Professional Documents
Culture Documents
Advanced PF Me A
Advanced PF Me A
Process Failure
Mode Effect
Analysis
CA/PA-RCA : Advanced Tool
2
Agenda
FMEA History
What IS FMEA
Definitions
What it Can Do For You
Types of FMEA
Team Members Roles
FMEA Terminology
Getting Started with an FMEA
The Worksheet
FMEA Scoring
3
Agenda Why does it always
seem we have plenty of
time to fix our
problems, but never
enough time to prevent
the problems by doing
it right the first time?
4
FMEA History
This “type” of thinking has been around for
hundreds of years. It was first formalized in
the aerospace industry during the Apollo
program in the 1960’s.
Initial automotive adoption in the 1970’s.
Potential serious & frequent safety issues.
5
What is FMEA ?
6
What is FMEA ?
Definition: FMEA is an Engineering “Reliability Tool” That:
Helps define, identify, prioritize, and eliminate known and/or
potential failures of the system, design, or manufacturing process
before they reach the customer. The goal is to eliminate the Failure
Modes and reduce their risks.
Provides structure for a Cross Functional Critique of a design or a
Process
7
What is FMEA ?
What it can do for you!
1.) Identifies Design or process related Failure Modes before
they happen.
8
Types of FMEAs ?
System/Concept “S/CFMEA”- (Driven by System functions) A
system is a organized set of parts or subsystems to accomplish one
or more functions. System FMEAs are typically very early, before
specific hardware has been determined.
9
Types of FMEAs ?
System/Concept “S/CFMEA”- (Driven by System functions) A
system is a organized set of parts or subsystems to accomplish one
or more functions. System FMEAs are typically very early, before
specific hardware has been determined.
10
The FMEA Team Roles
Champion
Champion //Sponsor
Sponsor
Provides resources & support
Provides resources & support
Attends
Attendssome
somemeetings
meetings
Promotes
Promotes teamefforts
team efforts
Shares
Shares authority / powerwith
authority / power withteam
team
Kicks
Kicksoff
offteam
team
Implements
Implementsrecommendations
recommendations
FMEA
FMEACore
CoreTeam
Team
Team Leader 44––66Members Facilitator
Members “Watchdog“ of the process
“Watchdog” of the project
Expertise Keeps team on track
Good leadership skills ExpertiseininProduct
Product//Process
Process
Cross FMEA Process expertise
Respected & relaxed Crossfunctional
functional
Honest Encourages / develops team dynamics
Leads but doesn’t dominate HonestCommunication
Communication
Active Communicates assertively
Maintains full team participation Activeparticipation
participation
Positive Ensures everyone participates
Typically lead engineer Positiveattitude
attitude
Respects
Respects otheropinions
other opinions
Participates
Participatesininteam
teamdecisions
decisions
Recorder
Recorder
Keeps documentation of teams efforts
Keeps documentation of teams efforts
FMEA
FMEAchart
chartkeeper
keeper
Coordinates
Coordinates meetingrooms/time
meeting rooms/time
Distributes
Distributesmeeting
meetingrooms
rooms&&agendas
agendas
11
FMEA Terminology
13
FMEA Terminology (continued)
14
Getting Started on FMEA
What Must be done before FMEA Begins!
Understand your
=QFD
Ready?
Customer
Needs
Determine 4 Determine5 66
Determine2
Determine1
Product or “Causes” of “Controls” Calculate &
Failure Modes The Failure
Process Assess Risk
of Function Mode
Functions Detection Rating
Occurrence Rating
15
The FMEA Worksheet
Resp. & p p p p
Product S O D R
Failure Failure Actions Target S O D R
or E Causes C Controls E P
Mode Effects / Plans Complete E C E P
Process V C T N
Date V C T N
1 2 3 4 5 6 7
Develop
Determine Determine Determine
and
Product or “Effects” of “Controls”
Drive
Process The Failure Detection
Action Plan
Functions Mode Determine Rating
Severity “Causes” of
Determine Rating The Failure Calculate
Failure Mode &
Modes Occurrence Assess
of Function Rating Risk
If an FMEA was created during the Design Phase of the Program, USE IT!
Create an Action Plan for YOUR ROOT CAUSE
and Re-Evaluate the RPN Accordingly
16
FMEA Scoring
Severity
Severity of Effect Rating
Extreme
No effect 1
17
FMEA Scoring
Occurrence
Failure Capability
Likelihood of Occurrence Rate (Cpk) Rating
Very High
1 in 2 < .33 10
Failure is almost inevitable
1 in 3 > .33 9
1 in 8 > .51 8
High
18
FMEA Scoring
Detection
Very Low Likelihood that control will detect failure Rating
9
Low
of a failure
3
Very High
19
FMEA Scoring
RPN or Risk Priority Number
The Calculation !
20
Failure Modes & Effect Analysis
(FMEA) Part or Process Improvement
FMEA is a technique utilized to define, identify, and eliminate known or
potential failures or errors from a product or a process.
Identify each candidate Part or Process, list likely failure mode,
causes, and current controls
Prioritize risk by using a ranking scale for severity, occurrence, and
detection
Mitigate risk – Can controls be added to reduce risk? Recalculate RPN.
Characteristics with high Risk Priority Numbers should be selected for
Improvement and Action Plans Created
Recalculate RPN After Completion of Action Plans to Validate
Improvements
Resp. & p p p p
Product S O D R
Failure Failure Actions Target S O D R
or E Causes C Controls E P
Mode Effects / Plans Complete E C E P
Process V C T N
Date V C T N
120
Hole Oversize Unable to Wrong Ball Gage Kit Drill
Drilling Hole Install BP 5 Drill Bit 8 Visual Insp 3 Bits
010103 51 1 5
Fastener Used
21
Failure Modes & Effect Analysis
Questions?
Call or e-mail:
22