QUALITY FUNCTION DEPLOYMENT & FMEA

By Prof. Raghavendran V

By Prof. Raghavendran V

2

FAILURE MODE AND EFFECT ANALYSIS(FMEA)

FMEA is also known as Failure mode, effect & critical analysis(FMECA).

Failure mode & Effect analysis is a group of activities intended to “recognize & evaluate the potential failure of a product or process and its effect before the product/ service being produced & used, identify actions that could eliminate or reduce the chances of potential failures and lastly documenting the process.

By Prof. Raghavendran V

3

FMEA is an analytical technique that combines the technology & Experience of the people in identifying foreseeable failures modes of a product or process and planning for its elimination. It is “Before-an-Event” action requiring a team effort to easily and Inexpensive effect changes in design and production.

By Prof. Raghavendran V

4

FMEA is categorized in broadly 3 systems and they are:

1. Failure mode analysis2. Failure effect analysis3. Failure criticality analysis

By Prof. Raghavendran V

5

FAILURE MODE ANALYSIS

It is analyzing the operations of the product or process to foresee, what are the most likely modes where the failure would occur. This would include the components involved, describing the components involved, the time, locations and many more.

By Prof. Raghavendran V

6

FAILURE EFFECT ANALYSIS

It is study of the potential failure to ascertain the likely impact on the performance of the whole product, the process or service and related elements.

By Prof. Raghavendran V

7

FAILURE CRITICALITY ANALYSIS

It is study of the criticality or intensity of potential failures of the product, process or service. The criticality may range from customer irritation to catastrophic occurrence.

By Prof. Raghavendran V

8

FMEA DOCUMENTATION

Block Diagram is very much needed to understand physical attributes of the product.

The Documentation of FMEA consists: FMEA number Item Design responsibility Prepared by Model number/year Key date FMEA Date Core Team Function

By Prof. Raghavendran V

9

TYPES OF FMEA’S

They are: Design FMEA, Process FMEA, Concept FMEA, Maintenance FMEA, System FMEA, Environmental FMEA, Service FMEA.

By Prof. Raghavendran V

10

DESIGN FMEA FORM TEMPLATE

By Prof. Raghavendran V

11

FMEA Analysis FMEA Number……………..

Page………….. Of ………….

Item……………………………………….Design Responsibility…………………………….Prepared by……………………

Model Number/year…………………………..Key date……………………….FMEA Date (Orig)…………(Rev)……….

Core team:……………………………………………………………………………………………………………………………………

Item/ Function

Potential Failure Mode

Potential Effects of failure

S Class

Potential causes mechanism of failure

O Current Design Controls

D RPN

Recommended Actions

Responsibility & Target completion dates

Action Results

Action Taken

SEV

OCC

DET

RPN

By Prof. Raghavendran V

12

BENEFITS OF FMEA Systematic review of component failures. Determining the effects that any failure will

have on other items in the product or process and their functions.

Determining those parts of the product or process whose failure will have critical effect or impact on product or process.

Helping uncover oversights, misjudgments and errors that may have been made.

Helping reduce development time and cost of manufacturing process.

By Prof. Raghavendran V

13

QUALITY FUNCTIONAL DEPLOYMENTIt is invented by Dr. Mizuno, professor of

Tokyo institute of technology. It is planning tool which can be applied to any organization to fulfill customer expectations.

It focuses on customers expectations or need, often referred to as customer’s voice. It is team based tool in which customer needs are the driving force for the product development process. Conflicting needs are identified early in QFD Process and can be resolved before production.

QUALITY FUNCTION DEPLOYMENT

A systematic method for transferring customer wants/needs/expectations into product and process characteristics

i Quality Function Deployment Voice of the customer House of Quality

QUALITY FUNCTION DEPLOYMENT

QFD: An approach that integrates the “voice of the customer” into the product and service development process.

By Prof. Raghavendran V

16

QUALITY FUNCTIONAL DEPLOYMENT

QFD employed to translate customers expectations, in terms of specific requirements, into directions & actions, in terms of engineering or technical characteristics, that can be employed through:

Product Planning Part Development Process Planning Production Planning Services

By Prof. Raghavendran V

17

QFD TEAM

There are two types of teams1. One is existing team with fewer members2. Other team composed of marketing,

design, quality, finance and product.

By Prof. Raghavendran V

18

BENEFITS OF QFD

Improves customer satisfaction Focus on requirement competitive information prioritizes resources Identifies items that can be acted upon

Reduces implementation time Decrease midstream design changes Limits production problems Avoid future redundancies Identifies future application opportunities

By Prof. Raghavendran V

19

BENEFITS OF QFD

Promotes team work Based on consensus Creates communication at surfaces Identifies actions at interfaces Create global views of details

Provides documentation Documents rationale for design Is easy to assimilate Adapts to changes Provides framework to sensitivity analysis

By Prof. Raghavendran V

20

HOUSE OF QUALITY

The primary planning tool used in QFD is the House Of Quality.

HoQ translates voice of customers into design requirements that meet specific targets.

Managers and Engineers consider the house of quality to be primary chart in quality planning

By Prof. Raghavendran V

21

HOUSE OF QUALITY’S PART DESCRIPTION:

1) The exterior walls of the house are the customer requirements. On the left side is a listing of the voice of customer. On right side are prioritized customer requirements.

2) The ceiling shows technical descriptors, consistency of the product is provided by engineering characteristics, design constraints and parameters.

By Prof. Raghavendran V

22

HOUSE OF QUALITY’S PART DESCRIPTION:3) The interior walls are relationship

between customer requirements and technical descriptors. Customers expectations (requirements) are translated into engineering characteristics (technical descriptors).

4) The roof is the interrelationship between the technical descriptors.

5) The foundation or base is known as prioritized technical descriptors.

HOUSE OF QUALITY

customerneeds

Technical Descriptors

Prioritized Customer

Needs

Prioritized Technical descriptors

Relationship B/W technical

descriptors

relationships

betweencustomer needs andengineering metrics

By Prof. Raghavendran V

24

ASSIGNMENT TIME: TO BE SUBMITTED BEFORE 20TH OCT’ 2011.

1. Explain in detail of QFD.2. Explain and construct House of quality.

END OF MODULE 6By. Prof. Raghavendran V