9 Process FMEA

August20,2019FailureModeandEffectsAnalysisFMEAFailureModeandEffectsAnalysisLearningObjectivesAttheendofthissectiondelegateswillbeableto:UnderstandtheroleofFailureModeandEffectsAnalysis,FMEAwithintheDMAICImprovementProcessConductaProcessFMEAonanexisting,newormodifiedtransactionalprocessUsetheProcessFMEAtoprioritiseareasforattentionUsetheProcessFMEAtosupportthegenerationofControlPlans23FailureModeandEffectsAnalysis-AgendaIntroductiontoFailureModeandEffectsAnalysisFMEAWithinDMAICFMEARoadmapFMEAFormandControlPlansImplementingFMEASummary“Classic”FailuresCitytraderbuys15,000,000sharesinsteadof15,000LeapdayshutsdownbankcashmachinesNASAprobelostduetoMetric/ImperialunitsconfusionWorldwidePerrierstockswithdrawnduetofilterfailurePilotshutsdownwrongaircraftengineCompanyemailsconfidentialaccountinformationtoanalystsandhastosuspendtrading45IntroductiontoFMEAFailureModeandEffectsAnalysis,FMEAis:Asystematicmethodofidentifyingandinvestigatingpotentialdesignorprocessweaknesses.Ameanstoevaluateandmanageproductrisks.Ameansofevolvingorganizationalknowledge.Developedintheaerospaceindustryinthemid1960’sFMEAPurposeRecogniseandevaluatethepotentialfailuremodesandcausesassociatedwiththedesignandmanufactureofaproductordesignandoperationofanyprocess.Identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring.Documenttheanalysisandchangesmade.67ApplicationofFMEAinSixSigmaInDesignforSixSigma-(DesignFMEA):toidentifypotentialfailuremodestoidentifypotentialcausesoffailuretoeliminate/minimisethepotentialfailuremodeswithintheDesignprocessInTransactional/OperationalSixSigma(ProcessFMEA):toanalysetheexistingprocesses(identifypossiblex’s)toimprovetheprocess(elimination/reductionoffailuremodes)toselectnewprocessalternativestodevelopcontrolplans8ApplicationofPFMEAinDMAICMeasure:PreliminaryrootcauseanalysisAnalyse:Toanalysetheexistingprocessesandidentifypossiblex’s(causesoffailure)Improve:Toimprovetheprocess(elimination/reductionoffailuremodes)ToselectnewprocessalternativesControl:TodevelopcontrolplansItisonlynecessarytoconductPFMEAonthemodified/changedareasoftheprocessLinksfromC&EMatrixPage9KPOVsKPIVsProcessFMEARoadmap1.DescribeProcess2.DefineFunctions3.IdentifyPotentialFailureModes4.DescribeEffectsofFailure5.DetermineCauses6.CurrentControls7.CalculateRisk8.TakeAction9.AssessResults11Step1:DescribeProcessProcessFlowDiagramsError&CorrectionDataInternalProblemDataCustomerFeedbackProcessKnowledge1.DescribeProcess12Suppliers:SalesStoresInputs:OrderProductPackagingCustomers:SalesShippingEndcustomerOutputs:PackagedProductShippingrequisitionOrderfulfilmentnoteStep1:DescribeProcess-OrderFulfilmentReceiveorderCheckstockPullproductandcheckPackageproductWeighproductCorrectweight?Allavailable?OrderstockNotifySalesTransfertoGoodsOutYesYesNoNo1.DescribeProcess13ProcessFlowDiagramListofFunctions(Purposes)Step2:DefineFunction2.DefineFunctions14ActionVerbNounGatherPublishApproveReleaseProjectReportCreditProductDataSalesTestPartCheckContactReceiveDeliverCalculateAddressCustomerStockOrderPriceActionVerbNounProcessInformationExamplesofFunctions2.DefineFunctions15Step2:DefineFunctionFunctions•Receiveorder•Checksufficientstock•Notifysales•Orderstock•Pullproduct•Checkproduct•Etc.2.DefineFunctionsReceiveorderCheckstockPullproductandcheckAllavailable?OrderstockNotifySalesYesNo16FunctionDoesNotFunction?ListofPotentialFailuresDoesnot/CannotToomuchToolittleTooearlyToolateDegradedIntermittentIncorrectUnwantedFunctionStep3:IdentifyPotentialFailureModes3.IdentifyPotentialFailureModes}17ProcessFunctionPotentialFailureModes•ReceiveOrderDoesnotreceiveorderReceivesincorrectorderReceivestoomanyorders•ChecksufficientstockDoesnotchecksufficientstockIncorrectcheck(wrongconclusion)InsufficientstockwhensufficientSufficientstockwheninsufficientStep3:IdentifyPotentialFailureModes•NotifySalesDoesnotnotifysalesNotifiessalestoolateNotifiessaleswithincorrectinformation18Assumethefailurecouldoccur-whatwouldbetheeffect?Consider:•Howitaffectstheprocess(processor):•nextoperation•subsequentdownstreamoperations•Howitaffectstheenduser(customer).•Immediate&delayedimpact.•Berealistic.Note:Theremaybeseveralpotentialeffectsforeachfailure,butthesearelistedtogetherasoneoveralleffect.Step4:DescribeEffectsofFailure4.DescribeEffectsofFailure19•DoesnotReceiveOrder•Incorrectstockcheck(Concludesinsufficientwhensufficientavailable)Step4:DescribeEffectsofFailure4.DescribeEffectsofFailureAssumethefailurecouldoccur-whatwouldbetheeffect?PotentialFailureModesPotentialEffects•Ordernotfulfilled,customerhastore-submitorder•Delayinfulfillingorder,excessstock,possiblelossoforder•Incorrectstockcheck(Concludessufficientstockwheninsufficientavailable)•Incompleteorder,delay,customerdissatisfaction•NotifySalestoolate•Customernotawareofdelay,salestakesfurtherorders20Whatcouldcausethepotentialfailuremodetooccur?Process/processorerrorsthatcouldleadtothefailureBespecific,“processorerror”or“equipmentfailure”aretoovagueConsidertheworkingenvironmen