FMEA Training2

FailureMode&EffectAnalysisExplanationandUseofFMEAQualityForwardSystemWhatisFMEA?•FMEAisaproblemsolvingprocessadoptedbySnap-onasakeycomponentoftheQualityForwardSystem.•Generally,FMEAisdonebyanon-sitemultifunctionalteamfacilitatedlocallyorbyanSEQGroupAdvancedQualityEngineer.•Objectiveistoidentifyallofthereasonswhyqualityofaprocessorproductdoesnotmeetexpectations.•Usesseverity,occurrenceanddetectionratingstodeterminecorrectiveactionpriorityforeachpossiblefailurereason.QualityForwardSystemWhenshouldaFMEAstudybeconducted?•AspartofaDesign/Developmentphase.•Whencorrectiveactionisneededduetounfavorableperformancedata–(performancebasedonQFSmetricsdoesnotmeetgoals).•WhenaneedtomakeincrementalimprovementisidentifiedbyfacilitymanagementortheSEQGroup.QualityForwardSystemFMEATeamStart-Up•TeamSelection–donebylocalqualitycoordinator,businessunitmanageror,onrequest,SEQGroupAdvancedQualityEngineer.•ProblemStatement–Aconciseandfocuseddescriptionofthequalityproblemoropportunityforimprovement,“whatwentwrong”or“whatneedsfixing”.•GoalStatement–adescriptionofwhatistobeaccomplishedbytheteam,inquantifiableterms“reduceby”,“increaseby”,“eliminate”,etc.Goodmetricstouseincludescrapcost,reworkcost,orDefectsPerMillionOpportunities(DPMO),etc.Forexample,agoalstatementcouldbe“ToreduceDPMOonproductfamilyXfrom3000to2000byyearend”.•CompleteFMEATeamStart-UpWorksheet(examplelocatedinprocedureSEQ80.10,Figure1).QualityForwardSystemProblemStatement&GoalStatement•ProblemStatementandGoalStatementshouldconsider:•Whatwentwrong?•Whatisthegapbetweenthedesiredqualitylevelandtheactualqualitylevel?•Whichprocessorprocessesareinvolved?•Whichdepartmentorcellisthedeficiencyoccurringin?•Istheproblemcyclic,canitbeattributedtospecificevents?•Whataretheappropriatemetricstomeasure?•Whatistheimpactonoperationalfitnessandprofitability?•Whatistheimpactonthebottomline(reduced,increased,eliminated)?•Arethereconstraintsrecognizedearlyintheprocess?Ifso,havetheybeenexploredandclarifiedwiththeappropriatemanagementlevelQualityForwardSystemFMEAProcess•FMEA’suncoverprocessproblemsrelatedtothemanufactureofproduct.•Examples:apieceofautomatedassemblyequipmentmaymisfeedpartsresultinginproductsnotbeingassembledcorrectly,or,inachemicalmanufacturingprocess,temperatureormixingtimecouldbesourcesofpotentialfailuresresultinginunusableproduct.•Thinkintermsofthefiveelementsofaprocess:people,materials,equipment,methodsandenvironment.Withthesefiveelementsinmind,ask“Howcanprocessfailureaffecttheproduct,processingefficiencyorsafety?”•NinestepsinFMEAprocess.QualityForwardSystemStep#1-ReviewtheProcess•EnsurethateveryoneontheFMEAteamhasthesameunderstandingoftheprocessbeingworkedon.•Reviewblueprint/engineeringdrawingofproduct(ifconductingFMEAonproduct)and/oradetailedflowchartoftheprocess.Ifthesearenotavailable,theteamwillneedtocreateone.•Usingtheblueprintand/orflowchart,teammembersshouldfamiliarizethemselveswiththeproductorprocess.Theyshouldphysicallyseetheproductoraprototypeoftheproduct,andphysicallywalkthroughtheprocessexactlyastheprocessflows.•Itishelpfultohavean“expert”ontheproductorprocessavailabletoansweranyquestionstheteammighthave.QualityForwardSystemStep#2–BrainstormPotentialFailureModes•Methodofgeneratinganddocumentingideasofpotentialfailuremodes.•Ifproductorprocessiscomplex,aseriesofbrainstormingsessions,eachfocusedonadifferentelement(i.e.people,methods,equipment,materials,environment),maybeneededtogenerateamorethoroughlistofpotentialfailuremodes.•Facilitatorshouldwritedownallideasgeneratedinbrainstormingsessions.•Oncebrainstormingiscomplete,ideasshouldbegroupedintolikecategories(asdeterminedbytheteam).Groupscanbetypeoffailure,whereontheproductfailureoccurred,estimatedseriousnessofthefailure,etc.Failuremodesmayalsobecombinediftheyarethesameorverysimilar.•Oncefailuremodeshavebeengrouped/combined,theyshouldbetransferredtothePotentialFailureModeandEffectAnalysisSheet(exampleinSEQ80.10,Figure2).QualityForwardSystemStep#2(continued)–BrainstormingGuidelines•Donotmakeanyjudgmentonideas.Teammembersshouldnotcommentonwhetheranideaisgoodorbad.•Thinkingshouldbeunconventional,imaginative,orevenoutrageous.•Aimforalargenumberofideasintheshortestpossibletime.•Teammembersshould“hitchhike”onotherideas,byexpandingthem,modifyingthem,orproducingnewonesbyassociation.•Allteammembersshouldparticipateinbrainstormingprocess.QualityForwardSystemStep#3–ListPotentialEffectsofEachFailureMode•AfterthefailuremodesarelistedontheFMEAworksheetform,theFMEAteamneedstorevieweachfailuremodeandidentifythepotentialeffectsofthefailureshoulditoccur.•Forsomefailuremodes,theremaybeonlyoneeffect,whileotherfailuremodesmayhaveseveraleffects.•Thisstepmustbethorough–thisinformationwilldetermineassignmentofriskratingsforeachofthefailures.•Itishelpfultothinkofthisstepasanif-thenprocess:Ifthefailureoccurs,thenwhataretheconsequences.QualityForwardSystemStep#4–AssignSeverityRating•Theseverityratingisanestimateofhowserioustheeffectswouldbeifagivenfailuredidoccur.•Maybebasedonpastexperience,oranestimatebasedontheknowledgeandexpertiseoftheteamme