AIAGVDAFMEA_UPDATEINFO2017

FMEAWorkshopUpdateontheAIAG-VDAFMEAHarmonizationProjectSeptember19,2017FormatofToday’sWorkshop•ExplanationoftheAIAG-VDAFMEAMethodology–ProjectOverview–ScottGray-AIAG–TheSixStepProcess–JoseAvalos–ZF/TRW–NewFormSheet–RhondaBrender–Nexteer–TheS,O,DRatingTables–MaryBethSoloy–Ford–ActionPrioritization(AP)-DaveDalby–HondaN.A.•QuestionandAnswers–PanelFormat2AIAG-VDAFMEAProjectWhy-●Experiencewithwarrantyresults,fieldfailures,recallsareindicativeofopportunitiestoimproveproductandprocessriskanalysismethodologies●FromtheAIAGCurrentStateofQualitysurvey,thenumbertwoindustryconcernisCustomerSpecificRequirements,specifically,thenumberofredundantCSR’s•AcommonsetofFMEArequirementswillenablesupplierstohaveasingleFMEAbusinessprocess,andassociatedmethods/toolstoproducearobust,accurate,andcompleteFMEAthatwouldmeettheneedsofalloftheircustomersWhat●Developasingleco-copyrightedAIAG-VDAFMEAManual,thatclearlydefinesanimprovedmethodology,thatisalignedwithSAEJ1739●TakethebestfromVDAandAIAGandcombinetheprocessessothattheywillmeetrequirementsforbothIndustrygroupsProjectTeamObjectiveProvideconsistentdirection,guidancetoallautomotivesuppliersUpdatetoinclude:-BestPractices-ImprovedExamples-FunctionalSafetyAIAG-VDAFMEAProjectTeamAIAGWorkGroupVDAWorkGroupOEMsFCAUSLLC,Ford,GM,HondaN.A.,DaimlerTruckNADaimlerAG,FordEurope,VolkswagenAG,AdamOpelAGSuppliersNexteer,Bendix,ONSemiconductor,ZF/TRWRobertBoschGmbH,Continental,SchaefflerAG,Knorr-Bremse,ZFFriedrichshafenAG5FMEAMethodologyChangesProjectObjectivesCurrentStatusAlignmentoftheSeverity,Occurrence,andDetectiontablesbetweenAIAG,VDA,andSAEJ1739OnesetoftablesforDFMEAandPFMEAAsecondsetforMSR-AlignmentofProcessAsixstepprocessNewformsheetAlignmentofkeytermsanddefinitionsOnesetoftermsanddefinitionsImprovedapproachfordocumentingandreducingrisksFunctionfocus4MAPinsteadofRPNAlignmentwithISO26262Definitionof“SupplementalFMEAforMonitoringandSystemResponse(MSR)”EnsurethemethodologycanbecompletedusingExcelBeingconfirmedthroughvalidationtesting6DevelopmentStatus•Projectiscurrentlyinthe“Build”phase–Althoughwehavepulledsomeelementsfromthe“validationphase”forward•WeexpecttoreleaseadraftmanualforAIAGStakeholderReview/VDAYellowbookinNovember.–90Daycommentingperiod•ReleaseofpublicationtargetedforearlyQ22018–Commontrainingisbeingplanned•EffectivitywillnotoccuruntilaftertheIATF16949transitiondeadlineofSept.14,20187FMEAWorkshopUpdateontheAIAG-VDAFMEAHarmonizationProjectSeptember19,2017SixStepProcess9New–Sixsteps,asystematicapproachtoperformtheanalysisPurpose:•Itisrecommendedthatthefailuremodeandeffectsanalysistobecarriedoutinsixstepstoachievegoodquality,reliability,safetyinourproductsandprocesses.ThissixstepsareapplicabletoDesignandProcessFMEA’s.CurrentSituation–•TherearetwomanualswithsimilarapproachesforFMEArealization,somecustomersrequiresupplierstohaveeithertheAIAGorVDAFMEAmethod.•ThequalityoftheFMEAanalysisisoftenreportedaspoor,duetomanyfactorssuchaslackofunderstandingonthesubject,keypositionsturnoverandsoon.SixStepProcess10SystemAnalysisFailureAnalysisandRiskMitigation1stStepScopeDefinition2ndStepStructureAnalysis3rdStepFunctionAnalysis4thStepFailureAnalysis5thStepRiskAnalysis6thStepOptimizationProjectidentificationSystemstructureforaproductorelementsofaprocessOverviewofthefunctionalityoftheproductorprocessEstablishmentofthefailurechain(potentialFailureEffects,FailureModes,FailureCauses)foreachproductorprocessfunction(step)AssignmentofPreventionControls(existingand/orplanned)totheFailureCausesandFailureModesIdentificationoftheactionsnecessarytoreducerisksOverview•Projectplan•Analysisboundaries•Lessonslearned•BasisfortheStructureAnalysisstep•Visualizationoftheanalysisscope•Identificationofinterfaces&interactions•BasisfortheFunctionAnalysisstep•Visualizationoftheanalysisscope•Identificationofinterfaces&interactions•Basisforthefailureanalysisstep•Visualizationofthefailurerelationships•Creationoffailurestructures•Identificationofsourcesofvariations•BasisfortherecordoffailuresontheFMEAform•Assignmentofprevention/detectioncontrols•Ratingofseverity,occurrenceanddetection•Collaborationbetweencustomerandsupplier(severity)•Basisfortheoptimizationstep•Assignmentofresponsibilities•Documentationofactions•Implementationofactions•Confirmationofeffectivenessoftheactions•Continuousimprovementoftheproductandprocess•BasistotherefinementofcontrolsSixStepProcess111stStep:ScopeDefinition•Current-DefinitionofScopesaystoconsideralltheproductionprocessesandtoselectwhichprocessorprocessestoapplyFMEAanalysis.•New-ConsiderallprocesseswithintheplantthatcaneffectthequalityoftheshippedproductandselectwhichprocessorprocessestoapplyPFMEAanalysis.•Thisopensthedoortoallowdatatodrivewhichprocessshouldbeanalyzed,i.e.ifbadlabtestingprocessesalloweddefectiveproducttobeshipped,thenthoseprocesscanbeanalyzed.NewScopeDefinitionOpensTheThoughtProcessToConsiderAllPlantProcessesForAnalysisSixStepProcess121stStep:ScopeDefinitionImportantpointsinthescopestepsare:1.-DefinewhattoincludeandexcludefromtheFMEA.2.-FMEAprojectplan,suchasimportantdates,FMEAresponsibl