FMEA Master Presentation
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Transcript of FMEA Master Presentation
Failure Mode and Effects Analysis
FMEA HistoryFMEA HistoryThis This “type” “type” of thinking has been around of thinking has been around for hundreds of years. It was first for hundreds of years. It was first formalized in the aerospace industry formalized in the aerospace industry during the Apollo program in the 1960’s.during the Apollo program in the 1960’s.
Initial automotive adoption in the 1970’s.Initial automotive adoption in the 1970’s.
Potential serious & frequent safety issues.Potential serious & frequent safety issues.
Required by QS-9000 & Advanced Product Quality Planning Process Required by QS-9000 & Advanced Product Quality Planning Process in 1994.in 1994.
Now adopted by many other industries.Now adopted by many other industries.
For all automotive suppliers.For all automotive suppliers.
Potential serious & frequent safety issues or loyalty issues.Potential serious & frequent safety issues or loyalty issues.
FMEA -- An Introduction
• Why Do FMEAs?
• Definition, Purpose, Types, Benefits
• FMEA Working Model
• Generating / Managing
• Team Approach
Day 1Day 1
IntroductionIntroduction
FMEA -- Definition
• Recognize and evaluate the potential failure of a product or process and its effects
• Identify actions which could eliminate or reduce the chance of the potential failure occurring
• Document the process
2-2
Structured group of activities which ...
FMEA PurposesFa
ilure
s
Time
Elimination ofFailures
JOB 1
Origin ofFailures
FMEA
• Identify potential failure modes and rate severity of effects
• Identify critical and significant characteristics
• Help engineers prioritize and focus on eliminating product and process concerns and helps prevent problems from occurring
• Test adequacy of controls from DCP process
FMEA -- Purposes
2-2
FMEAs are intended to ...
FMEA -- Types
2-4
ConceptFMEA
ConceptFMEA Component
DesignFMEA
DesignFMEA
System
Sub-System
ProcessFMEA
ProcessFMEA
Assembly
Manufacturing
System
Component
Sub-System
System
Component
Sub-System
Benefits -- Concept FMEAs
• Helps select optimum concept• Identifies potential failure modes• Considers potential effects• Helps generate occurrence ratings• Identifies testing requirements• Helps determine if hardware system
redundancy is required
2-5
Design
Process
ConceptConcept
Benefits -- Design FMEAs
• Aids in evaluating requirements and alternatives
• Aids in initial design for DFM
• Increases probability of detecting failure modes and their effects
• Provides additional information for testing requirements
• Helps identify critical and significant characteristics
• Helps validate DVPs and SDSs
2-5
Process
Concept
DesignDesign
Benefits -- Process FMEAs
• Identifies potential product related failure modes
• Assesses effects on all customers• Identifies potential Manufacturing and
Assembly causes to focus controls on reducing occurrence and/or increasing detection
• Establishes a priority system for considering corrective actions
• Identifies confirmed critical and significant characteristics
2-6
Design
Concept
ProcessProcess
Generating FMEAs
FMEAs
Who initiates?Who initiates?
2-9
Failure Mode and
Effects Analysis
Failure Mode and
Effects Analysis
Who prepares?Who prepares? Who updates?Who updates?
Who is FMEA customer?
Who is FMEA customer?
When started and updated?
When started and updated?
Relationshipto FPDS?
Relationshipto FPDS?
When is FMEA complete?
When is FMEA complete?
How is FMEA documented?
How is FMEA documented?
When to discard?
When to discard?
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
FMEA Working Model
Managing FMEAs
• Modification to a component, process or system is planned
• Component is to be used in new environment
• Customer concern arises: Global 8D
FMEAs are living documents, and are updated when ...
FMEAs and Systems Engineering
2-13
Vehicle Level Inputs• Purchaser / owner / operator• Regulatory (FMVSS, EPA, ...)• Corporate (WCR, ABS, Manuf, ...)
Vehicle Level Requirements• Vehicle Attributes• Vehicle System Specification - VDS
System / Subsystem Level• System &• Subsystem Design Specifications -
SDS
Part/Component Design
Part /Component Fabrication /
Verification
SystemVerification
Purchase, Operate& Maintain
VehicleVerification
Disposal
Customer Focus
Customer Experience & Feedback
Customer
DVM / DVP Production
RequirementsCascade
RequirementsCascade
RequirementsCascade
FeasibilityFeedback
DVM / DVP
FeasibilityFeedback
FeasibilityFeedback
Requirements
CustomerMusts / Wants
CustomerSatisfaction
Component Design Specification - CDS
CFMEA
DFMEA
PFMEA
•
KO SI SC PA PR J1
CoreTeam
Team Approach -- FMEA
SupportTeam
3-5
Design FMEA -- An Introduction
Identify FMEA Team
Establish Scope
Describe Function
» Brainstorming
» Function Trees
Practice Exercise 1
Day 1Day 1
Design FMEA Design FMEA IntroductionIntroduction
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Design FMEA
Team
ScopeTeam
Design FMEA -- Team
Design Engineer
Manufacturing / Process Engineer
CORETeam
Representatives from:
• Customer Service
• Suppliers
• Global Test Operations
• Corporate Quality
Support
Team
Facilitator or Application Engineer
Technical Affairs
3-5
Design FMEA -- Scope
• Create a block diagram
• Identify the boundary for analysis
• Confirm composition of the support team
Once core team is established...
3-8
Constructing Block Diagrams
Component/Assembly
Adhesive
Screw WeldPart X
Part Y
Part Z
Service
OtherSystems
Assembly
User
3-10
Block Diagram -- Example
Headlamp Assembly
Block Diagram -- Example
Vertical Trimmer Assembly
Block Diagram -- Example
VerticalTrimmer
Assembly
ReflectorVehicle BodyUpper Cross
Member
Hood(Clearance)
AdjusterSocket
User
Lateral Location
ScrewClips
2
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Determine Function
Team
Scope
What is Function ?
• Design intent or engineering requirement
• Must be measurable or set at an actionable level
• Representation of all wants, needs and requirements, both spoken and unspoken
5-6
VerbVerb
Indicates action, occurrence, being
Generate
ControlDispense
Prevent Retain
NounNoun
Indicates what the action relates to
Describe Function
5-7
LightSpeedFuelSeat TrackRust
Describe Function
Thought Starters ...• Satisfy user
• Attract user
• Assure convenience
• Assure dependability
• Governmental requirements
• Safety requirements
Brainstorming
Exercise in creative thinking
Method to generate ideas
Brainstorming -- Guidelines
• Warm up
• Suspend judgment
• Anything goes
• Quantity counts
• Springboard
• Persevere
• Warm down
Brainstorming -- Pitfalls
• Low team trust
• Broad task definition
• Criticism, competition, defensiveness
• Silliness, lack of focus
• Questions and explanations
• Organizing ideas during creative stage
Brainstorming -- Agreement
• Everyone explains view(s)
• Identify needs of individuals
• If you can’t meet a need, say so
• Check out feelings -- yours / others
• Don’t compromise, average, or ‘split the difference’
Function Trees
• Provide an organized approach to identify the essential features of a product (or process sometimes)
• Help ensure that ‘unspoken’ and ‘spoken’ requirements are defined
• Provide a graphical representation of functions to ensure clear, total team understanding
Primary Level
SecondaryLevel
Constructing Function Trees
TertiaryLevel
HOW ? WHY ?
AdjustHeadlamp
Vertical Trimmer Function Tree
HOW ?
Permit / Maintain HorizontalAdjustment
Permit / Maintain Vertical Adjustment
Retain Setting 10 Years, 150,000 Miles
Retain Setting 10 Years, 150,000 Miles
Adjust Light Beam XBoth Directions
Locate Headlamp Laterally 10 Years, 150,000 Miles
Adjust Light Beam XBoth Directions
Locate Headlamp Vertically 10 Years, 150,000 Miles
WHY ?
Guidelines
• Brainstorm all functions (VERB - NOUN)
• Document individual functions by asking “HOW is function achieved?”
• Repeat left to right, until actionable level
• Use worksheet to check that actionable level is measurable
• Work right to left and check structure by asking “WHY is function included?”
Practice Exercise 1
Block diagram Brainstorming Function Tree
Presentation -- Practice 1
TechnicTechnical al
DebriefDebrief
TechnicTechnical al
DebriefDebrief
Team Team DebriefDebriefTeam Team
DebriefDebrief
Design FMEA Functions
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Function 3
Function n
Function 2
Function 1
Function
Sub-Function
Sub-Function
Sub-Function
Sub-Sub-Function
Sub-Sub-Function
Sub-Sub-Function
Design FMEA Path 1
Day 1Day 1
DFMEA -- Path DFMEA -- Path 11
Failure Modes
Effects -- Severity
Recommended Actions
Potential Special
Characteristics
Practice Exercise 2
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Design FMEA -- Path 1
Potential Failure Modes
5-8
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Function 1
Potential Failure Modes:• No function• Partial function• Intermittent function• Unintended function
Function 2
Function 3
Function 4
Function n
Potential Failure Modes
No function
Partial function
Intermittent function
Unintended function
Failure Mode Type Potential Failure Mode
Not operational
Not all of function operating
Occasionally does not function
Unexpected function occurs
3-21
Failure Modes -- Vertical Trimmer
No function No adjustment
Partial function Adjustment in one direction
Intermittent function Adjustment sometimes and not at others
Unintended function Trimmer itself produces light
Failure Mode Type Potential Failure Mode
Failure Mode: Adjust Light Beam Xin Both Directions
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Effects of Failure Modes
5-10
Effects of Failure Modes
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Function 2
Potential Effects of Failure Modes:• Part / Sub-component• Assembly• System• Vehicle• Government Regulations• Customer (Internal and End User)
Function 1
Failure Mode 1
Failure Mode n
Function n
5-11
Design FMEA -- Effects Table
Failure
Mode
Doesn’t
Retain
Setting
Assbly
Headlamp
Cannot be Adjusted
System
Lt System
Misaligned Lightbeam
Vehicle
(-)
Impaired Night/Fog
Perforsmance
Gov’t
Regs
Road Vehicle
Light Regs ‘89
F/CMVSS Non-
Compliance
Custmr
Driver
Impaired Night/Fog
Vision
Vertical Trimmer
Part / SC
Trimmer
May Be Stripped By Adjustment
Attempt
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
Design FMEA -- Severity
5-13
Criteria: Severity of Effect RankingEffect
... affects safe vehicle operation and/or government regulation without warning 10
Hazardous With Warning
Hazardous Without Warning
... affects safe vehicle operation and/or government regulation with warning 9
Low… operable at reduced level of performance. Customer experience some dissatisfaction
5
None No Effect1
Suggested Severity Evaluation Criteria
Vertical Trimmer/
Retains Setting
Potential Failure Mode
Does not maintain
adjustment
Potential Effects of Failure
Part: May be stripped during adjustment (7)
Assembly: Headlamp cannot be adjusted (6)
System: Misaligned lightbeam (8)
Vehicle: Impaired night/fog performance (7)
Govt Regs: Non-compliance (10)
Customer: Impaired night/ fog (7)
10
DFMEA Severity Rating Example
SEV
Item
Function
___ System___ Subsystem___ ComponentModel Year / Vehicle(s):Core Team:
PotentialFailure Mode and Effects Analysis
Design Responsibility:Key Date:
FMEA Number:Page 1 of 1Prepared by:FMEA Date ( Orig): (Rev)
Action ResultsPotentialFailureMode
PotentialEffect(s)
of Failure
Sev
Class
PotentialCause(s)/
MechanismsFailure
Occur
CurrentDesign
Controls
Detec
RPN
RecommendedAction(s)
Responsibility &Target
Completion DateActionsTaken
Sev
Occ
Det
RPN
Item
Function
DFMEA -- Recommended Actions
5-32
Select and Manage Actions
Consider This Action: To Accomplish This:To Reduce:
Change the design ... Eliminate failuremode(s) ...
Severity
3-37
YC
S=9 S=10
Design FMEA
Identify Potential Special Characteristics
7-11
Practice Exercise 2
Failure Modes Effects Severity
Recommended Actions Classifications
BreakBreakBreakBreak
FMEAplus
Managing FMEAs
Presentation -- Practice 2
TechnicTechnical al
DebriefDebrief
TechnicTechnical al
DebriefDebrief
Team Team DebriefDebriefTeam Team
DebriefDebrief
Section Summary
Day 1Day 1
DFMEA -- Path DFMEA -- Path 11
Failure Modes
Effects -- Severity
Recommended Actions
Potential Special
Characteristics
Practice Exercise 2
Warm-Down -- Day 1
AgendaAgendaPurposePurpose
TeamTeamOthersOthersSelfSelfPlacePlace
Course Purpose
These three days are designed
to ...
help you function effectively
as an FMEA team member,
but not to leave as an FMEA
team leader or an FMEA expert
Day 1
Failure Mode and Effects Analysis