FMEA11401070.ppt

11/28/2019,FMEAFailureModeGoback&ReviewItScalingforSeverity,OccurrenceandDetectioncanbelocallydeveloped.YoullseeanexampleinafollowingcasestudyOthercategoriescanbeadded.,UsedWithPermissionAlliedSignal1995-Dr.SteveZinkgraf,11/28/2019,DefinitionofRPNTerms,Severity(ofEffect)-importanceofeffectoncustomerrequirements-couldalsobeconcernedwithsafetyandotherrisksiffailureoccurs(1=NotSevere,10=VerySevere)Occurrence(ofCause)-frequencywithwhichagivenCauseoccursandcreatesFailureMode.CansometimesrefertothefrequencyofaFailureMode(1=NotLikely,10=VeryLikely)Detection(capabilityofCurrentControls)-abilityofcurrentcontrolschemetodetect:thecausesbeforecreatingfailuremodethefailuremodesbeforecausingeffect1=LikelytoDetect,10=NotLikelyatalltoDetect,UsedWithPermissionAllied-Signal1995-Dr.SteveZinkgraf,11/28/2019,GeneralRatingScales,11/28/2019,1,2CosmeticErrorNolossinproductfunctionality.Includesincorrectdocumentation3,4ProductPerformanceReduction-TemporaryThroughtime-outorsystemloadtheproblemwill“goaway”afteraperiodoftime5,6FunctionalImpairment/LossTheproblemwillnotresolveitself,buta“workaround”cantemporarilybypasstheproblemareauntilfixedwithoutlosingoperation7,8FunctionalImpairment/LossTheproblemwillnotresolveitselfandno“workaround”canbypasstheproblem.Functionalityhaseitherbeenimpairedorlostbuttheproductcanstillbeusedtosomeextent9,10ProductHalts/ProcessTakenDown/RebootRequiredTheproductiscompletelyhungup,allfunctionalityhasbeenlostandsystemrebootisrequired,SoftwareFMEAScoringExample,PreparedByBobHody-Salem,VA,SeverityGuidelines,11/28/2019,RateofOccurrenceScale,11per100units-years(1/50m)21per10unit-years(1/5m)31per1unit-year(1/525k)41per1unit-month(1/43k)51perweek(1/10k)61perday(1/1440)71pershift(1/480)81perhour(1/60)91per10min(1/10)101+permin(1/1),SoftwareFMEAScoringExample,PreparedByBobHody-Salem,VA,11/28/2019,1,2Requirements/DesignReviews3,4CodeWalkthroughs/UnitTesting5,6SystemIntegration&Test7,8Installation&Start-up9,10Detectableonlyonce“online”,SoftwareFMEAScoringExample,PreparedByBobHody-Salem,VA,DetectionScale,11/28/2019,PreparingtheFMEA.JustLikeTheOtherTools,TeamEffort:Operators,Technicians,Engineers,Managers,Customers,Co-workers,Suppliers,ARMI,etc.InputstoMappingProcessMapC&EMatrixBrainstormingEngineeringSpecifications/OperatingManualsEmployeeExperience6Ms(FishboneDiagram)Man,Machine(Equipment),Method(Procedures),Measurement,MotherNature(Environment),Materials,UsedWithPermissionAllied-Signal1995-Dr.SteveZinkgraf,11/28/2019,11/28/2019,ProcessMapToBeUsedInExample,11/28/2019,C&EMatrixExample,11/28/2019,11/28/2019,2.ForeachFailureModedetermineEffects,Theseeffectsareinternalrequirementsforthenextprocess.,11/28/2019,3.IdentifypotentialCausesofeachFailureMode,Inmostcases,therewillbemorethanoneCauseforaFailureMode.Wellkeepitsimpleforthisexercise.,11/28/2019,4.ListtheCurrentControlsforeachCause,ForeachCauselisthowweareeitherpreventingordetectingit.RecordtheprocedurenumberwhereverthereisanSOP.,ThisishowtheFMEAidentifiesinitialholesintheCurrentControlPlan.Teamscanstartworkingontheseholesrightaway.,11/28/2019,5.AssignSeverity,OccurrenceandDetectionratingstoeachCause,Ifyouhavedevelopedascalingmatrix,includeinyourdocumentation.,Note:Iftherearenocurrentcontrolstheabilitytodetect=10.,11/28/2019,6.CalculateRPN,RPN=Severity*Occurrence*Detection,11/28/2019,7.DetermineRecommendedActionstoreduceHighRPNs,ActionsarerecommendedforonlythehighRPNs.ThekeyisFOCUS!,First,sortallcausesbyRPN.NoticethatyouhavetofillallcellsforeachcolumnsoyoucancarrytheFailureModes,Effects,CausesandCurrentControlsalongwiththesort.,11/28/2019,8.TakeappropriateActionsandDocument,Ifthereisan“easy”fixforlowRPNitems.takeactionanddocument,11/28/2019,9.RecalculateRPNs,WorkonrevisedhighestRPNs,11/28/2019,Overview,WhatistheInput,WhatcangowrongwiththeInput?,WhatistheEffectontheOutputs?,WhataretheCauses?,HowOften?,Howcanthisbefound?,Howwell?,Whatcanbedone?,UsedWithPermissionAllied-Signal1995-Dr.SteveZinkgraf,SoftwaretoolshavebeenpreparedtoassistyouinthepreparationoftheFMEAJ:Sixclass6BlackBBwk1DataFMEAform.xls,HowSevere?,11/28/2019,SixSigmaToolsLinkage,SuspectKeyInputs(Largest#s),Datashouldthenbecollectedon:1)TheassociatedYs(CTQs).2)TheKeyInputsandpotentialcausesoffailurerelatedtothoseKeyInputswiththehighestRPNnumbersandanyunknowns.,STEP#1:ProcessMappinga.-FormateamusingSubjectMatterExpertsandProcessOwnersb.-Definethecurrentprocessstepsandinputs(Xs)c.-IdentifywhichprocessstepseffecteachCTQd.-Identifythecharacteristicofeachprocessinput(Controllable,Criticaland/orNoise)DonotproceeduntilallpreviousiscompleteSTEP#2:C&EMatrixa.-ListthecontrollableandcriticalinputsverticallyintheC&Ematrixb.-ListtheCTQshorizontally(UsethecustomertodeterminetheimportanceofeachCTQ)c.-UsethesameteamtocorrelateandweightheimpactofeachinputtoeachCTQDonotproceeduntilallpreviousiscompleteSTEP#3:FMEAa.-ListtheKeyInputs(whichrankhighontheC&E)inthe“KeyInputs”columnoftheFMEAb.-WorkthroughtheFMEAwiththeteamDonotproceeduntilallpreviousiscompleteSTEP#4:GatherDataa.-Gatherdataaboutthosepotentialcauses(Xs)withthehighestRPNNumbersandanyunknowns.,StepTwo:Cause&EffectMatrix,StepThree:FMEA,StepFour:DataGathering,1,2,3,StepOne:MapTheCurrentProcess,CTQsA-CTQ1B-CTQ2,A,A,AB,ProcessInputs(Xs),11/28/2019,FMEA“RealLifeExamples”,11/28/2019,11/28/2019,