Process FMEA.ppt

November28,2019,FailureModeandEffectsAnalysis,FMEA,FailureModeandEffectsAnalysisLearningObjectives,Attheendofthissectiondelegateswillbeableto:UnderstandtheroleofFailureModeandEffectsAnalysis,FMEAwithintheDMAICImprovementProcessConductaProcessFMEAonanexisting,newormodifiedtransactionalprocessUsetheProcessFMEAtoprioritiseareasforattentionUsetheProcessFMEAtosupportthegenerationofControlPlans,2,3,FailureModeandEffectsAnalysis-Agenda,IntroductiontoFailureModeandEffectsAnalysisFMEAWithinDMAICFMEARoadmapFMEAFormandControlPlansImplementingFMEASummary,“Classic”Failures,Citytraderbuys15,000,000sharesinsteadof15,000LeapdayshutsdownbankcashmachinesNASAprobelostduetoMetric/ImperialunitsconfusionWorldwidePerrierstockswithdrawnduetofilterfailurePilotshutsdownwrongaircraftengineCompanyemailsconfidentialaccountinformationtoanalystsandhastosuspendtrading,4,5,IntroductiontoFMEA,FailureModeandEffectsAnalysis,FMEAis:Asystematicmethodofidentifyingandinvestigatingpotentialdesignorprocessweaknesses.Ameanstoevaluateandmanageproductrisks.Ameansofevolvingorganizationalknowledge.Developedintheaerospaceindustryinthemid1960s,FMEAPurpose,Recogniseandevaluatethepotentialfailuremodesandcausesassociatedwiththedesignandmanufactureofaproductordesignandoperationofanyprocess.Identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring.Documenttheanalysisandchangesmade.,6,7,ApplicationofFMEAinSixSigma,InDesignforSixSigma-(DesignFMEA):toidentifypotentialfailuremodestoidentifypotentialcausesoffailuretoeliminate/minimisethepotentialfailuremodeswithintheDesignprocessInTransactional/OperationalSixSigma(ProcessFMEA):toanalysetheexistingprocesses(identifypossiblexs)toimprovetheprocess(elimination/reductionoffailuremodes)toselectnewprocessalternativestodevelopcontrolplans,8,ApplicationofPFMEAinDMAIC,Measure:PreliminaryrootcauseanalysisAnalyse:Toanalysetheexistingprocessesandidentifypossiblexs(causesoffailure)Improve:Toimprovetheprocess(elimination/reductionoffailuremodes)ToselectnewprocessalternativesControl:TodevelopcontrolplansItisonlynecessarytoconductPFMEAonthemodified/changedareasoftheprocess,LinksfromC&EMatrix,Page9,KPOVs,KPIVs,ProcessFMEARoadmap,1.DescribeProcess,3.IdentifyPotentialFailureModes,5.DetermineCauses,6.CurrentControls,9.AssessResults,11,Step1:DescribeProcess,12,Suppliers:SalesStores,Inputs:OrderProductPackaging,Customers:SalesShippingEndcustomer,Outputs:PackagedProductShippingrequisitionOrderfulfilmentnote,Step1:DescribeProcess-OrderFulfilment,Receiveorder,Checkstock,Pullproductandcheck,Packageproduct,Weighproduct,Correctweight?,Orderstock,NotifySales,TransfertoGoodsOut,Yes,Yes,No,No,13,Step2:DefineFunction,14,ActionVerb,Noun,Gather,Publish,Approve,Release,Project,Report,Credit,Product,Data,Sales,Test,Part,Check,Contact,Receive,Deliver,Calculate,Address,Customer,Stock,Order,Price,ActionVerb,Noun,Process,Information,ExamplesofFunctions,15,Step2:DefineFunction,FunctionsReceiveorderChecksufficientstockNotifysalesOrderstockPullproductCheckproductEtc.,Receiveorder,Checkstock,Pullproductandcheck,Allavailable?,Orderstock,NotifySales,Yes,No,16,Function,DoesNotFunction?,ListofPotentialFailures,Doesnot/CannotToomuchToolittleTooearlyToolateDegradedIntermittentIncorrectUnwanted,Function,Step3:IdentifyPotentialFailureModes,3.IdentifyPotentialFailureModes,17,ProcessFunction,PotentialFailureModes,ReceiveOrder,DoesnotreceiveorderReceivesincorrectorderReceivestoomanyorders,Checksufficientstock,DoesnotchecksufficientstockIncorrectcheck(wrongconclusion)InsufficientstockwhensufficientSufficientstockwheninsufficient,Step3:IdentifyPotentialFailureModes,NotifySales,DoesnotnotifysalesNotifiessalestoolateNotifiessaleswithincorrectinformation,18,Assumethefailurecouldoccur-whatwouldbetheeffect?,Consider:Howitaffectstheprocess(processor):nextoperationsubsequentdownstreamoperationsHowitaffectstheenduser(customer).Immediate&delayedimpact.Berealistic.,Note:Theremaybeseveralpotentialeffectsforeachfailure,butthesearelistedtogetherasoneoveralleffect.,Step4:DescribeEffectsofFailure,19,DoesnotReceiveOrder,Incorrectstockcheck(Concludesinsufficientwhensufficientavailable),Step4:DescribeEffectsofFailure,Assumethefailurecouldoccur-whatwouldbetheeffect?,PotentialFailureModes,PotentialEffects,Ordernotfulfilled,customerhastore-submitorder,Delayinfulfillingorder,excessstock,possiblelossoforder,Incorrectstockcheck(Concludessufficientstockwheninsufficientavailable),Incompleteorder,delay,customerdissatisfaction,NotifySalestoolate,Customernotawareofdelay,salestakesfurtherorders,20,Whatcouldcausethepotentialfailuremodetooccur?,Process/processorerrorsthatcouldleadtothefailureBespecific,“processorerror”or“equipmentfailure”aretoovagueConsidertheworkingenvironmentoftheprocess,conditionofequipment,ITsystemsTherewilltypicallybeseveralcausesforeachfailuremodeIdentifyrootcausesforseverefailures,Step5:DetermineCauses,21,Step5:DetermineCauses,Whatcouldcausethepotentialfailuremodetooccur?,PotentialCauses,PotentialFailureModes,IncorrectlyaddressedDeliveredtowrongdepartmentLostinpost,Incorrectstockcheck,ErrorininventorylevelsEnteredwrongpartcodeEnteredwrongquantityMultipleordersinprocess,22,Forthegivenexample,describetheprocessusingaprocessflowchart.Describeeachprocessstepintermsofitsfunctionusingaverbnouncombinatione.g.checkstock,calculateprofit,completeinvoice,checkformetc.(N.B.dependingonthedetailoftheflowcharttheremaybemorethanonefunctionateachstep).Workingfromtheprocessflowchart,identifypotentialfailuremodesbyaddingthekeywords:doesnot/cannot/incorrectfunction,toomuch/toolittlefunction,tooearly/latefunctionetc.Eachfunctionshouldhaveatleastonefailuremode.Foreachofthefailuremodesidentifythepotentialeffectsofthefailureontheprocess,processorand/orthecustomer.Ifthereareseveraleffectsthengroupthesetogetherastheoveralleffectforthefailuremode.Eachfailuremodeshouldhaveoneeffect.Foreachfailuremode,identifythepossiblecausesofthefailure.Bespecific,“processorerroristoovague.Therewilltypicallybemorethanonecauseperfailuremode.Prepareashortpresentationonyourteamsfindings.,Workshop1Time:,Workshop1:IdentifyPotentialFailuresModes,ProcessFMEARoadmap,1.DescribeProcess,3.IdentifyPotentialFailureModes,5.DetermineCauses,6.CurrentControls,9.AssessResults,24,Inorderofpreferencetherearethreetypesofcurrentcontrols:PreventthecauseDetectthecause,leadingtocorrectiveactionDetectthefailure(defect)Thesemightinclude:ControlChartsCheckSheetsMistakeProofingTrainingInformationTechnology,Identifythecurrentcontrolstoprevent/detectthefailurebeforeitreachesthecustomer,Step6:CurrentControls,25,Step6:CurrentControls,Incorrectstockcheck,ErrorininventorylevelsEnteredwrongpartcodeEnteredwrongquantityMultipleordersinprocess,Stocktake(annual),StockcontrolsystemDoubleentryrequiredDoubleentryrequiredNocontrols,PotentialFailureModes,Identifythecurrentcontrolstoprevent/detectthefailurebeforeitreachesthecustomer,PotentialCauses,CurrentControls,26,ProbabilityofOccurrence,Detection(CapabilityofCurrentControls),RiskPriorityNumber,X,X,=,Step7:CalculateRisk,SeverityoftheEffect,27,ProcessFMEASeverityRating,Howseriousistheeffect?,Note:Manyorganisationschoosetomodifythedescriptionstobestdescribetheirindustry.,Inconvenient,serviceprovidedbutnotuptoexpectations,Someprocessdisruption,sometransactionalreworking,28,ProcessFMEAOccurrenceRating,Howlikelyisthecause?,Note:Manyorganisationschoosetomodifythedescriptionstobestdescribetheirindustry,Occ,Probability,Likelyfailurerates,11,Veryhigh,persistentfailures,7,1in100transactions(opportunities),4,Moderate,occasionalfailures,2,Low,relativelyfewfailures,29,ProcessFMEADetectionRating,HoweffectivearetheCurrentControls?,30,EffectIncompleteorder,delay,customerdissatisfaction,CauseMultipleordersinprocess,CurrentControlsNoControls,Severity=4,Occurrence=4,Detection=11,RPN=4x4x11=176,Step7:CalculateRisk,FailureModeIncorrectStockCheck,31,CorrectiveActionEffectsOnRPNRating,Note:DonotmodifyRPNuntilcorrectiveactioniscompleted(Step9),Step8:TakeAction,32,EffectIncompleteorder,delay,customerdissatisfaction,CauseMultipleordersinprocess,CurrentControlsNoControls,Severity=4,Occurrence=4,Detection=11,RPN=4x4x11=176,Step8:TakeAction,FailureModeIncorrectStockCheck,StockCheckisimproved,33,ReviewcorrectiveactionsandmodifyRPNfigurebasedonresults.,Step9:AssessResults,34,EffectIncompleteorder,delay,customerdissatisfaction,CauseMultipleordersinprocess,CurrentControls,Severity=4,Occurrence=4,Detection=2,RPN=4x4x2=32,Step9:AssessResults,FailureModeIncorrectStockCheck,StockCheckisimproved,ProcessFMEARoadmap,1.DescribeProcess,3.IdentifyPotentialFailureModes,5.DetermineCauses,6.CurrentControls,9.AssessResults,36,FMEAPurpose,Recogniseandevaluatethepotentialfailuremodesandcausesassociatedwithabusinessprocessormanufactureofaproduct.Identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring.Documenttheanalysisandchangesmade.,37,FMEAForm,FMEABrainstorming(MeasureStage),Page38,FMEARiskAnalysis(Analyzestage),Page39,FMEAActionPlanning(AnalyzeStage),Page40,FMEAImplementActionPlan(ImproveStage),Page41,42,FMEAVerify(beforeprojectclosure),43,Workshop2:RiskAssessment,Transferthefailuremodes,effectsandcausesidentifiedinworkshop1tothelargeFMEAform.UsingtheSeverityratingscale,rateeachofthefailuremodeeffectsandrecordthenumberintheappropriatecolumn.Wherethereareseveralpossibleeffectsforafailuremode,taketheworstcasefortherating.Thereshouldbeonlyoneseverityratingforeachfailuremode.UsingtheOccurrenceratingscaleandyourteamsexpertise,rateeachofthepotentialcausesoffailureandrecordthenumbersintheappropriatecolumn.Forthepurposeoftheexercise,assumetherearenoCurrentControls(Detectionrating=11),calculatetheRiskPriorityNumbers(RPN)andrecordonthechart.ThereshouldbeoneRPNscoreforeachcauselistedontheFMEAform.ForthetopfiveRPNs,identifypossibleactionstoreducetheRPNscores.Identifywhichofthecategories(Severity,Occurrence,andDetection)wouldbereducedoncetheactionhasbeencompleted.Prepareashortpresentationtosummariseyourteamsfindings.,ImplementingFMEA,Improve,44,45,TeamnotanindividualCrossfunctionalopportunitytoimprovecommunicationandunderstandingIncludetheprocessors(peoplewhoworkintheprocess)Considerincludingthecustomerwhereappropriate,WhoShouldDoFMEA?,46,10KeysToFMEASuccess,Supportbytop&middlemanagementMotivatedteammembersCrossfunctionalrepresentationontheteamTreatas“beforetheevent”not“afterthefact”GeneratecompanyspecificratingscalesTreatasalivingdocument-reflectlatestrevisionsExecuterecommendedactionsIntegrationintoyourdevelopmentprocessGenerate&usealibraryofgenericFMEAsFollowthespirit,nottheform,CommonMistakes,AppliedtoolatePoorteam