MFMEA Workshop Class Overhead 04

Sheet1

CUSTOMER RESPONSIBLE FMEAsMACHINERY SUPPLIER RESPONSIBLE FMEAs

Product DFMEACustomer Process FMEAMachinery Design FMEA (MFMEA)Machinery Supplier's Internal Process FMEA

RESPONSIBLECustomerCustomerMachinery SupplierMachinery Supplier

FOCUSDesign evaluation of customer product along with every related system, subassembly and component.Evaluation of (customer) process design to ensure that it meets operational requirementsEvaluation of the overall operating performance of the machinery in a production environment (safety, reliability, maintainability, durability, cycle time, other specific machine quality issues)Evaluation of machinery supplier's internal manufacturing and assembly process

ASSUMPTIONThe machinery will meet the design intent and the product will be manufactured and assembled to the designed intent.The machinery capability performance is defined.The machinery will meet the design intent and will be manufactured and assembled to the designed intent. The process will meet its design intent.The machinery, as designed, will meet the designed intent.

NEEDED FORNew product design, modification to existing product design, use of existing design in new environmentNew process, new machinery design, modification to existing design or process, use of existing design or process in new environmentNew machinery designs, new technology, new process, modification to existing process or design, use of existing machinery in new environmentNew supplier's internal process, modification to existing process; new machinery when a generic FMEA cannot be applied

WHO COULD BE AFFECTEDEnd User + Design Responsible Engineers + Material Engineers + Manufacturing + Assembly Operation + Service + Quality + SuppliersEnd User (Customer: Subsequent Manufacturing + Downstream Manufacturing + Assembly Operation + Service Operation)End User (Customer: Plant Engineering + Maintenance + Production + Support Personnel)Supplier Internal: Subsequent Manufacturing + Downstream Manufacturing + Assembly Operation + Service Operation

FMEA STARTBeginning of product design processDuring process verification phaseAfter (customer) manufacturing process is definedPrior to manufacturing of any machinery that will be used for production

FMEA UTILIZATIONBefore the production drawings are released for toolingPrior to the start of machinery design phasePrior to the start of machinery buildBeginning of supplier's internal manufacturing and assembly process

Note : FMEAs never finish; they are living documents that should be continually updated as changes to the original machinery design/process occur and/or new information is obtained

&C&"Arial,Bold"&18DIFFERENT TYPES OF FMEAs

&C&14 29

Sheet2

Sheet3

*

MFMEA MANAGEMENT PROCESS WORKSHOP

MFMEA MANAGEMENT PROCESS

*

MFMEA MANAGEMENT PROCESS Who has the lead responsibility for the MFMEA Management Process?

The machinery design responsible Supplier (Tier 1/OEM)The component design responsible Supplier (Tier 2)The AME EngineerThe Supplier Quality Specialist

*

MFMEA MANAGEMENT PROCESS Who has the lead responsibility for the MFMEA Management Process?

The machinery design responsible Supplier (Tier 1/OEM)The component design responsible Supplier (Tier 2)The AME EngineerThe Supplier Quality Specialist

Note:MFMEAs should be initiated and managed by the Suppliers Project Manager and supported by the Quality Department.

*

MFMEA MANAGEMENT PROCESSThe MFMEA management process includes three steps:

Step I: Managing an MFMEA Kick-Off Meeting at the beginning of design phase

Step II: Managing / Performing MFMEA activities Step III: Managing MFMEA Follow Up

*


Managing an MFMEA Kick-Off Meeting at the beginning of the design phase

1. Identifying team members2. Defining OEM/Suppliers responsibilities3. Defining required supporting documentation 4. Defining critical sub-system/component list

Note: It is the OEMs responsibility to explain the purpose and objective of MFMEAs during this meeting.

*


Sheet1

MFMEA TEAM

OEMDCX EngineeringDCX User Plant*DCX PurchasingEtc. As Required

Project ManagementProcess Engineering*MaintenanceQuality

Design*TechniciansProductionBuyer

Field Service*Tool Follow UpManufacturing Engineering

QualityTool Design

Tier 2*

Design* Minimum requirement

Field Service

Quality

&C&14 &R&"Times New Roman,Regular"&14 14

Sheet2

Sheet3

*

MFMEA MANAGEMENT PROCESSOEM/Suppliers responsibilities:

Assigning an MFMEA manager/team leaderManaging and scheduling all MFMEA design reviewsFacilitating Tier-2, Tier-3 MFMEAs, if necessary Reviewing Tier-2, Tier-3 MFMEAs before presentation to DCXIssuing MFMEA Meeting Minutes Tracking status of all required MFMEAs via internal project MFMEA tracking matrixTracking issues to closureMaintaining an Evidence Book (a part of the Project Book that contains all MFMEAs and supporting documentation)

FAQ: What if a Tier-2 does not have their own MFMEA?The Tier-2 may not have pre-existing MFMEAs. If they do not have them, the OEM will make sure they come prepared with data to the MFMEA review meeting, and the Tier-1 will facilitate the MFMEA.

*

MFMEA MANAGEMENT PROCESSRequired supporting documentation:

Step-by-step sequence of equipment operations (also for sub-system / components)*Process flow chartsLayout drawingsSub-system/Component drawings*Sub-system/Component MFMEAs - Tier-2, Tier-3Actual components, if possibleWarranty/Service data, Field Performance data, Component Reliability studiesSeverity, Occurrence, Detection sheet*Corrective Action Requests, if any (external and internal)PM Task list (Recommended scheduled maintenance)*Revision history of the component

* Must Have

*

MFMEA MANAGEMENT WORKSHOPCritical sub-system / component list

(OEM) MFMEA team leader presents a list of all component suppliers and all components required for machinery design and buildMFMEA team decides which sub-systems/components require an MFMEA, based on teams past experience and criticality of the component or sub-system.All required MFMEAs are listed in a standard project MFMEA tracking matrix used for MFMEA scheduling and status update

*

MFMEA MANAGEMENT WORKSHOPCritical sub-system / component list FAQ:

When is an MFMEA required?MFMEA is recommended for: New machinery designs, new technology, new process, modification to existing process or design, use of existing machinery in new environment.

What kind of components/sub-systems do you perform MFMEAs for? MFMEAs are performed for replaceable components such as cylinders, cutting tools, slides, drive motors; or subsystems such as sealing systems, weld guns, an elevator etc.

What if a supplier has an existing generic MFMEA?It still needs to be reviewed and updated with new information (flow chart, CARs - internal, DCX and other customers)

*

MFMEA MANAGEMENT WORKSHOPCritical sub-system / component list FAQ continued:

What if a same component/subsystem (Tier-2) MFMEA was done on a previous program under a different management?Although previously done, it still has to be reviewed and updated.

What if there is a same Tier-2 supplier/component for different OEMs on the same program that requires an MFMEA?A SQA Specialist coordinates / schedules an MFMEA review or one of the OEMs takes a lead.

Are all MFMEAs Tier-2 responsibilities?No, if a component/subsystem is an OEMs internal design, the MFMEA is done by the OEM.

*

MFMEA MANAGEMENT WORKSHOPCritical sub-system / component list FAQ continued:

Whose responsibilities are MFMEAs for component specified by DCX?Although DCX specifies component suppliers, it is still the OEMs responsibility to manage MFMEAs.

What is SQA role in the MFMEA Management Process?If involved in a program, DCX Quality Specialists role is to: - Participate in MFMEA Kick-Off meetings - Coach MFMEAs, if necessary - Coordinate Tier-2 MFMEAs that are the same for different OEMs, if necessary - Help leverage Tier-2

*




Note: It is the OEMs responsibility to assess if a Tier-2 MFMEA needs to be facilitated or reviewed only.

*


Managing / Performing MFMEA activities 1. Presenting a detailed step-by-step of the sequence of operations of the suppliers equipment2. Reviewing field data, corrective actions & PM requirements3. Utilizing the MFMEA process

*


Who Facilitates the MFMEAThe Plant Maintenance ManagerThe Supplier Quality SpecialistThe OEM Project ManagerThe OEM Project or Quality Engineer

*


Who Facilitates the MFMEAThe Plant Maintenance ManagerThe Supplier Quality SpecialistThe OEM Project ManagerThe OEM Project or Quality Engineer

*




*

MFMEA MANAGEMENT PROCESSManaging MFMEA Follow Up

Follow Up is based on criticality or number of recommended actionsIssues should be transferred to project issues tracking document with the assigned responsibility and timingOnce issues are resolved, an updated MFMEA should be distributed

Note:The MFMEA process for the specific project is not considered closed until all recommended actions are satisfied

*

MFMEA MANAGEMENT PROCESSManaging MFMEA Follow-Up FAQ:

Do we need to define an RPN threshold prior to the start of the MFMEA?

YESNo

*

MFMEA MANAGEMENT PROCESSManaging MFMEA Follow-Up FAQ:

Do we need to define an RPN threshold prior to the start of the MFMEA?

NOThe RPN should be used to prioritize actions. In many cases a predefined threshold drives the wrong behavior of trying to keep values under the defined threshold.

Focus on the issues not the numbers!

*


DAIMLERCHRYSLER EXPECTATIONS

*

MFMEA MANAGEMENT PROCESSEXPECTATIONS

It is the expectation of DaimlerChrysler that all Tooling & Equipment Suppliers:

Follow the MFMEA management process intent that was presented at this workshopUpdate MFMEAs continually as changes to the original machinery design/process occur and/or new information is obtainedUtilize the MFMEA process for each projectIssue meeting minutes after each MFMEA review / follow upUse MFMEA as a design review tool, not as a separate activity

*

MFMEA MANAGEMENT PROCESS EXPECTATIONS continued

Have at least one person that is adequately trained in FMEA facilitation and is available for current projectsUtilize MFMEAs with a team that consists of individuals who collectively possess a complete knowledge of the machinery and its processUtilize MFMEAs during the design phase, not after machinery is builtEvaluate reliability and maintainability of existing similar equipment as a part of the MFMEA processUSE MFMEAs, DONT JUST DO THEM!ASK QUESTIONS!

*


EXAMPLE of MFMEA PROCESS at ABC COMPANY

*

MFMEA KICK-OFF MTG AT ABC COMPANY2002 CS UNDERBODY LINE EQUIPMENT Date: 02/03/01Present: See attached attendees list w/phone numbers and e-mail addressesMeeting Agenda:Review DCX MFMEA Management ProcessIdentify MFMEA team members (see attached list). Tim Moc, ABC company, identified as the MFMEA team leaderIdentify required MFMEA supporting documentation; including AIAG S, O, D criteria/scaleIdentify sub-system/components (critical list) that require an MFMEA, see the attached MFMEA Status Tracking Matrix- ABC company

*

MFMEA STATUS TRACKING MATRIXABC COMPANY (after initial MFMEA Kick-Off Mtg.)Updated by Tim Moc on Feb. 4, 01

Sheet1

Major SystemSystem/Comp.Supplier (OEM/2nd)Preparation DateMFMEA Reviewed (DC)Notes/Comments% Complete

UnderbodyTransfer System:0%

Cross-TransferXYZ0%

Lift-TableXYZ0%

Roller-TableXYZ

0%

Sealing SystemsDFG Co.0%

Clinch NutFastener Group0%

Robot Weld GunsWelding Corp.0%

(Trans-guns)

Overall % Complete0.00%

Sheet2

Sheet3

Sheet1

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

MACHINERY FMEA

System:Sealing SystemsFMEA #:001-CS

Subsystem:Controlled Pressure Sealer GunPage: 1 of 3

Component:RegulatorDesign Responsibility:DFG CompanyPrepared by:T. Smith

Program/Plant:CS / WindsorKey Date:15-Oct-01FMEA Date (Orig.): 15-Oct-01 (Rev.): 5-Jan-02

Core Team:T. Smith, J. Jones, P. Borick

CPotentialODAction Results

PotentialPotentialSlCause(s)/cCurrenteRRecomm.Resp.SODR

Item /FailureEffect(s) ofeaMechanism(s)cControlstPActions& TargetActionseceP

FunctionModeFailurevsofu-PreventioneNCompl. DateTakenvctN

sFailurer-Detectionc

ConstantFluid (sealer)Incorrect5Worn packing seal5None10250Perform reliabilityJ. Jones /Added52330

Pressureleakageamount ofcaused by sealertesting to determine30-Nov-01verification /

Fluidsealer toincompatibilitycompatibilityreliability testing

Regulatorproduct (partperformance betweenfor assessing

quality issue)packing seal andcompatibility

sealer type (sealer -(interaction)

packing sealbetween packing

interaction)seal and sealer

type to design

Fluid flowprocess.

rate isRe: Test Doc. 10-01

proportional

to voltage

inputWorn shaft1Design reliability210None required.

testing validates

shaft performance

(1 mil. Cycles)

Regulates

sealer flow toProportionalSealer flow not5Lost of external air3None10150Add pressure sensingJ. Jones /Pressure switch33654

specificationsair valveto specificationsource to regulatorswitch to monitor air20-Jan-02(Model

(width 4mm xregulator fails(part qualitycauses overheatflow from externalNo. FTC-125)

height 2mm)to control airissue).conditionsource (Switchadded to system.

source forRegulatorsignals system shutDesign validation

proper sealerrequiresdown under no-airtesting completed

flowreplacementflow condition)on 5-Jan-02.

Sheet2

Sheet3

*

MFMEA STATUS TRACKING MATRIXABC COMPANY (after DFG Co MFMEA Review)Updated by Tim Moc on Nov. 16, 01

Sheet1

Major SystemSystem/Comp.Supplier (OEM/2nd)Preparation DateMFMEA Reviewed (DC)Notes/Comments% Complete

UnderbodyTransfer System:0%

Cross-TransferXYZPending0%

Lift-TableXYZPending0%

Roller-TableXYZPending

0%

Sealing SystemsDFG Co.15-Oct-015-Nov-01Pressure switch addition under review. Ref. Open Action Item No. 77. Reliability testing for compatibility of packing seal and sealer type in process. Ref. Open Action Item No. 7830%

Clinch NutFastener Group1-Oct-0110-Oct-01No action items identified100%

Robot Weld GunsWelding Corp.Pending0%

(Trans-guns)

Overall % Complete16.25%

Sheet2

Sheet3

*

EXAMPLE: PROJECT OPEN ISSUESABC COMPANY - 2002 CS UNDERBODY LINE EQUIPMENT

Sheet1

ABC Company

Troy, Michigan

Telephone: (810) XXX XXXX, Telefax: (810) XXX XXXX

OPEN ACTION ITEMS

Last Meeting:1/22/02Project Description:UNDERBODY LINE

Last Update:1/22/02Project Manager:Tim Moc

Item NoPriorityIssue / ConcernOriginatorDate EnteredResolutionPerson ResponsibleDue DateDate ResolvedStatus

77GreenPneumatic regulator fails due to overheating caused by insufficient air supplied to deviceMFMEA15-Nov-0111-15-01: Under investigation 12-12-01: Design validation test in progress (adding pressure switch to monitor air source).T. Glass1/20/021/20/02Closed

78GreenPacking seals worn due to sealer incompatibilityMFMEA15-Nov-0211-15-01: Verification / reliability testing for assessing compatibility (interaction) between packing seal and sealer type in process (Ref. DFG Co. Test Document 10-01). Target completion date 11-30-01.T. Glass11/30/0111/30/01Closed

Sheet2

Sheet3

*

MFMEA MANAGEMENT PROCESSWORKSHOP

QUESTIONS?

"Product" - the equipment / machinery that a T&E supplier is designing, manufacturing and delivering.Underline the importance of subsystem / component level.MFMEA Kick-Off Mtg has to be scheduled at the beginning of the design phase.

Also, OEM needs to identify the best timing for regular MFMEA reviews.This chart does not represent who should be at the MFMEA Kick-Off Mtg. but who should be in MFMEA regular review meetings.

Team should consist of individuals who collectivelly possess a complete knowledge of the machinery and process.There is no required format for Meeting Minutes. The minimum information you need to include in your meeting minutes is: Date of meeting; Location of the meeting; Subject; Program; Atendee list that includes Names, Company, Phone #, E-mail Address; Discussion Points including updated Project MFMEA matrix, updated MFMEA, other open issues.

It is very important that you have all details of how a certain equipment operates in order to come up with an accurate assessment of potential failures.Step II includes:- Managing - scheduling and facilitating OEM/Tier-1 MFMEA\- Scheduling Tier-2 and facilitating it (if necessary) or just reviewing it.

Before this step, you defined MFMEAs schedule, team members, and a list of all required MFMEAs

PUT SLIDE #20 BACK AND TALK ABOUT REQUIRED SUPPORTING DOCUMENTS AGAIN!

SHOW AIAG MANUAL FOR SUPPLIERS TO USE AND FOLLOW.

Don't forget Meeting minutes after MFMEA meetings. These meeting minutes must include an updated MFMEA & project MFMEA tracking matrix.









By this phase you went through MFMEA process and identified open issues that required actions. During this Follow-up mtg you will identify these actions, assign responsible person and define target completion date.DCX responsibility is monitoring only.

Analogy:A MFMEA is to a Standard Design ReviewasA Computer is to a Typewriter

MFMEA Workshop Class Overhead 04

Documents

Transcript of MFMEA Workshop Class Overhead 04