Ensuring reliability in lean new product developme

Part2:Part 2:Using FMEA, DFR, Test and Failure Analysis in Lean NPDJohn J. Paschkewitz©2011 ASQ & Presentation JohnPresented live on Feb 24th, 2011http://reliabilitycalendar.org/The_ReliabilityCalendar/ShortCourses/Shliability_Calendar/Short_Courses/Short_Courses.htmlASQReliabilityDivisionASQ Reliability Division ShortCourseSeriesShort Course SeriesThe ASQ Reliability Division is pleased to present a regular series of short courses featuring leading international practitioners, academicsandconsultantsacademics, and consultants.ThegoalistoprovideaforumforthebasicandThe goal is to provide a forum for the basic and continuing education of reliability professionals.http://reliabilitycalendar.org/The_ReliabilityCalendar/ShortCourses/Shliability_Calendar/Short_Courses/Short_Courses.htmlPart2:UsingFMEA,DFR,TestandFailureAnalysisinLeanNPDOverviewIntroductionandDefinitionsPart1:LeanProductDevelopmentLeanvs.TraditionalProductDevelopmentKeyElementsofLeanNPDCustomerDefinesValueFrontLoadedandKnowledgeBasedEliminateRedesignWasteReliabilityRequirementsPart2:ReliabilityElementsofLeanNPDLeanFMEAandDRBFMCriticalCharacteristicsDFRandPhysicsofFailureAcceleratedTestingtoFailureFailureAnalysisandKnowledgeCaptureLeanFMEASometeamsattempttoleanFMEAprocessbycreatingproductfamilyFMEAsbutfailtoupdateFMEAfornewapplicationsorchangesInsteadLeanFMEAShouldFocusonNewDesignFeaturesandChangestoBaselineDesigntoAssessAssociatedRisksToolstoFocusLeanFMEADiagrammingToolsFunctionalBlockDiagramBoundaryDiagramParameterDiagramProcessFlowDiagramHighlightChangestoProductorProcessontheDiagramsFunctionalBlockDiagramAnnotateRetainedandChangedItems&FunctionsBoundaryDiagramConstructionSubsystem1Subsystem3Subsystem2FMEABoundaryInterface-PhysicalInterface-InfoTransfer-DataTransfer-ExternalInputConsideraFunctionalBlockDiagramoftheSystemWithModulesandInterfacesParameterDiagramofProduct,Process,SystemProduct,Process,orSystemNoiseFactorsResponse(Output,Function)ControlFactorsSignal(Inputs)ElementsoftheP-DiagramControlledbyInputFunctionStaticorDynamicMaybeVariablePerformanceMean,StdDevCustomerRequirementForcesBeyondControlCauseOutputVariationEnvironmentFactorsFunctionalDesignParametersFixedorAdjustableFundamentaltoDesignofFunctionReduceVariationProcessFlowDiagramAnnotateRetainedandChangedProcessStepsSelectingProcessStepsforAnalysisOnProcessFlowMap:IdentifyStepsBeingModifiedIdentifyNewStepsRequiredforNewProductDrillDowntoIdentifySub-StepsWithintheTargetStepsIdentifiedforAnalysisCompleteLeanPFMEAonSelectedProcessStepsIntegratewithPreviousPFMEAonStandard/UnchangedProcessStepsKeyCharacteristicsInclude:ProductFeaturesManufacturingProcessesAssemblyCharacteristicsThatSignificantlyAffect:ProductPerformanceForm,Fit,FunctionLeanNPDFocusesontheCriticalFewCharacteristicstheCustomerValuesKeyCharacteristicsDetectPreventRPNDETOCCSEVActionTakenActionResultsResponse&TargetCompleteDateRecommendedActionsRPNDetecCurrentControlsOccurPotentialCause(s)/Mechanism(s)OfFailureClassSevPotentialEffect(s)ofFailurePotentialFailureModeItem/ProcessStepDetectPreventRPNDETOCCSEVActionTakenActionResultsResponse&TargetCompleteDateRecommendedActionsRPNDetecCurrentDesignControlsOccurPotentialCause(s)/Mechanism(s)OfFailureClassSevPotentialEffect(s)ofFailurePotentialFailureModeItem/ProcessStepFunctionDFMEA&PFMEATechnicalRequirements,ToolsIdentifySpecialProductCharacteristicsSeverityProcessStepsReceiveMaterialMaterialhandlingShippingDamageComponentManufactureVehicleAssemblyPrimaryDriveManufacturingProcessStepsOp100Step1PRE-LOADDOWELPINSTOFIXTUREOp100Step2PRE-LOADJACKSHAFTSEALTOFIXTUREOp100Step3PRE-LOADPRIMARYHOUSINGBUSHINGTOFIXTUREOp110Pre-loadbearingtofixture#2Op120Pre-loadmainshaftoilsealtomandrelOp200Housingtofixture#1Op210OperatepressOp220RetainingringtotopgrooveOp230Reloadfixture#1Op300Housingtofixture#2Op310OperatepressOp320RetainingringtotopgrooveOp330MandreltomainshaftboreI.D.OP340OperatepressOp350Re-loadfixture#2andmandrelOp400HousingtotableOp410ReservedOp420ChainadjsubassytohousingOp430Lubricatebushing&sealOp445MoveorstageforfinalassyOp10O-ringtoshiftertubeOp500ShiftertubetohousingOp510ClamptoshiftertubeOp20AssembleshifterleverOp520WavewashertoshifterleverOp530ShifterlevertoshiftertubeOp535QueforfinalassylineCustomerAssessmentDirectionofImprovementPotentialCriticalandSignificant1.090TO1.110FACEOFPRIMARYHOUSINGBUSHINGTOFACEOFJACKSHAFTSEALDOWELPINS0.260TO0.270TOFACEJACKSHAFTSEALAGAINSTSHOULDERBEARINGFLUSHTOSNAPRINGFACESEALCOMPRESSIONHEIGHTPRIMARYGASKETSEALSURFACEFINISHSERATIONDAMAGEWeightedImportanceRelativeImportanceGFHFHFGFGHGHHFHHFFYHHHHHGGF539399508181720941002754261305481300027045990000000SpecialCharacteristicsMatrixCharacteristicsMatrixRequirementsDocumentsCustomerSpecificationRegulatoryDimensionsAppearanceRequirementsDocumentDrawingsFieldHistoryRobustnessToolsFunctionalBlockDiagramBoundaryDiagramP-DiagramInterfaceMatrixIdentifyingKeyCharacteristics1098765432112345678910OccurrenceSeverityPotentialCriticalCharacteristicPotentialKeyCharacteristicPossibleAnnoyanceZoneSpecialC