SAE_FMEA_draft_std

1SURFACEVEHICLERECOMMENDEDPRACTICEPOTENTIALFAILUREMODEANDEFFECTSANALYSISINDESIGN(DESIGNFMEA),POTENTIALFAILUREMODEANDEFFECTSANALYSISINMANUFACTURINGANDASSEMBLYPROCESSES(PROCESSFMEA),ANDPOTENTIALFAILUREMODEANDEFFECTSANALYISFORMACHINERY(MACHINERYFMEA).DraftProposalfromtheSAEJ1739MainWorkingCommitteeWilliamCarlson-DaimlerChryslerCarlCarlson-GeneralMotorsGlenVallanceandCynthiaTaaffee-FordWithMachineryWorkingSub-CommitteeDavidJanas-DaimlerChryslerAdhiKersala-GeneralMotorsGaryGivens-FordNOTE:FormatofthisReviewDocument:ChangestotheOriginalSAEJ1739documentintheIntroductionandDesignandProcessFMEAsectionshavebeenhighlightedforeaseofcomparison.Textthatisboldanditalicizeisneworrevised.TheMachineryFMEAsectioniscompletelynewandhasnotbeenboldedoritalicizedforpurposesofreadability.FinalFormatoftheStandardispendingapprovalofcontent.Thisdocumentisbeingprovidedfor‘content’relatedcommentsonly.21.Scope—GeneralInformation1.1Overview—ThisSAERecommendedPracticewasjointlydevelopedbyDaimlerChrysler,Ford,andGeneralMotors.ThisdocumentintroducesthetopicofpotentialFailureModeandEffectsAnalysis(FMEA)andgivesgeneralguidanceintheapplicationofthetechnique.AllFMEA’sfocusonthedesign,whetheritbeoftheproduct,theprocessorthemachineryusedtobuildtheproduct.AnApplicationsSection(seeSection5)hasbeenaddedtoprovideinformationonapplyingtheFMEAtechniquetoplantmachineryandequipmentusingtheMachineryFMEA(MFMEA).1.2RecommendedPracticeFormat—Foreaseofuse,thisreferencedocumentpresentsthetwobasictypesofFMEA(DesignFMEAandProcessFMEA)intheirownseparatesections.ThisdocumentalsocontainsanApplicationsSection(Section5)whichdiscussesinsomedetailhowanFMEAisappliedtoPlantMachineryandEquipment(MachineryFMEA).TheMachineryFMEA(MFMEA)informationhasbeenprovidedduetotheimportanceofPlantMachineryandEquipmentfunctioningasintendedinmanufacturingandassemblyplants.TheuseoftheMFMEA,onPlantMachineryandEquipment,willassistwiththeidentificationofpotentialfailuremodes,sothatdesignandprocessingalternativescanbeconsidered,priortofinalizingthePlantMachineryandEquipmentDesigns.Itshouldbenotedthatthisdocumentisarecommendedpractice,andassuch,eachTeamisfreetousetheguidelineslistedhereininthemannerwhichwillbemosteffectiveforagivensituation.Section5.2.17.1containsatableofSuggestedDetectionEvaluationCriteriaforMFMEAwhichhasrankingsof10,7,5,3,and1(doesnotcontainrankingsof9,8,6,4,and2).ThisApplicationsSectionDetectionTableillustratesthattheTeamcanmakemodificationstothestandardformatof10-1rankings,ifthiswillbemosteffectivefortheTeam'ssituationandapplication.Figure1illustratesanapproximatetimelinewheretheDesignFMEA(DFMEA)fortheproductisstartedsomewhatbeforetheProcessFMEA(PFMEA)forproducingtheproduct.Figure1showsthattheMachineryFMEA(MFMEA)shouldbestartedataboutthesametimeasthePFMEA.TheOEMProductDevelopmentTimeLinereferstotheOriginalEquipmentManufacturer'sTimeLinewhichisusedforthedesign,development,andproductionoftheproduct.Insomesituations,allthreeFMEAs(i.e.,DFMEA,PFMEA,andMFMEA)mightbestartedatthesametime.Ingeneral,theearlierthatFMEAsarestarted,thebetterthechancesofoptimizingthevariousactivities/designs/processesinacostandtimeeffectivemanner.3FIGURE11.3WhatisanFMEA?-AnFMEAcanbedescribedasasystemizedgroupofactivitiesintendedto:(a)recognizeandevaluatethepotentialfailureofaproduct/processanditseffects,(b)identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring,and(c)documenttheprocess.Itiscomplementarytotheprocessofdefiningwhatadesignorprocessmustdotosatisfythecustomer.1.4FMEAImplementation—Becauseofthegeneralindustrytrendtocontinuallyimproveproductsandprocesseswheneverpossible,theneedforusingtheFMEAasadisciplinedtechniquetoidentifyandhelpminimizepotentialconcernisasimportantasever.StudiesofvehiclecampaignshaveshownthatfullyimplementedFMEAprogramscouldhavepreventedmanyofthecampaigns.OneofthemostimportantfactorsforthesuccessfulimplementationofanFMEAprogramistimeliness.Itismeanttobeabefore-the-eventaction,notanafter-the-factexercise.Toachievethegreatestvalue,theFMEAmustbedonebeforeaproductorprocessfailuremodehasbeenincorporatedintoaproductorprocess.UpfronttimespentproperlycompletinganFMEA,whenproduct/processchangescanbemosteasilyandinexpensivelyimplemented,willminimizelatechangecrises.AnFMEAcanreduceoreliminatethechanceofimplementingapreventive/correctivechangewhichwouldcreateanevenlargerconcern.CommunicationandcoordinationshouldoccurbetweenalltypesofFMEAs(i.e.Design-DFMEA,Process-FMEA,andMachinery-MFMEA).(SeeFigure1).DesignFMEAMachineryComponent1,**DesignFMEAMachineryFMEA*ProcessFMEAOEMProductDevelopmentTimeLineMachineryComponent2,DesignFMEAMachineryComponentN,DesignFMEA*MachineryFMEAmayormaynotfollowOEMProductDevelopmenttimeline**DesignFMEAonmachinerycomponentsfollowSuppliercomponentdevelopmenttimelineandisindependentofOEMProductDevelopmenttimelineFailuremode&CausesFailuremode&Causes4Figure2FMEAProcessSequenceFigure2depictsthesequenceinwhichanFMEAshouldbeperformed.Itisnotsimplyacaseoffillingoutthecolumn,butratherunderstandingtheprocessandhowtoeliminateriskandplantheappropriateco