IntroductiontoFMEA

SECTIONONEIntroductionToFAILUREMODEEFFECTS&ANALYSISFMEA1.0Definition,Purpose,andPracticesFMEA:ASYSTEMIZEDGROUPOFACTIVITIESDESIGNEDTO1.RECOGNIZEandEVALUATEthePOTENTIALFAILUREofaPRODUCT/PROCESSanditsEFFECTS2.IDENTIFYACTIONSWHICHCOULDELIMINATEorREDUCEtheCHANCEofPOTENTIALFAILUREOCCURRING3.DOCUMENTthePROCESS1.1DESIGNFMEA(DFMEA)PROCESSFMEA(PFMEA)AREANALYTICALTECHNIQUESUTILIZEDBYDESIGNRESPONSIBLEENGINEER/TEAMORMANUFACTURINGRESPONSIBLEENGINEER/TEAMTHESETOOLSAREUSEDTOASSURETHATPOTENTIALPRODUCTFAILUREMODESAndTHEIRASSOCIATEDCAUSESHAVEBEENCONSIDEREDandADDRESSEDINTHEDESIGNORMANAUFACTURINGPROCESS1.2DFMEASUPPORTSDESIGNPROCESSinREDUCINGRISKofFAILURESbyAIDINGINTHEOBJECTIVEEVALUATIONOFDESIGNREQUIREMENTSANDDESIGNALTERNATIVESAIDINGINTHEINITIALDESIGNFORMANUFACTURINGANDASSEMBLYINCREASINGTHEPROBABILITYTHATPOTENTIALFAILUREMODESANDTHEIREFFECTSONSYSTEMSANDPRODUCTOPERATIONHAVEBEENCONSIDEREDINTHEDESIGN&DEVELOPMENTPROCESSPROVIDINGADDITIONALINFORMATIONTOAIDINTHEPLANNINGOFEFFICIENTDESIGNTESTINGANDPRODUCTDEVELOPMENTPROGRAMS1.3DFMEAALSOSUPPORTSDESIGNPROCESSByDEVELOPINGALISTOFPOTENTIALFAILUREMODESRANKEDACCORDINGTOTHEIREFFECTONTHE“CUSTOMER,”THUSESTABLISHINGAPRIORITYSYSTEMFORDESIGNIMPROVEMENTSANDDEVELOPMENTTESTINGPROVIDINGANOPENISSUEFORMATFORRECOMMENDINGANDTRACKINGRISKREDUCINGACTIONSPROVIDINGFUTUREREFERENCETOAIDINANALYZINGFIELDCONCERNS,EVALUATINGDESIGNCHANGESANDDEVELOPINGADVANCEDDESIGNS1.4PFMEATHEPROCESSFMEAIDENTIFIESPOTENTIALPRODUCTRELATEDPROCESSFAILUREMODESASSESSESTHEPOTENTIALCUSTOMEREFFECTSOFTHEFAILURESIDENTIFIESTHEPOTENTIALMANUFACTURINGORASSEMBLYPROCESSCAUSESANDIDENTIFIESPROCESSVARIABLESONWHICHTOFOCUSCONTROLSFOROCCURRENCEREDUCTIONORDETECTIONOFTHEFAILURECONDITIONSDEVELOPSARANKEDLISTOFPOTENTIALFAILUREMODES,THUSESTABLISHINGAPRIORITYSYSTEMFORCORRECTIVEACTIONCONSIDERATIONSDOCUMENTSTHERESULTSOFTHEMANUFACTURINGORASSEMBLYPROCESS1.5FMEAAPPLICATIONSINMANUFACTURINGSETTINGSDFMEASHOULDBEINITIATEDBEFOREORATDESIGNCONCEPTFINALIZATIONSHOULDBECONTINUALLYUPDATEDASCHANGESOCCURORADDITIONALINFORMATIONISOBTAINEDTHROUGHOUTTHEPHASESOFPRODUCTDEVELOPMENTSHOULDBEFUNDAMENTALLYCOMPLETEDBEFORETHEDRAWINGSARERELEASEDFORTOOLING,OROTHERMANUFACTURINGNEEDSADDRESSESTHEDESIGNINTENTANDASSUMESTHEDESIGNWILLBEMANUFACTUREDANDASSEMBLEDTOTHISINTENTDOESNOTRELYONPROCESSCONTROLSTOOVERCOMEPOTENTIALWEAKNESSESINTHEDESIGN,BUTITDOESTAKETHETECHNICALANDPHYSICALLIMITATIONSOFAMANUFACTURINGORASSEMBLYPROCESSINTOCONSIDERATION1.6FMEAAPPLICATIONSINMANUFACTURINGSETTINGSPFMEASHOULDTAKEINTOACCOUNTALLMANUFACTURINGOPERATIONS,FROMINDIVIDUALCOMPONENTSTOASSEMBLIESDOESNOTRELYONPRODUCTDESIGNCHANGESTOOVERCOMEWEAKNESSESINTHEPROCESSDOESTAKEINTOCONSIDERATIONAPRODUCT’SDESIGNCHARACTERISTICSRELATIVETOTHEPLANNEDMANUFACTURINGORASSEMBLYPROCESSASSURESTHAT,TOTHEEXTENTPOSSIBLE,THERESULTINGPRODUCTMEETSCUSTOMERNEEDSANDEXPECTATIONS1.7KEYRESOURCESNECESSARYTOCONDUCTSUCCESSFULFMEAPROGRAMSCOMMITMENTOFTOPMANAGEMENTKNOWLEDGEABLEINDIVIDUALS,I.E.EXPERTISEIN:DESIGNMANUFACTURINGASSEMBLYSERVICEQUALITYRELIABILITYINDIVIDUALSATTENTIVETOFMEATIMELINESS,I.E.ACHIEVEGREATESTVALUE:BEFOREADESIGNORPROCESSFAILUREMODEHASBEENUNKNOWINGLYDESIGNEDINTOTHEPRODUCTPEOPLERESOURCESMAYBEINTERNALOREXTERNALTOTHEBUSINESS,ORACOMBINATIONTHEREOF1.8FMEAADVANTAGES(ANDLIMITATIONS)ADVANTAGES:ENHANCEDESIGNANDMANUFACTURINGEFFICIENCIESALLEVIATELATECHANGECRISESMINIMIZEEXPOSURETOPRODUCTFAILURESAUGMENTBUSINESSRECORDSIMPROVE“BOTTOMLINE”RESULTSADDTOCUSTOMERSATISFACTION1.9FMEAADVANTAGES(ANDLIMITATIONS)LIMITATIONS*EMPLOYEETRAININGREQUIREMENTSINITIALIMPACTONPRODUCTANDMANUFACTURINGSCHEDULESFINANCIALIMPACTREQUIREDTOUPGRADEDESIGN,MANUFACTURING,ANDPROCESSEQUIPMENTANDTOOLS*TheseLIMITATIONSshouldberecognizedandtreatedas“shortterm”and“minimal”interruptionstoabusiness,andunderstoodtoultimatelyofferdynamicADVANTAGES!1.10SECTIONTWOFMEAPLANUTILIZINGKEYPRODUCTIONPROCESSESANDPRODUCTEVALUATIONTOOLS2.0QUALITYMANAGEMENTPROCESSPRINCIPLESDRIVINGCUSTOMERSATISFACTIONTEAMWORKMANAGINGPROCESSESSTATISTICALPROCESSCONTROL2.1FMEAREQUIRESTEAMWORKBUILDQUALITYINTOPEOPLETHROUGHTRAININGandCOMMITTEDLEADERSHIP2.2MANAGINGPROCESSESUTILIZEASTYLEOFMANAGEMENTTHATISALSOPEOPLEORIENTEDINCONTRASTTOONETHATISSOLELYORIENTEDTOWARDRESULTSPROCESS-ORIENTEDMANAGEMENTSUPPORTANDSTIMULATEEFFORTSTOIMPROVETHEWAYEMPLOYEESDOJOBSREINFORCES“LONGTERM”OUTLOOKMANAGEMENTCRITERIADISCIPLINETIMEMANAGEMENTSKILLDEVELOPMENTPARTICIPATION&INVOLVEMENTMORALECOMMUNICATION2.3STATISTICALPROCESSCONTROL(SPC)STATISTICALTOOLSPARETODiagramsCAUSE-AND-EFFECTDiagramsHISTOGRAMSCONTROLChartsSCATTERDiagramsGRAPHSCHECKSHEETS2.4PROCESSINCORPORATIONAPROCESSINCLUDESSOMECOMBINATIONOF:METHODSMATERIALSMACHINESMANPOWERENVIRONMENTMEASUREMENTTHESEAREINCORPORATEDTOCOMPLETETASKS,SUCHASPRODUCINGAPRODUCTORPERFORMINGASERVICE.APROCESSHASMEASURABLEINPUTSANDOUTPUTS.2.5FMEAPROJECTSSELECTION&PURPOSETANGIBLEEFFECTSSUCCESSFULDEVELOPMENTOFNEWPRODUCTSSHORTENINGOFPRODUCTDEVELOPMENTTIMEINCREASEDMARKETSHAREINCREASEDSALESVOLUMEDEVELOPMENTOFNEWMARKETSINCREASEDPRODUCTIONVOLUMEFEWERPROCESSESIMPROVEDQUALITYREDUCEDDEFECTCOSTSFEWERC