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Failure Mode and Effects Analysis based on FMEA 4 th Edition Mark A. Morris ASQ Automotive Division Webinar November 30, 2011

[email protected] www.MandMconsulting.com

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Purpose of Purpose of this Course • Enab Enable le pa part rtic icip ipan ants ts to to und under erst stan and d the the importance of FMEA in achieving robust capable designs and processes. • Teac Teach h par parti tici cipa pant nts s how how to impr improv ove e the the efficiency and effectiveness of their FMEA efforts. Get Get tthe he righ rightt p

ple ple i

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d i th

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Learning Objectives Participants will be able to: 

Explain the purpose, benefits and objectives of FMEA.



Select cross-functional teams to develop FMEAs.



Develop and complete a FMEA.



Review, critique, and update existing FMEAs.



Manage FMEA follow-up and verification activities.



















Changes in Changes in the FMEA Manual (4th Ed.) • • • • • • •

Imp mpro rove ved d fo form rma at, easie asierr to read read.. Bet ette terr exa exam mples ples to imp improve rove utili tilitty. Rein Re info forc rces es ne need ed fo forr man manag agem emen entt sup suppo port rt.. Stre St reng ngth then ens s link linkag age e betw betwee een n DFME DFMEA/ A/PF PFME MEA. A. Rank Ra nkin ing g tab table les s bett better er refl reflec ectt rea reall wor world ld use use.. Intr In trod oduc uces es alte altern rnat ativ ive e me meth thod ods s in in use. use. Sugg Su gges ests ts be bett tter er me mean ans s tha than n RP RPN N to to ass asses ess s risk risk..



















Process FMEA Report POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (Process FMEA) Item _________________________________ Model Year(s) Program(s) ________________

FMEA Number ___________ Page _____ of ______

Process Responsibility ______________________

Prepared by _________________________

Key Date _________________________________

FMEA Date (Orig.) _______ (Rev.) _______

Core Team ________________________________________________________ _______________________________________________________________________________________________ _________________________________________________________________ __________________________ Process Step Function

Potential Failure Mode

Potential Effects of Failure

S e v

C Potential O l Current a Causes/ c Process Mechanisms s c Control s of Failure (Prevention)

Action Results Current Process Control (Detection)

D e t

R. P. N.

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S O D e c e v c t

R. P. N.



















Process FMEA Analysis Process Step Function

Process Step is simply the focus of the analysis



S e v

Describe how the item could potentially fail to perform its function

State the effects of the failure in Describe terms of the specific the function or system, subsystem, requirement to or component

C l a s s

Potential Causes/ Mechanisms of Failure

O c c

Current Process Control (Prevention)

Identify potential causes of the item not performing its intended function

Current Process Control (Detection)

D e t

R. P. N.

This column is used to document methods that have been used to detect either the cause or the failure mode

This column is reserved for the methods that have been used to





















Process FMEA Analysis Process Step Function



Severity evaluates

S e v

C l a s s


O c c


Occurrence rates how often


D e t

Detection ranks our ability

R. P. N.



















Four Common Classes of FMEA • System FMEA – Focuses on how interactions among systems might fail.

• Design FMEA



















AIAG Model for Quality Planning



















Understanding a Failure Sequence

Cause Detection

Failure Mode Detection



















Is it a Cause Cause or or Failure Mode ? ? System Level Failure Modes

Effects

Causes





















Examples of Weld Process Failure Modes



















A Rational Structure for Quality Planning

TM



















Motivation for Specific FMEAs



















DFMEA Information Linkages



















The Underlying Message







































































































































































































































Identi Ide ntify fy Proces Process s and Functi Function on – Traditi Traditional onal Forma Formatt Process Step Function Clearance hole for 12 mm bolt - Hole si size - Hole Hole loca locati tion on - Free Free of burr burrs s



S e v

C l a s s


O c c



D e t

R. P. N.



















Identification of Failure Modes Omission of an Action

Function Not Done

Functional Requirements

Incorrect Actions

Function Done Poorly

Correct



















Example: Failure Modes Color Change System Spray Paint

Function Dispense Paint Properly

Failure Modes No Paint Spitting Paint Stream of Paint Too Much Paint Too Little Paint



















Example: Failure Modes Color Change System Measure Fluid Flow

Function

Failure Modes No Feedback Signal Intermittent Signal Signal Too High

Send Accurate Feedback Signal

Signal Too Low Feedback Signal with No Flow



















Example of Failure Modes





















Example of Failure Modes



















Identi Ide ntify fy Proces Process s and Functi Function on – Traditi Traditional onal Forma Formatt Process Step

Function Clearance hole for 12 mm bolt - Hole size


No hole Hole too large


S e v

C Potential l Causes/ O a Mechanisms c s c of Failure s



D e t

R. P. N.



















Failure Mode Identification Worksheet Process Step:

Potential Failure Modes



















5. Identify Potential Causes • Pote Potent ntia iall cau cause se of fa faililur ure e des descri cribe bes s how how a pro proce cess ss failure could occur, in terms of something that can be controlled or corrected.



















Causes

Direct Cause

Causes Precede the Failure Mode





















FMEA Worksheet Form



















Transfer of Failure Mode to to Worksheet



















Example of Causes



















Example of Causes



















Identi Ide ntify fy Cause Causes s of Failu Failure re – Tradit Traditiona ionall Format Format







































































































































































































































Assess Severity, Occurrence, Detection Process Step Function



Severity evaluates the impact of the effect.

S e v

C l a s s


O c c


Occurrence rates how often a specific cause is likely to result in the failure mode being analyzed.


D e t

Detection ranks our ability to detect either a cause or a resulting failure mode. Use best detection available.

R. P. N.



















Example of Severity, Occurrence, Detection



















Example of Severity, Occurrence, Detection



















Prioritization of Prioritization of Risk Several strategies exist for the mitigation of risk, for example: 1. High Ri Risk Pr Priority Nu Numbers 2. Hi High gh Se Seve veri rity ty Ri Risk sks s (reg (regar ardl dles ess s of RP RPN) N) 3. Hi High gh De Desi sign gn Ri Risk sks s (Sev (Sever erit ity y x Occu Occurr rren ence ce)) 4. Oth Other Alte Altern rnat ativ ives es (S, (S,O,D O,D) an and (S, (S,D) D)



















Identi Ide ntify fy Current Current Cont Controls rols – Tradit Traditiona ionall Format Format Process Step Function Clearance hole for 12 mm bolt - Hole size


Hole too large


S e v

Bolt may not 5 hold torque Violation of specification

C Potential l Causes/ O a Mechanisms c s c of Failure s



D e t

R. P. N.

Feed rate too 2 DOE Results high

Set Up Verification

5

50

Spindle speed 2 DOE Results too slow

Set Up Verification

5

50

Wrong drill size

2

First Piece Inspection

5

50

Dull drill bit

4

Load Meter

2

40

Drill improperly 2 sharpened

Set Up Verification

5

50

Wrong tool

Set Up

5

50

2 DOE Results





















9. Recommend Actions • The The int inten entt wit with h rec recom omme mend nded ed acti action ons s is is to to reduce risk.



















Managing Recommended Actions • Tran Transf sfer er FMEA FMEA acti action on item items so ont nto o tthe he me mech chan anis ism m used to track and ensure closure of open issues on the project.



















Recommended Actions Action Results Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S O D e c e v c t

R. P. N.



















10. Verify Results

• When Whenev ever er you you chan change ge a pro proce cess ss on one e of of two two things happen:



















Summary and Closure





















Key Points to Points to Remember





































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