Lecture: FMEA

Subject: What is FMEA ?

FMEA
Failure Mode Effect Analysis

A risk analysis

Identify & Evaulate

Potential Risks

Risk mitigation

«Meant to be BEFORE-THE EVENT»

Lecture: FMEA
Subject: Why is so important ?

Safety issues

Warranty problems

Recall ! – The worst scenario

--

First Time Quality

Lecture: FMEA
Subject: History of FMEA ?

In the late 1940’s

WW2 – Military Reasons
By reliability engineers

Popularity
APOLLO program of NASA
1960-1970

1980
FORD
To solve quality problems of PINTO
Lecture: FMEA
Subject: Brief Flow of FMEA

1_EVAULATE POTENTIAL FAILURES

2_RPN NO
(Severity x Occurence x Detection)

3_PIORIZATION

4_IDENTIFY ACTION

5_DOCUMENT PROCESS
Lecture: FMEA
Subject: When We need/review FMEA

1_New design / process

2_Modifications

3_Customer Claims

4_Warranty issues

5_Improvement activities
Lecture: FMEA
Subject: STEPS 1-2-3 (Team)

Team agree
elements to be analyzed.

Detailed flow diagram

will be prepared.
Should include all steps.

A system boundary
will be defined.

Team decides to analyze

interactions or not.
Lecture: FMEA
Subject: STEP 4 (Inputs)

Warranty/recall data

Internal scraps information

Enginnering specs / req.

Drawings

Previous FMEAs

Lesson Learnts / Best Practice

Lecture: FMEA
Subject: STEP 5 (Function & Requirement)

FUNCTION – REQUIREMENT

PROCESS – LOAD – UNLOAD

REQUIREMENT
HARDNESS
OUTSIDE DIAMETER
Lecture: FMEA
Subject: STEP 6 (Failure Mode)

FAILURE MODE

HOLE TO SHALLOW
HOLE TO DEEP
DEFORMED
Lecture: FMEA
Subject: STEP 7 (Potential Effects)

POTENTIAL EFFECTs

NEXT PROCESS
CURRENT PROCESS
CUSTOMER
Lecture: FMEA
Subject: STEP 8 (Severtiy Ranking Number)

Excel

SEVERITY

For 10 & 9 rankings,

Action must be taken.
Lecture: FMEA
Subject: STEP 9 (Classification)

CLASSIFICATION

Report/Safety

Critical
Lecture: FMEA
Subject: STEP 9 (Classification)

CLASSIFICATION

Report/Safety

Critical
Lecture: FMEA
Subject: STEP 10 (Potential Causes)

POTENTIAL CAUSE fo
FAILURE

4M:
Machine
Method
Material
Man

5Why
Lecture: FMEA
Subject: STEP 11 (Occurence)

Excel

OCCURENCE
Lecture: FMEA
Subject: STEP 12 (Process Controls)

Process Controls

Prevention !
Do not make mistake.

Detection !
If you did it,
Block it.
Lecture: FMEA
Subject: STEP 13 (Process Controls) https://www.youtube.co
m/watch?v=guluDl8QDS
M

PREVENTION
ERROR PROOFING
EQUIPMENT MAINTENANCE
WORK INSTRUCTION

DETECTION
GAUGING
END OF LINE CONTROL
VISUAL CONTROL

Excel
Lecture: FMEA
Subject: STEP 14 (Process Controls)

Detection Ranking

Excel
Lecture: FMEA
Subject: STEP 15 (RPN)

RPN:
Severity
x
Occurence
x
Detection

Not absolute criteria

an indicator of
improvement
Lecture: FMEA
Subject: STEP 16 (Actions...)

ACTIONs

Recomended actions
Responsbility
Target Completion
Date

Örnek