Potential Potential S l Causes/
Current Current D R.
Responsibility
Failure Effects of e a c Process Process e P. Recommended R.
Mechanisms & Target Actions S O D
Mode Failure v s of Failure c Control Control t N. Actions
Completion Date Taken e c e P.
s (Prevention) (Detection) N.
Function v c t
Process FMEA Analysis
Process C Current
Potential Current D R.
Step Potential Potential S l O Process
Causes/ Process e P.
Failure Effects of a
e Mechanisms c Control Control t N.
Mode Failure v s c (Detection)
Function of Failure (Prevention)
s
Occurrence Detection
Severity rates how often ranks our ability
evaluates a specific cause is to detect either a
the impact likely to result in cause or a resulting
of the effect. the failure mode failure mode. Use
being analyzed. best detection
available.
• System FMEA
– Focuses on how interactions among systems might fail.
• Design FMEA
– Focuses on how product design might fail.
• Process FMEA
– Focuses on how processes that make the product might fail.
• Machinery FMEA
– Focuses on how machinery that perform processes might fail.
Design FMEA
Failure
Modes Effects Causes
Subsystem Level
Failure
Modes Effects Causes
Component Level
Failure
Modes Effects Causes
Examples of Weld Process Failure Modes
12
A Rational Structure for Quality Planning TM
Product
Product
Design FMEA
Design FMEA
Process
Process
Process FMEA
Process FMEA
Customer Plant
Customer Plant Tool
Tool Design
Design
Control Plan
Control Plan Machinery FMEA
Machinery FMEA
Internal
Internal Processes
Processes
Process FMEA
Process FMEA
Internal
Internal Process
Process
Control Plan
Control Plan
Motivation for Specific FMEAs
Product Customer
Life Design FMEA
Cycle Satisfaction
Cost
Process
Process FMEA
R&M
Internal Processes
Process FMEA
First-Time
Capability
Internal Process
Control Plan
DFMEA Information Linkages
The Underlying Message
Internal Processes
Identify and Manage
Process FMEA
Deliverables
Required for Internal Process
Build & Buy-Off
Control Plan
Three Phases of Control Plan
Phase 1 Product
Control Plan Design FMEA
for Phase 2
Prototype Process Control Plan
Process FMEA for
Pre-Production
• Cost of Defects
• Risk of Defects
• Bracketing Strategies
• Protecting On-Time Delivery
• Cost of Stopping Production
• Cost of Recall Campaigns
• Benefits of Traceability
FMEA Teams
Clearance hole
for 12 mm bolt
- Hole size
- Hole location
- Free of burrs
Identification of Failure Modes
Omission
Functional
Incorrect
of an Action Requirements
Actions
Function Function
Not Done Done Poorly
Correct
Actions
Surprise
Results
Example: Failure Modes
Spitting Paint
Function
Stream of Paint
Dispense
Paint
Properly Too Much Paint
Void in Fan
Example: Failure Modes
Intermittent Signal
Function
Hole too
small
Hole violates
MMC
boundary
- Hole location
- No burrs
Failure Mode
Identification Worksheet
Process Step: Potential Failure Modes
Functional requirements
or specifications:
5. Identify Potential Causes
Direct
Cause
Direct
Cause
FMEA Worksheet Form
Transfer of Failure Mode to Worksheet
Example of Causes
Example of Causes
Identify Causes of Failure – Traditional Format
Process C Current
Potential Current D R.
Step Potential Potential S l O Process
Causes/ Process e P.
Failure Effects of a
e Mechanisms c Control Control t N.
Mode Failure v s c (Detection)
Function of Failure (Prevention)
s
Wrong drill
size
Drill improperly
sharpened
Wrong tool
geometry for
material
- Hole depth Hole not Missing drill
drilled thru
6. Identify Potential Effects
Causes
Precede the Immediate
Failure Mode Effect
Immediate
Effect
Two Focal Points for Effects
Wrong drill
size
Drill improperly
sharpened
Wrong tool
geometry for
material
Clearance hole Hole too Bolt may not Feed rate too DOE Results Set Up
for 12 mm bolt large hold torque high Verification
- Hole size
Violation of Spindle speed DOE Results Set Up
specification too slow Verification
Occurrence Detection
Severity rates how often ranks our ability
evaluates a specific cause is to detect either a
the impact likely to result in cause or a resulting
of the effect. the failure mode failure mode. Use
being analyzed. best detection
available.
Example of Severity, Occurrence, Detection
Example of Severity, Occurrence, Detection
Prioritization of Risk
Clearance hole Hole too Bolt may not 5 Feed rate too 2 DOE Results Set Up 5 50
for 12 mm bolt large hold torque high Verification
- Hole size
Violation of Spindle speed 2 DOE Results Set Up 5 50
specification too slow Verification
Action Results
Responsibility
Recommended Actions S O D R.
& Target
Actions Taken e c e P.
Completion Date
v c t N.
10. Verify Results