Failure Mode and Effective Analysis

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    FMEAFailure Mode And

    Effective Analysis

    All Rights Reserved

    Trade marks and/or proprietry names indicated are the property of respective owners.

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    Low - High

    Process

    1 to 10

    Primary Process Responsibility Outside Suppliers Affected Engineer

    Model year /Vehicle(s) Part Number

    Other Div or people involved Scheduled Production Released PMEA Date Rev

    Approvals Quality Assurance Manager Quality Assurance Engineer

    Operations Manager Senior Adivisor

    Part Name Process Function Potential Failure Potential Effects of Potentail Cause OF Failure Current Control Recommended Actions

    Operation Mode Failure Actions and Taken

    Number Status

    SIR Take TPPE Wrong Material Fragmented Container Insufficient Supplier Material Certif

    Container Material Held in Unpredictable Control improper required with

    1 Storage Area Deployement Handling each

    Misidentified shipment

    Material release

    Verification

    Out of Spec Fragmented Container Open Boxes Visual

    Material Unpredictable Inspection

    Deployement

    Contaminated Fragmented Container Open Boxes

    Material Unpredictable

    Deployement

    Material Fragmented Container Engineering Change Release

    Occurred

    Severity

    Detection

    RPN

    Occurred

    Severity

    Detection

    RPN

    1 9 2 18

    3 10 3 90

    1 9 7 63

    1 10 7 70

    Dana Quality Assurance ServicesF il M d Eff i A l i

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    Composition Unpredicatble Suppier Change verification

    Change Deployement Green OK Tag

    Release

    Verification

    2 Move To Unreleased Fragmentation Untrained LTO Check For OK

    Approved Untrained Personnel Tag at press

    Storage Trace Card

    Check List

    Training

    5 10 1 50

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    To understand the role and function of the FMEA

    To understand the concepts and techniques of

    Design FMEA and how to apply it.

    To Understand the concepts and techniques of

    Process FMEA and how to Apply it

    To understand the role and function of FTA

    To understand the concepts of Zero Quality

    Control or Mistake - Proofing (e.g. Poke - Yoke) and

    its implications for FMEA.

    Course Goals

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    Customer Requirements

    Engineering Specifications

    System And Components Specifications

    Process and Supplier Requirements and

    ControlDevelop System Design And Process FMEA

    Eliminate Potential Failures

    Improve Upon Design And Process

    Design is the Critical element

    How FMEA Fits With Elements Of TQM

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    An Advanced Quality Planning tool used to

    evaluate potential failure modes and their causes.Prioritizes Potential Failures according to their Risk

    and drives actions to eliminate or reduce their

    likehood of occurrence.

    Provides a disciplinary /methodology for documenting

    this analysis for future use and continuous process

    improvement.

    By its self ,and FMEA is not a problem solver .It is

    used in Combination with other problem solving tools,

    The FMEA presents the oppurtunity but does notSolve the Problem .

    FMEAs Have Failure Modes

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    The team developing the FMEA turns out to be one

    individual.The FMEA is created to satisfy a customer or third

    party requirement ,not to improve the process.

    The FMEA is developed too late in the process and

    does not improve the product /process development

    cycle.The FMEA is not reviewed and revised during the life

    of the product .It is not treated as a dynamic tool.

    The FMEA is percieved either as too complicated or

    as taking too much time.

    FMECA

    Failure Mode Effects And Critically Analysis

    Origins

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    1950's Origin - Aerospace & US Military

    To categorize and rank for focusTargeted prevention as a critical issue

    Addressed saftey issues

    FMEA

    Failure Mode And Effects Analysis - 1960's and 70's

    First notices & used by reliability engineers

    System of various group actvities provided through documentation

    of potential failure modes of products and /or processes and its

    effect on product performance .

    The evaluation and documentation of potentail failure modes of a product & process

    Actions are then identified which could eliminate or reduce the potential failure.

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    Automotive

    QS 9000 Paragraph 4.2

    Cited in the AIAG APQP Manual

    Process Saftey Management Act (PSM)

    Where And Why

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    CFR 1910.119999999 lists the process FMEA as one of about

    6 methods to evaluate hazards

    Example ICI Explosives - Hazardous Operability studiesFDA - GMPS

    One of several methods that should be used to verify a new design (21 CFR

    Part 820).Inspectors check list questions cover use of the Design FMEA.

    ISO 9001

    Requires Preventive Actions .The utilization Of FMEAs is one

    Continuous iimprovement tool which can satisfy the requirement .

    ISO 14000

    Can be used to evaluate potential hazards and their accompanying risks.

    Components

    sub systems,

    ain system

    Subsystems

    Main systems

    Man power

    Machine

    Components

    System Design Process

    Material

    Measurement

    Types Of Automotive FMEAs

    Method

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    Focus Focus Focus

    Minimize failure Minimize processMinimize Failure effects on the failures effects on

    Effects on the system design the Total Process.

    Objective /Goal Objective /Goal Objective /Goal

    Maximize System Maximize Design Maximize Total

    Quality,reliability Quality ,reliability Process Quality

    Cost Cost and reliability,cost,

    and maintainability. maintainability. Process,Gauges Productivity andmaintainability .

    Syste

    FME

    Design

    FME

    The effect from the

    The Ramifications of

    the problem

    The Problem The cause (s) of the

    Problem

    System FMEA with a

    The cause (s) of the

    problem from the

    Effect CauseFailure Mode

    New Root Causes for

    the Design Failure

    Machines

    Tools ,Work

    Stations

    Production lines

    Operator Training

    Relationships Of Automotive FMEAs

    Envirnoment

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    Proces

    FME

    Design FMEA Process FMEA

    Sign Off

    Concept Design

    Go - Ahead

    Design

    Completion

    Modes

    Production

    Start

    Automotive FMEA Time Line

    Problem from the

    Design FMEA

    Prototype

    Build

    Eng/Mfg

    system FMEA

    The same effect as the

    Design FMEA

    The causes of the Specific Root Causes

    For the Process Failure

    ModesBetter Definition

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    Design FMEA :

    Start early in process.Complete by the time preliminary

    drawings are done but before any tooling is initiated.

    Process FMEA :

    Start as soon as basic manufacturing methods have been

    discussed .Complete prior to finalizing production plans

    and releasing for production.

    Customer Input

    Team - Team Selection ( Cross - Functional)

    Ranking - Ranking Of Decisions

    Some Key FMEA Terms

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    Risk Priority Assessment

    Design Process

    Production Process

    AIAG Automotive Industry Action Group

    APQP Advanced Product Quality Planning

    DFMEA Design Failure Mode And effects analysis

    DOE Design Of experiments

    FMA Faiulure Modes Analysis

    FMEA Failure Mode and Effects Analysis

    KCC Key Control Characterstic

    Automotive Acronyms

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    KPC Key Product Characterstic

    PFMEA Process Failure Mode and Effects Analysis

    PPAP Production Part Approval Process

    PSW Production Submission Warrant

    QFD Quality Function Deployement

    Characterstic : A distinguishing feature ,dimension or property of a process or its output ( Product) on

    Which variable or attribute data can be collected .

    Characterstic ,Critical ,Chrysler Definition: Characterstic applicable to a component ,

    material assembly or vehicle assembly operation which are designated by Chrysler Corporation

    Engineering as being critical to part function and having particular quality ,reliability and /or durability

    significance .These include characterstic identified by the shield ,pentagon ,and diamond.

    Characterstic , critical ( Inverted Delta) , Ford Definition: Those Product requirements

    ( Dimensions , performance tetst) or Process parameters that can affect compliance with government

    regulations or safe vehicle/product function ,and which require specific supplier ,assembly ,shipping or

    monitoring and included on Control Plans.

    Characterstic ,Key Control ( KCCs): Those process parameters for which variations must be

    Controlled around a target value to ensure that significant characterstic is maintained at its target value.

    KCCs require ongoing monitoring per an approved Control Plan and Should be considered as candidates

    Characterstics I

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    For Process improvement .

    Characterstic, Key Product ( KPC): those product feature that affect subsequent operations,

    Product function ,or customer satisfaction .KPCs are established by the customer engineer ,Quality

    representative ,and supplier personnel from a review of the Design and Process FMEAs and must beincluded in the Control Plan.Any KPC s included in Customer -released engineering requirements are

    provided as a starting point and do not affect the suppliers responsibility to review all aspects of the design,

    Manufacturing process,and customer application and to determine additional KPCs.

    Characterstic , process : Core team Identified process variables ( Input variables) that have a

    Cause and effect relationship with the identified Product Characterstic (s) which can only be measured at

    the time of occurrence.

    Characterstic , Product : Feature or properties of a part , Component or assembly that are

    described on drawings or other primary engineering information

    Characterstic , Product , Critical (D) Chrysler Definition : a defect which is critical to part Function and having particular qu

    Characterstic , Product , Major , Chrysler Definition : a defect not critical to function ,but which could materially reduce the

    Satisfaction , or reduce production Efficiency .

    Characterstic , Product ,Saftey /Emmission /Noise (S), Chrysler Definition: A defect

    Which will affect compliance with Chrysler Corporation and Government Vehicle Saftey /Emission /Noise

    Characterstic II

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    Requirements.

    Characterstic ,Saftey ,Chrysler Definition : Specifications of a Component.

    material ,assembly or vehicle assembly operation which require special manufacturing control to assureCompliance with Chrysler Corporation and Government vehicle safety requirements.

    Characterstic saftey Chrysler Defnition : Specifications which require special

    manufactruing control to assure compliance with Chrysler or Government vehicle saftey reqiirements.

    Charactertsic ,Significant ,Chrysler Defnition : Special characterstics selected by the

    supplier through knowledge of the product and process.

    Characterstic , Special : Product and process charactertsic designated by the customer, including

    governmental regulatory and saftey ,and /or selected by the supplier through knowledge of the product and process.

    Charactertsic , Special ,Chrysler Definition : Specifications of a component ,material ,assembly or vehicle

    assembly or vehicle assembly operation which are designated by Chrysler as being critical to functionand having particular quality ,reliability and durability significance .

    Charactertsic Special Chrysler Definition : Specific Critical Characetrstic that are process

    driven (controlled ) and therefore require SPC to measure process stability , Capability ,and

    control for the life of the part.

    Charactertsic ,Special Chrysler Definition : Limited to highlighting critical Characterstics on

    Production ( Production) part drawings ,tools and fixture ,and tooling aid procedures where ongoing

    process control is not automatically manadated.

    Charactertsic , Special , Chrysler Definition: Engineering Designated specifications

    Characterstics III

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    or product requirements applicable to component material,assembly operations which require

    special manufacturing control to assure complinace with governmental vehicle saftey,emissions

    noise ,or theft prevention reuqirmenets .

    Characterstic , Special , Ford Definition "Critical Charactertsic" : those productrequirements (Dimensions , Specifications ,Tests) or process parameters which can affect

    compliance with government regulations or safe vehicle /Product Function and which require specific

    producer ,assembly ,shipping or monitoring actions and inclusions on the control plan.

    Characterstic ,Specification , Ford Definition "Significant charactertsic : those

    Product ,process and test requirements that are important to Customer satisfaction and for which quality

    planning actions shall be included in the Control Plan.

    Charatcetrtic ,Special Ford Definition : Significant /Characterstic :

    characterstic that are important to the customer and that must be included on the Control Plan.

    Charactertsic ,Special , GM Definition "fit /Function : Product charactertic for which

    reasonably anticipated variation is likely to significantly affect customer satisfaction with a product (other

    than S/C) such as its fits , function,mounting or appearance ,or the ability to process or build the product.

    Characterstic , Special ,GM Definition Saftey/Compliance : Product charcterstic for

    which reasonably anticipated variation could significantly affect customer the products safety or its

    compliance with government regulations (such as : Flammability ,occupant protection ,streering control,

    braking etc..) Emmisions ,noise , radio frequency interference etc.

    Characaterstic , special GM Definition " Saftey /Compliance : Product Charactertsic for

    Characterstics IV

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    Which reasonably anticipated variation could significantly affect customer the products saftey or its

    complaince with government regulations ( such as : Flammibility ,occupant protection ,steering control,

    braking etc) Emmissions ,noise ,radio frequency interference etc .

    Characterstic , Special ,GM Definition " Standard : Product characterstic for which

    reasonably anticipated variation is unikely to significantly affect a products saftey,compliance with

    governmental regulations ,fit/function .

    Charcterstic ,Special , Process (e.g.Critical ,Key Major , significant): A Process

    characterstic for which variation must be controlled to some target value to ensure that variation in a

    special product characterstic is maintained to its target value during manufacturing and assembly.

    Characterstic ,Special ,Product : Core team compilation of important product characterstics

    From all sources.All special characterstics must be listed on the control Plan.

    Charactertic , Special Product (e.g Critical ,Key ,Major Significant ): a Product

    characterstic for which reasonably anticipated variation could significantly affect a products saftey or

    Compliance with governmental standards or regulations ,or is likely to significantly affect customer

    satisfaction with a product.

    Characterstic ,Special ,Tooling , Chrysler definition : Critical tooling

    symbol used identitity special charactertic of fixtures ,gauges ,developmental parts,and initial product

    parts.

    Control Item Part , Ford Definition:Product drawings /specifications containing Critical

    Charactertics .Ford Design and Quality Engineering approval is required for changes to Control item

    FMEAs and Control Plans.

    Characterstic V

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    Flow CHART , Preliminary Process

    Description of anticipated manufacturing process

    developed from preliminary bill of material and

    product /process assumptions .

    Flow DIAGRAM, PROCESS

    Depicts the flow of materials through the process,

    including any rework or repair operations .

    Process Flow Document

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    FMEA: Failure Mode and effects Analysis- systemized technique which identifies

    and ranks the potential failure modes of a design or manufacturing of a design or manufacturing process in order to prioritiz

    improvement actions.

    Failure Cause Potential : How the Failure could occur,described in terms of somtheing that can be

    corrected or can be controlled .

    Failure Modes Analysis (FMA) : a Formal structered procedure used to analayse failure mode data

    from both current and prior processes to prevent occurrence of those failure modes in the future.

    Failure Mode Potential : The manner in which the process could potentially fail to meet the process

    requirements and/or design intent a description of the non -conformance at that specific operation.

    FMEA , Design : analytical technique used by a design responsible engineer /team as a means to assure,

    to the extent possible ,that potential failure modes and their associated causes /mechanisms have been

    considered and addressed.

    FMEA , Machine /Equipment : Same as process FMEA , Except machine /equipment being designed is

    considered the product.

    FMEA , Process:Analytical technique used by a manufacturing responsible engineer /team as a means

    to assure that , to the extent possible ,potential modes and their associated causes /mechanisms

    have been considered and addressed.

    FMEA & Failure Terms

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    Control Plan: Written descriptions of the system for controlling production parts and

    processes.They are written to address the important characterstics engineering

    requirements of he product.Types of control Plans include "family" device or technology

    Control Plans which apply to a number of parts produced using a common process.

    Customer approval of control plans may be required prior to PSW submission.Refer to

    Section III For customer -specific requirement .

    Control Plan , Prelaunch : A description of the dimensional measurements and

    material and performace tests that will occur after prototype and before full (normal)

    production.

    Control Plan Production: A Comprehensive documentation of product/process

    characterstic ,process controls ,tests , and measurements systems occuring during mass

    (normal) Production.

    Control Plan , Prototype: A Description of the dimensional measurements and

    material and performance tests that will occur during Prototype Build.

    Control Plan Definitions

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    Before Or after ?

    Individual or Team Approach ?

    FMEA Timing

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    Process Flow Diagram(Includes All Proceses)

    Process FMEA Critical Charactertsics

    (On all Processes) & Failure Effects Issues

    Process Control Plan( Critical Processes From FMEA)

    Critical Charactertsics

    & Charactertsic Control Issues

    Design FMEA( On Intended Use)

    Typical Automotive Triology Development

    APQP Time Line

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    Check For CustomerRequirements.

    Give careful consideration

    to that you consider a

    Major Process.

    Use the appropraite RPN

    numbers and

    considerations of other

    appropraite information/

    data to determine Critical

    Give careful Charactertics.

    consideration todefining Contro Develop Control

    plan stages mechanisms appropriate

    Prototype for critical

    Pre-launch charactertsic

    Production

    Element for every

    Process

    Develop the

    Control Plan with

    Critical

    Charactertsics

    flow Listing

    Enter Every

    Major Process

    from flow listing

    into FMEA Form

    Develop FMEA(s)

    Automotive Document Development

    Develop Process

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    Advanced Product Quality Planning Timeline

    Process Flow Listing Flow /Process Control Plan(Includes All Processes) (All Major Processes)

    APQP Procedure should Process Flow Listing

    Trigger this Process Becommes the

    Process Control Plan

    Some Elements may Process FMEAbe Included On ( All MAJOR Processes)

    Use to Determine

    Critical Charactertic

    From RPN

    Design FMEA( Intended Use)

    Control Plan / Process Flow Combination Example

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    Check for customer

    requirements.

    Give careful consideration

    to what you consider a

    Major process.

    Use the appropriate RPN

    numbers and

    considerations of other

    appropriate information/

    data to determine critical

    charactertics.

    Develop Control

    mechanisms appropriate

    for critical

    charactertsics.

    One Document ? Or More ?

    Process in the

    Control Plan

    Revise the

    Control Plan with

    Critical

    Charactertsics

    Major Process

    Form Flow Listing

    into Control Plan

    Form

    Develop FMEAs

    Element for Every

    Control Plan /Process Flow Combination ExampleDocument Development

    Develop Process

    Flow Listing

    Entry Every

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    Manufacturing Entity

    Receiving Machine or Machine Pack

    Cell 1 Or Cell 2

    & Ship

    Segmenetd + By machine or Cell Receiving

    Pack

    Device ,Technology or Family = a Flow of a technology or device & Ship

    QS 9000 :1996 - FMEAs

    Internal Or

    External

    Customer

    Machine

    or Cell 3

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    4.2.3 - Quality Planning

    Process Failure Mode And effects

    analysis ( Process FMEAs)

    Process FMEAs shall consider all special

    Charactertsics.Efforts shall be taken to improve

    the process to achieve defect prevention ratherthan defect detection.Certain customers have

    FMEA review and approval requirements that shall

    be met prior to production part approval ( See

    Customer specific pages).Refer to the Potential

    Failure Mode and effects Analyisis reference

    manual.

    4.2.3 - Quality Planning

    QS 9000 :1996 - Control Plans

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    The Control Plan

    Suppliers shall develop ControlPlans at the system

    subsystem,Component and /or material level,as apporiatefor the product supplied.

    The Control Plan requirement encompasses processes

    producing bulk material(e.g Steel , Plastic resin ,Paint ) as

    well as those producing parts.

    The output of the advanced quality planning process,beyond

    the development of robust processes,is a control Plan.

    control Plans may be ebased on existing plans ( for mature

    Products and capable processes). New Plans are required

    when products or processes differ significantly from those in

    current production.

    4.2.3 - Quality Planning

    QS 9000 : 1996 - Control plans

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    The Control Plan

    The Control Paln shall cover three distinct phases as appropriate:

    Prototype - a description of the dimensional meausrements and

    material and performance test that will occur during Prototype build.

    Note: Prototype Control Plans may not be required from all suppliers

    Prelaunch - a description of the dimensional meausrements and

    material and performance test that will occur after Protype and

    before full Production.

    Production - a Comprehensive documentation of product /process

    characterstcis , process controls test and measurement systems that

    will occur during mass production.

    Suppliers shall establish cross - functional teams to develop Control Plans for

    approval by the appropriate customer engineering and quality personnel

    unless this approval requirement is waived by the customer .In Some cases,

    the Customer will establish a cross functional team to develop the control Plan.

    Quality Planning - 4.2.3 S

    SemiConductor Supplement

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    During the advanced quality planning processes,the supplier shall

    include all processes from the incomming material through shipping

    and warehousing.

    Failure Mode And Effects Analaysis and Control Plan Documents

    Shall include these processes.

    The Intent :

    The supplier Shall " Consider " All Processes .But does it mean that

    all process shall be included In the FMEA and Control Plan?

    6.2 Overview

    APQP Manual : 1995

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    A Control Plan is written description of the

    system for controlling parts and processes "

    "In effects, the Control Plan describes the actions

    that are required at each phase of the process

    including receiving , in - process , out going , and

    periodic requirements to assure that all process

    outputs will be in taste of control"

    " Process Potential FMEA"

    IS " aSummary of engineer's /teams thoughts

    FMEA Manual : 1995

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    ( Including an analysis of items that could go wrong

    based upon experience and past concerns ) as a

    Process is developed".

    " A process FMEA should begin with a flow chart/

    risk assessment of the general process.This flow

    chart should identify the products charactertsics

    associated with each operation."

    Prevention Planning

    Identifies Change requirements

    Benifits Of FMEAs

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    Cost reduction

    Increased through-put

    Decreased Waste

    Decreased warranty costs

    Reduce non-value added operations

    Select proper team and organize members effectively

    Select teams for each product /Service , process/system.

    Create a ranking system

    FMEA Pre Requisites

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    Agree on format for FMEA matrix ( Typically set by AIAG)

    Define the customer and customer needs/

    expectations

    Design /Process requirements

    Develop a process flow Chart

    What is a team

    Two or more individuals who coordinate actvities

    to accomplish a common task or goal.

    The Team

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    Maintaining Focus

    A sepearte team for each product or projects.

    Brainstorm

    Brainstorming ( The Team ) is necessary as the

    intent is to discover many possible possibilities.

    Two Types Structures

    Natural Work Group Task Team

    Work area or unit Representatives who have key

    representatives from support information or are stakeholders.

    groups on as - needed basis.

    Participation is mandatory. Assigned by steering committee

    Team Structures

    Membership

    Member SelectionDana Quality Assurance Services

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    or upper management

    Assigned by management or Assigned by or negoiated with

    identified by team and within its steering committee or upper

    authority. management.Ongoing Disbands when task is finished .

    Leader appointed by management. Leadership shared or delegated by

    members.

    Are management directed and foccussed

    Build their own identity

    Are accountable and use

    Measurements

    roject Identificatio

    Team Life Span

    Leadership

    Succesful Teams

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    Have corporate champions

    Fir into the organization

    Some Teams Just " Do not

    Are cross - functional Work"

    Determine if there should be a meeting

    Decide who should attend

    Provide advance notices

    Maintain meeting minutes or records

    Basic Team Rules

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    Establish ground rules

    Provide and follow an agenda

    Evaluate meetings

    allow NO interruptions

    Ground Rules are an aid to "self -

    management"

    Team must develop their own ground rules

    Once deveolped,everyone must live by them

    They can modify or enhance the rules as they

    Team Ground Rules

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    continue to meet

    Clarify

    Participate

    Listen

    Summarize

    Stay on Track

    Team Meeting Responsibility

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    Manage time

    Test For Consensus

    Evaluate meeting process

    One Person makes the decision

    One person consults the group,then

    makes the final decision

    Team or group makes decision based

    upon majority rule or consensus

    Decision Criteria /Model

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    Start During Prototype stage

    Design Engineer - Generally the Team Leader

    Test Engineer

    Reliability Engineer How do you Currently

    Material Engineer prevent problmes from

    Field Service Engineer occuring?

    Component Process Engineer

    Vehicle Process Engineer

    Styling Engineer

    Project Manager or Rep.

    Design FMEA Team

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    Quality Engineer

    Customer Contact Person

    Others ,including Mfg., Sales , Mkting ,QA / QC, Process ,Pacakaging

    Process Engineer - Generally the Team MembersProcess Operator

    Industrial Engineer

    Design Engineer How do you presently

    Reliability Engineer prevent problems?

    Tooling EngineerMaintenance Engineer

    Styling Engineer

    Project Manager or Rep.

    Quality Engineer

    Process FMEA Team Members

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    Others including supplier , Sales ,QA/QC, MFG.

    Design FMEA Customer

    End User : person who uses the product

    Use Failure

    This can help in Repair manuals & Filed Service

    More in the DFMEA section herein.

    Process FMEA Customer

    Subsequent operations

    Defining the Customer

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    End users : person who uses the product

    More in the DFMEA section herein

    Do not mix up :

    Design Failures & Causes

    With

    Process Failures & Causes

    Design Failures Process Failures

    Insufficient lubrication capabilitry Insufficient lubrication applied

    Incorrect specified Incorrect material used

    CAUTION

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    RPN = (S) x (O) x(D)

    S = Severity

    O = Likehood of Occurrence

    D = Likelihood Of Detection

    Prevention vs Detection- Automotive Expectations:

    1000 is the Maximum and 75 is considered "OK"

    High and low numbers are the important ones to consider

    Input Concept

    Risk Assessment (RPN) Factors

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    From Experience From

    & Data Guess

    Design FMEAItem- Function Potential Failure Potential Effects Potential Current Design Recommended Responsible

    Mode Of Failure Cuases /Mechanisms Of controls Actions Activity and

    Failure and status target completion

    date

    Process FMEAProcess Function Potential Failure Potential Effects Potential Current Design Recommended Responsible

    Requirements Mode Of Failure Cuases /Mechanisms Of controls Actions Activity and

    Failure and status target completion

    date

    Device /

    Process

    Failure Mode Chance OF Severity Chance Not

    Occurrence Detected

    RPN Flow

    Effect ControlCause

    Severity

    Occurenc

    Detection

    RPN

    Occured

    Severity

    Severity

    Occurenc

    Detection

    RPN

    Occured

    Severity

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    Design FMEADana Quality Assurance Services

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    A Design FMEA is an analytical

    Techniques utilized primarily by a Design

    FMEA team to ensure potential Failure

    modes and their associated causes are

    identified , Considered and addressed.

    Reference page 8 in the AIAG FMEA Reference Manual

    This systematic approach parrels,Formalizes and documents the

    mental discipline that an Engineer normally goes through in any

    Design process.

    Design FMEA FociDana Quality Assurance Services

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    Customers include

    End userRepair functions

    Dealership or other Sales Outlet

    Designer of the next level system or product

    Process Engineers

    Assembly Engineers

    Test Engineers

    Product Analysis

    Start with a list of :

    Typical Design Considerationms

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    What the design is expected to do

    What the design is expected NOT to do

    Design Intent

    Customer Needs

    Customer Wants

    Product Requirement

    Manufactring assembly requirements

    Think about what Quality Function Deployement

    documents in your customer Contacts

    company Competative Analysis

    define these Known Product Quality

    Reliability Requirements

    Manufactruring Requirements

    Aids in the objective evaluation of design requirements and

    Design FMEA Benefits

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    alternatives.

    Increases the probablity that potentail modes and their

    effects on the system/product have been considered.

    Aids in the planning of design test and development programs

    Aids in analyzing field concerns ,design changes and in

    developing advanced designs.

    Ranks potential failure modes according to their effect on the

    customer ,thus prioritizing improvements and development

    testing.

    Provides an open issue format for recommending and tracking

    risk reducing actions.

    Can reduce product development timming ,Production startup

    problems ,reduce costs and enhance product quality,reliabiity

    and saftey.

    The Design FMEA is a living document and should be initiated

    More Design FMEA Considerations

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    at ,or by ,design concept completion.

    The design FMEA should be continually updated as changes

    occur throughout all phases of product development.The Design FMEA should be fundamentally complete along with

    the final product drawings.

    The design FMEA addressess the design intent and assures

    the design will be manufacturers /asembled to this intent.

    The Potentail Failure Mode /Causes which can Covered by the Process

    FMEA ad therefore should NOT be included in a design

    FMEA.

    Causes of design failure modes are

    Design Failure Causes

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    those things that ,from a designer 's

    prespective ,would , by ommission or

    improper use ,result in the failure mode.

    Improper Tolerancing

    Design Failure Cause Examples

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    Incorrect Stress Calculations

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    Incorrect Stress Calculations

    Wrong Assumptions

    Wrong Material Call outLower Grade Component

    Lack of design Standards

    Improper Heat Treatment

    Improper Torque Call out.

    Design Block diagram ExampleIf the product is complex ,break it

    down into smaller sub -systems .Identify

    System Primary vs Secondary Fuctions.Body

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    Subsystem

    Exterior Window Interior

    Glass Sealing Latch/

    Component with Lock

    Strip

    Doors

    Door

    Inner

    Panel

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    Effect Critreria: Severity of Effect Ranking

    Hazardous Very high ranking when a potentail failure mode affects safe 10

    without vehicle operation and/or involves noncomplaince with government

    warning regulation without warning

    Hazardous Very high seviriaty ranking when a potential mode affects safe 9

    with vehicle operation and/or involves non compliance with government

    warning regulation with warning.

    Very High Vehicle /item inoperable ,with loss of primary function 8

    Generic Design FMEA Severity

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    High Vehicle /Item operable ,but at a reduced level of performance 7

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    Customer dissatisfied.

    Moderate Vehicle /Item operable ,but comfort convinence items inoperable 6

    Customer experiences discomfort.

    Low Vehicle /Item operable but comfort /convenience items (s) operable at 5reduced level of performance .Customer experiences some

    dissatisfaction.

    Very Low Fit & Finish /Squeak & Rattle item does not conform .Defect noticed 4

    by most customers.

    Minor Fit & Finish /Squeak &rattle item does not conform .Defect noticed 3

    by average customers.

    Very Fit & Finsih /Squeak & rattle item does not conform .Defect noticed 2

    Minor by discriminating customers.None No effect 1

    Possible Failure Rates Ranking

    Very High : Failure is almost inevitable > 1 in 2 10

    1 in 3 9

    High : Repeated Failures 1 in 8 8

    1 in 20 7

    Moderate : Occasional Failures 1 in 80 6

    1 in 400 5

    1 in 2000 4

    Generic DFMEA Occurrence

    Probability Of Failure

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    Low : Relatively Few Failures 1 in 15000 3

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    1 in 150000 2

    Remote : Fialure Unlikely < 1 in 1,500,000 1

    Detection Criteria : Likelyhood of detection by Design Control Ranking

    Absoulete Design Control will not and /or can not detect potential 10

    Uncertainity cause /mechanism and subsequest failure mode: or there is no

    Design Control.

    Very Very remote chance the design Control will detect a potential 9

    Remote causes/mechanism and subsequent failure mode.

    Remote Remote chance the design Control will detect a potential 8

    cause /mechanism and subsequent failure mode.

    Very Low Very low chance the design Control will detect a potential 7

    cause /mechanism and subsequent failure mode.

    Generic DFEMA Detection

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    Low Low chance the design control will detect a potential 6

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    g p

    cause /mechanism and subsequent failure mode.

    Moderate Moderate chance the design Control will detect a potential 5

    cause /mechanism and subsequent failure mode.

    Moderately Moderatly high chance the design Control will detect a potential 4

    High cause /mechanism and subsequent failure mode.

    High High chance the design Control will detect a potentail 3

    cause /mechanism and subsequent failure mode.

    Very High Very high chance the design Control will detect a potential 2

    cause /mechanism and subsequent failure mode

    Almost Design Control will almost certainly defect a potential 1

    Certain cause /mechanism and subsequent failure mode.

    Design Controls are those actions taken as

    a normal part of the development process

    that are designed into the process to

    minimize the occurrence of failure or to

    detect specific failure modes.

    Design Controls

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    Design controls should directly relate to the

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    Design controls should directly relate to the

    Prevention and/or detection of specific

    causes of failures.

    Reliability Tests/Prototype Testing

    Design Reviews

    Worst Case stress Analysis

    Robust Design

    Envirnomental Stress Testing

    Designed Experiments

    Design Control Examples

    Consider

    Interpretation of

    DataDana Quality Assurance Services

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    Finite Element Analysi

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    Finite Element Analysi

    Variation Simulation

    FT AnalysisComponent Derating ( 60% to 80 %)

    100,000 Mile Pilot Test

    When the failure modes have been ranked by their RPN,

    corrective actions should be first directed at the highest ranked

    concerns and critical items identified .

    The intent of any recommended action is to reduce one or more

    (or all) of the occurrence ,severity and/or detectioin rankings.Only a design revision can bring about a reduction in the

    severity ranking .If no actions are recommneded for a specific

    cause ,this should be indicated.

    A reduction in the occurrence ranking can only be effected by

    Recommended Actions

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    removing or controlling one or more of the causes of the failure

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    g g

    mode through a design revision.

    An increase in design verification actions will result in a

    reduction in the detection ranking ONLY.

    Design FMEA doesnt rely on process controls to overcome

    potentail weakness in the design: however ,it does take

    technical and physical limitations of a process into consideration (Design rules)

    Sample Sizes

    Evaluation

    For the Control Plan Frequency

    Method of

    characterstics

    and is therefore the

    Starting Point

    The Process FMEA

    Identifies

    Critical and Significant

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    Evaluation

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    Evaluation

    Out-of-Control

    Action Plan

    (OCAP)

    You want to understand your current process

    You are looking for oppurtunities to improve

    You want to illustrate a potential solutionYou have improved a process and want to

    document the new process

    Use a Process Flow ChartBecause:

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    Lets Try A Process Flow Chart

    1 Identify the process or task you want to analyze.Defining the

    scope of the process is improtant because it will keep the

    improvement effort from becoming manageable.

    2 Ask the people most familiar with the process to help construct

    the chart.

    3 Agree on the starting point and ending point.Defining the scope

    of the proces to be charted is very important ,otherwise the

    Creating a Process Flow Chart

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    task can become unwieldly.

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    4 Agree on the level of detaiul you will use .Its betetr to start out

    with less detail ,increasing the detail only as needed to

    accomplish your purpose.

    5 Look for areas for improvement

    Is the process standardized ,or are the people doing the work in different ways?

    Are steps repeated or out of sequence ?

    Are there steps that do not ad value to the output?

    Are there steps where errors occur frequently?

    Are there rework loops?

    6 Identify the sequence and the steps taken to carry out the

    Process.

    7 Construct the proces flow chart either from left to right or from

    Creating A Process Flow Chart

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    top to bottom ,using the standard symbols and connecting the

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    steps with arrows.

    8 Analyze the results.

    Where are the rework loops?

    Are there process steps that dont add value to the output?

    Where are the differences between the current and the desired situation?

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    TTOOOOOOOOOO makeeeeeeeee

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    Use to help determine who should be involved by

    identify all the work areas in a process

    Use as a job aid to remind people about processs

    standards

    Use as a check list to collect data on where problems

    occur

    Use to investigate why rework is occurring at a

    certain place in the process

    Use the ideal process flow chart data to

    communicate your proposed solution

    How To Use The Flow Chart

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    If a process step or box has two output

    arrows ,consider whether a decision box is

    needed

    Remember that the people closest to the work it best .Make sure pe

    involved in developing the flow chart

    Software packages make flow chartproduction easy.

    Flow Chart Tips

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    Identifies potential product-related failure modes

    Assesses the potential customer effects of the

    failures

    Identifies the potential internal and externalmanufacturing or assembly process causes and

    identifies process variables on which to focus

    controls for occurence reduction and/or detection of

    the failure conditions

    Develops ranked list of potential failure modes,thru

    establishing a priority system for corrective action

    considerations

    Documents the results of the manufacturing or

    The Process Potentail FMEA

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    assembly process

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    A process potential FMEA is an analytical tool utilized by a process

    FMEA team as a means to ensure potential failure modes and their

    associated causes are identified ,considered and addressed.

    Teams should be run by the owner of the process or someone who

    understands the process well.Defines reasons for rejection at specific operations.

    In preparation for the FMEA ,the assumption should be made that

    the incomming parts and materials are correct.

    A comparision of similar components is a recomended starting point.A

    knowledge of the purpose of the design necessary.It can be cause -associated with a potential failure mode in a

    subsequent operation or an effect associated with a potential failure

    in a previous operation.

    Each potential mode for the particular operation should be

    Process Potential FMEA

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    listed in terms of a part or process characterstic.

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    Dana Quality Assurance Services

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    Process FMEA Foci

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    Customer include:End user

    Next Manufacturing or Process step

    Process Engineers

    Assembly Engineers

    Repair FunctionsTest Engineers

    Product Analysis

    Dealership or other Sales Outlet

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    Process FMEA Beneifts

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    As a systematic approach ,the process potentail FMEA

    parrallels and formalizes the mental discipline that an engineer

    goes through in any manufacturing planning process.

    The Process Potential FMEA identifies potential product related

    process failure modes.

    The process potential FMEA assesses the potential customer

    effects of the failures.The process potential FMEA identifies potential manufacturing

    and/or assembly process causes.

    The process potential FMEA identifies significant process

    variables to focus controls for occurrence reduction and

    detection of failure conditions.

    The process potential FMEA develops a list of potential failuremodes ranked according to their affect on the customer,thus

    establishing a priority system for corrective and preventive

    action considerations.

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    More Process FMEA Considerations

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    The process FMEA is a living document.

    The Process FMEA should be continually updated as changes

    occur throughout all phases of product development and on into

    and through to the end of production.

    The process FMEA should begin with a flow chart of the

    processes - from receiving through shipping and warehousing.

    The potential Failure Modes /Cause which can occur during

    manufacturing or assembly process are covered by the Process

    FMEA but some information (severity rankings,identification of

    some effects ) may come from the Design FMEA.

    A reduction in occurrence ranking can on by be achieved by

    implementing a proces change that controls and eliminates

    one or more causes of the failure mode.Dana Quality Assurance Services

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    RPN

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    Effect Criteria Sevrity Of effect Rankingazar ou ay en angere mac ne or assem y operator . ery g sever ty

    Generic PFMEA Severity

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    t out ran ng w en a potenta a ure mo e a ects sa e ve c e operat onarn ng an or nvo ves noncomp ance w t government regua t on. a ure

    w occur w ou warn ng.azar ous ay en angere mac ne or assem y operator . ery g sever ty

    w t ran ng w en a potent a a ure mo e a ects sa e ve c e operat onwarn ng an or nvo ves noncomp nace w t government regu at on. a ure

    w occur w warn ng.

    ery g a or srupt on to pro uct on ne . o pro uct may ave toe scrappe . e c e tem n opera e , oss o pr mary unct onus omer very ssa s e .

    g nor srupt on to pro uct on ne . ro uct may ave to e sortean a port on ( ess t an ) c rappe . e c e t em opera e , uta a re uce eve o per ormance . us omer ssa s e .

    o erate nor srupt on to pro uct on ne . port on ( ess t an ) o

    t e pro uct may ave to e scrappe (no sort ng) . e c e temopera e , ut some mcom ort conv en ence tem (s) nopera e

    us omers exper ences scom or .

    ow nor srupt on to pro uct on ne . o pro uct may ave toe rewor e . e c e tem opera e , ut some com ort conv en encetems opera e at re uce eve o per romance . utsomer

    exper ences some ssa s ac on.

    ery ow nor srupt on to pro uct on ne . e pro uct may a ve to esorte an a port on( ess t an )rewor e . t

    n s quea ratt e tem oes not con rm . e ect not ce ymos cus omers.

    nor nor crupt on to pro uct on ne. e pro uct may ave too e

    sorte an port on ( ess t an ) rewor e on- ne ut out ostat on. t n s squea ratt e tems oes not con orm . e ectno ce y a scr m na ng cus omers.

    ery nor srupt on to pro uct on ne . e pro uct may ave to enor sorte an port on ( ess t an ) rewor e on- ne ut n-

    stat on . t n s squea ratt e tem oes not con orm . e ectno ce y a scr m na ng cus omers

    one o e ect

    Generic PFMEA OccurrenceDana Quality Assurance Services

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    CpK Ranking

    Very High : Failure is almost inevit > 1 in 2 < 0.33 10

    i

    Probablity OF Failure Possible Failure Rates

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    1 in 3 > 0.33 9

    High : Generally Associated with processessimilar to previous processes which 1 in 8 > 0.51 8

    often failed

    1 in 20 > 0.67 7

    Moderate : Generally associated with

    processes similar to previous proces 1 in 80 > 0.83 6

    which have experienced occasional

    failures ,but not in major proportion 1 in 400 > 1.00 5

    1 in 2000 > 1.17 4

    Low: Isolated failures associated wi 1 in 15000 > 1.33 3

    similar processes.

    Very Low: Only isolated failures 1 in 150000 > 1.50 2

    associated with almost identical

    Processes.

    Remote : failure Unlikely .No Failu < 1 in 1500000 >/1.67 1

    associated with almost identical

    processes

    If a process is under SPC or is similar to previous process process under SPC ,then the Statisticaldata should be used to determine Occurrence ranking.

    Assessment of occurrence ranking can be made using the word descriptions in the evaluation

    creteria if statistical data is not available.

    Detection Criteria : Liklyhood the existence of a defect will be Ranking

    Generic PFMEA Detection

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    detected by process controls before next or subsequent

    process, or before part or component leaves

    manufacturing or assembly location

    Al t N K C t l il bl t d t t f ili d 10

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    Almost No Known Controls available to detect failiure mode 10

    ImpossibleVery Very remote likelyhood current controls will detect failure mode 9

    Remote

    Remote Remote likehood current controls will detect failure mode 8

    Very Low Very low .likelyhood current controls will detect failure mode. 7

    Low Low likelyhood current current controls will detect failure mode. 6

    Moderate Moderate likelyhood current controls will detect failure mode 5

    Moderately Moderately likelyhood current controls will detect failure 4

    High mode

    High High Likelyhood current controls will detect failure mode. 3

    Very High Very high likelyhood current controls will detect failure mode. 2

    Almost Current Controls almost certain to detect the failure mode 1

    Certain reliable detection controls are known with similar processes.

    Assume the failure has occurred and then assess the capabilities of all current controls to prevent

    shipment of the part having this failure mode or defect.

    Random quality control checks would be unlikely to detect the existence of an isolated defect and

    therefore would result in low to remote detection ranking.

    Sampling done on an statistical basis is a valid detection control.

    A reduction in detection ranking can only be achieved by improving process control system(s).

    Process Failure Causes

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    1 Omitted processing 11 Poor control procedures

    2 Processing errors 12 Improper equipment

    3 E i k i i

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    3 Errors setting up work pieces maintenance

    4 Missing parts 13 Bad recipe

    5 Wrong parts 14 Fatigue

    6 Processing wrong work p 15 Lack of saftey

    7 Mis-operation 16 Hardware failure

    8 Adjustment error 17 Failure to enforce controls

    9 Equipment not set proper 18 Envirnoment

    10 Tools and /or fixtures 19 Stress connections

    improperly prepared 20 Poor FMEA(s).

    1 Standardized work instructions /procedures

    Process Control Examples

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    2 Fixtures and jigs

    3 Mechanical interference interfaces Controls can be

    4 Mechanical counters process controls fool

    5 M h i l fi PSC

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    5 Mechanical sensors proofing or PSC ,or

    6 electrical /Electronic sensors can be post -process7 Job sheets or process pacakages inspection/testing.

    8 Bar coding withj software integartion and

    control Inspection /testing

    9 Marking may occur at the

    10 Training and related educational safegaurds subject operation or

    11 Visual Checks at subsequent

    12 Gauge studies operations that can

    13 Preventive Maintenance detect the subject

    14 Automation (Real Time Control ) failure mode.

    SPC records

    Typical Process Documents

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    Visual aides

    Work instructions

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    Inspection instructions /recordsEquipment operating instructions

    Training records

    Traceability records

    Corrective Action should be first directed at the highest

    concerns as rank ordered by RPN.

    Recommended Actions

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    The intent of any recommended action is to reduce the

    occurrence ,severity and/or detection rankings.

    If ti d d f ifi th thi

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    If no actions are recommended for a specific cause ,then this

    should be indicated.

    Only a design revision can bring about a reduction in the

    severity ranking.

    To reduce the probability of occurrence ,process and/or

    specification revisions are required.

    To increase the probability of detection ,process control and /or

    inspection changes are required .Improving detection controls is

    typically costly.The emphasis should be placed on preventing,

    rather than detecting ,defects.

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    FTA

    Inductive logic (bottom up) Deductive (top Down)

    Determines all possible way gdbgbndgnbd

    equipment can fail .Determines the Assumes a system failure and

    effect of such failures on the system. determines the possible causes

    FMEA

    FMEA vs FTA

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    Focus is on the parts of which the Focus is on the total system

    system is comprised

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    The ellipseThe top event ,the ellipse contains the descrption of the system-level fault or

    undesired event.The symbol appears at the head or top of the the tree and is

    included on by once I any tree.The input to the ellipse is from a logic gate.

    The Rectangle

    Fault Tree Symbols

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    The fault event ,the rectangle , contains a brief descriptiuon of a lower level fault

    This decriptiom should be short without being vague.Fault events appear

    throughout the tree and have both their input and output from a logic gate.

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    Logic Gates

    Logic Gate inputs and outputs ,except for the inhinitgate,which is addresses

    below ,have similar connections. The out put from a logic gate is to any fault

    event block or to a transfer out function.The input is from any fault event block

    or from a transfer in function.The AND Gate is the logic gate in which the

    output occurs only if all inputs exist.

    The or is thelogic gate in which the output occurs only if one or more of

    the input events occur.

    1 Defining the Undesired Events (Major Faults)

    a) The undesired event is often the fault which ,upon occurrence ,results incomplete failure of the system,the failure of a back -up system ,degradation or

    an undetected failure .This is considered catasophic failure.The major fault is

    a failure which causes loss of availability through the degradation or system

    shut down and/or poses a saftey hazard to operators and/or maintanence

    personnel .The undesired event however ,may be unusual failure at a sub-

    Fault Tree Fundamentals

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    system level ,the root caue of which is unknown .Any observable event may be

    chosen as the "undesired event" .The analayst must recognise that the FTA will

    not identify failures unrelated to the chosen event.

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    b. To define the undesired event ,the normal system operation and envirnomentmust be known in order to allow the analysis to show the undesired event as a

    failure .When defining the undesired event,are must be taken to prevent the

    range of the faults from becoming too broad .For example ,Failure to complete

    trip " for an automobile, is not specific enough to allow for ease of analysis .This

    is because failure could vary from an air conditioning fault ,which caused

    discomfort ,to loss of engine power ,which caused loss of mobility .Both faults

    could be considered failure : however ,loss of mobility is obiviously a much more

    severe fault than losing air conditioning.

    2 Defining Types of Faults

    Faults fall into two basic categories : operational and Component

    Operation Fault

    The operational fault is one which occurs when a component is operating as it

    was designed to ,but at an inappropriate time or place .An example is a failure of

    a control valve to close or to interruypt the introdiuction of a reactant into a

    chemical process due to an inappropriate signal from another device.

    Fault Tree Fundamentals

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    Component Fault

    The component fault can be further decided into two sub categories primary and

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    The component fault can be further decided into two sub categories , primary and

    secondary .a primary component fault occurs when a component fails to

    function in its intended envirnoment .Example : A radar unit designed for use in

    aircraft which fails due to vibration .a Secondary component failure occurs when

    a componnet fails to function in an envirnoment other than the envirnoment for

    Which it is intended ,Example : A radar unit designed for a cargo aircraft fails in a further aircraft

    3 Comparision of Fault Occurrence and Faulty Existence

    The term Fault Occurrence refers to the fact that an undesired event has taken

    place and may or may not still exist .Fault Existence ,however implies that the

    place and may or may not still exist .Fault Existence ,however implies that the

    fault has occurred and continues to exist .Therefore the fualt can be describeas being either transient or permanent.

    During the construction of the fault tree ,all systems analyst should use Fault

    Occurence ,rather than Fault Existence as the focus of interest.

    Fault Tree Fundamentals

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    4 Comparison Of Failure Causes and Fault Effects

    A failure is considered to be an ability to perform a normal fucntion Example:

    Valve does not open .A Fault is a higher Occurrence which is usually

    preceded by a lower -level failure such as a casing cracking due to overheating

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    preceded by a lower -level failure,such as a casing cracking due to overheating

    because of a lack of coolant induction due to an inoperable valve (lower level ogf

    Failure ),However , a fualt may also occur when no failure is present .Example :

    Coolant valve operates properly,but the signal to operate it encounters a delay

    A Fault has occurred ,but there is no valve failure .Becuase of this ,it can be

    stated that any failure causes a faulktr ,but not every fault is caused by a failure.

    Failure Categories : a Component B.Envirnoment c.Human .D Software

    Determine the level to which the examination should

    be constructed

    Begin with the system-level fault

    Fully describe all events which immediately cause

    this event

    Fault Tree construction Steps Summary

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    With each lower -level; fault , continue describing its

    immediate causes until a component level failure or

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    immediate causes until a component level failure or

    human error can be attributed to the fault

    Fully define each branch of the tree before begining

    another branch

    During the construction of the tree ,it is advisable touse a block diagram of the system to simply

    determining the main branches

    Fault Tree Construction Steps Summary

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    If the results of the FMECA on the system are

    available at the time of the FTA it is advisable to use

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    the results in defining the top events

    1 Determine the minimal cut-sets to simplify the tree

    (Qualitative analysis ).

    2 Determine the probability of each input event

    3 Combine the probability inputs to logic gates asfollows :

    a. AND Gate - The probability of output is the product of the

    Analyzing the Fault Tree

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    probabilities of the inputs (Po=PI1Pi2..Pin)

    b. OR Gate - The probability of output is the sum of the

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    probablities of the inputs (Po=Pi1+Pi2.Pin)

    4 Combine the gate input probablities until the

    probablity of the top event is determined.

    Identify the system or equipment level

    fault state (s) (Undersed event(S))

    Construct the fault tree

    Perform the analysis to the component

    level

    Fault -Tree Analysis Procedures

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    The top event must be measurable and

    definable

    The top event must be inclusive of the lowerevents

    The top event is the result of the lower

    Criteria for Identifying the undesired Event

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    events

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    Can any equipment failures contribute to this effect?

    Materials faults ?

    Human errors?

    Methods and Procedures?Software performance ?

    Maintenance errors or the absence of maintenance ?

    Inaccuracies or malfunctions of measurement

    Clues About Causes

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    devices(s)?

    Envirnoments such as chemicals ,duct ,vibration,

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    shock and /or temprature?

    Almost all errors are caused by human errors

    Forgetfulness- Sometimes we forget things when we are not

    concentrating .Example : A person forgets to set his /her alarm

    close at night .Safegaurd establish a routine which include

    checking before going to bed.

    Errors due to misunderstanding - Sometimes we make

    mistakes when we jump to wrong conclusion before we are

    familiar with the situation .Example : A person used to a stick

    Errors 1

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    shift pushes the brake petal in an automatic thinking it is the

    clutch .Safegaurds : Training , checking in advance ,

    standardizing work procedures .

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    Errors in identification - Someties we misjudje a situation

    because we view it too quickly or too far away to see it

    clearly .

    Safegaurds : Training ,attentiveness ,vigilane.

    Errors made by amateurs - Some times we make mistakes

    through lack of experience .Example : A new worker does not

    know the operation or is just barely familiar with it .Safe gaurds :

    Training ,Skill buliding work standerdization.

    Willfull errors - Sometimes errors occur when we decide that

    we can ignore the rules under certain circumstances .Examples "

    Crossing a street against a red light because we no cars

    Safe gaurds : Basic eductaion \Experience.

    Inadverant errors- Sometimes we are absent minded and

    Errors 2

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    make mistakes without knowing how they happened .Example:

    Someone lost in thought tries is red or not .Safegaurds:

    Attentiveness ,discipline Work standardization.

    E d t l S i k i k h

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    Errors due to slowness - Sometimes we make mistakes whenour actions are slowed down by delays in judjement .Example

    A person learning to drive is slow to step on the brake .

    Safegaurds : Skill buliding ,Work standardization.

    Errors due to lack standards- some errors occur when

    there are suitable instructions or standards .Example :

    A measurement may be left to an individuals disdretion.

    Safegaurds : Work standardization , Work instructions.

    Surpirse errors- errors sometimes occur when equipment runs

    differently than inspected .Example : A machine malfunction

    without warning ,Safe gaurds : Total Productive MaintenanceWork Standardisation.

    Surprise errors- Errors sometimes occur when equipment runs

    differently than expected .Example : A machine malfunction

    without warning .Safe gaurds : Total Productive Maintenance

    work Standardization.

    Errors 3

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    Intentional errors- Some People make mistakes deliberately

    crimes and sobtage are examples Safe gaurds : Fundamentals

    eductaion , Disiclipilne .

    Mistakes happen for many reasons , but almost all

    b t d if t k ti id tif h d

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    can be prevented if we take tie identify when and

    why they happen and then take steps to prevent

    them, by using Poka -Yoke methods with

    consideration to another available safe gaurds.

    Variation control using assembly aidsIdentification by visual techniques

    Standaredization work and work placce

    organisation

    Self - Check (In- process)Poke - Yoke

    Five /methods of Mistake - proofing

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    Emphasizes Prevention

    Principles

    Build into processes

    Eliminate inadverant errors

    Stop doing inadverant errors

    Stop doing it wrong - Do it Right

    Work TogetherFind Together

    Find True Cause

    Examples

    Guide for part (Fixtures)

    Mistake - Proofing

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    Error detection alarm

    Limit switchCounter

    Check List

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    Responsibility Responsibility activity

    actvity

    Dana Quality Assurance ServicesF il M d Eff ti A l i 10

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    lity,reliability and durability significance .

    expected performance of a product , unfavorably affect customer.

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    e 4.

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