DesignFMEA.ppt

1,DesignandProcessFMEA,HANDBOOKBySamuelChungHeadofQuality,ReferenceFQEI2.2,2,DESIGNFMEACHECKLISTDevelopment,3,DesignFMEAChecklist,4,DesignFMEAChecklist,5,DesignFMEAChecklist,6,DesignFMEAChecklist,7,DesignFMEAChecklist,8,DesignFMEAChecklist,9,DesignFMEAChecklist,10,DesignFMEAChecklist,11,DesignFMEAChecklist,12,DesignFMEAChecklist,13,DESIGNFMEA-Development,FlowChartsandBlockDiagramsareusedtoestablish:inputinformationprocess(function)thedeliverablesoroutputTheydemonstrateprimaryrelationshipsandlogicalorderandareattachedtotheFMEA,14,Workshop1BlockDiagram,YouaregoingtobesplitintoteamsTheteamswillbemulti-disciplinedNominateateamleader,“EngineerResponsible”Usethe“BlockDiagramBlank”todevelopablockflowdiagramtorepresentthedesignconsiderationsfor.,15,Workshop1BlockDiagram,ACompanySwitchforXXXXXSomepointsyoumightwishtoconsiderwhoisgoingtouseit?whereisitgoingtobeused?howisittobepowered?expectedlife?,16,Workshop1BlockDiagram,Didyoucompletethekeydetailsatthetop?Anyareaswhereyouneedhelp?Anyadditionalinformationrequired?,17,THEFMEAFORM,18,THEFMEAFORM,FMEANUMBER,DocumentnumberforTrackingtheanalysis,System,Subsystem,Componentnameandnumber,Indicationofthelevelofanalysisbyreferencetothenameandreferencenumberofthesystem,sub-systemorcomponent.,DesignResponsibility,Thenameofthegroup,department,supplierorOEM,19,THEFMEAFORM,Preparedby,NameandcontactnumberfortheEngineerwhopreparedtheFMEA,ModelYear(s)/Vehicle,Theintendedproductmodelandproposedlinespotentiallyaffectedbythecomponentsbeinganalyzed.,KeyDate,InitialduedatefortheFMEAnottoexceedthescheduledproductiondesignrelease,20,THEFMEAFORM,FMEADate,ThedatetheoriginalFMEAwascompiledandthelatestrevisiondate,CoreTeam,Thoseresponsible,individualsanddepartments,whohavetheauthoritytoidentifyand/orperformtasksNBteammembersnames,departmentsandcontactreferencesaretobeincludedinthedistributionlist.,21,THEFMEAFORM,9Item/Function10PotentialFailureModes11PotentialEffect(s)ofFailure,22,ITEM/FUNCTION,9,Name/referenceofitemanalyzedReferencesasondrawingDesignlevelasondrawingUseexperimentalnumberpriortoinitialreleaseDetailFunctionandEnvironmentMultiplefunction=multiplemodes,23,POTENTIALFAILUREMODE,10,ThemannerinwhichtheitembeinganalyzedcouldfailtomeetdesignintentMaycausepotentialfailureofahigherlevelsystemMaybecausedbyafailureinalowerlevelsystem,24,POTENTIALFAILUREMODE,10,ListthepotentialfailuremodeforeachAssumeamodecanoccurbutmaynotWherehasitgonewronginthepast?Hasanythingsimilarhappened?Anyconcerns?TeamcanbrainstormFailuremodesmayoccuronlyundercertainconditions,25,POTENTIALFAILUREMODE,2,Conditionsmayinclude:abnormalenvironmenthot,cold,wet,dry,humidity.corrosiveatmosphereUsageandabuseconsideredaboveaverageloading,roughhandlinghighspeed,irregularuse,10,26,POTENTIALFAILUREMODE,2,TypicalFailureModes.,CrackedDeformedLeadsbentLeakage,DiemisalignedShortCircuitedOxidizedFractured,.arephysicalconditionsnotsymptoms,10,27,POTENTIALEFFECT(S)OFFAILURE,2,Whatdoesthecustomersee?Howdoescustomerrecognizeornoticethefailure?ExternalandinternalCustomers,Definedasthecustomerperceivedeffectsofthefailure,11,28,POTENTIALEFFECT(S)OFFAILURE,Foreachfailuremode,listitsconsequenceson:Partfunction/performanceNexthigherassembly/systemVehicle/product,customer,Governmentregulation,11,29,WORKSHOP2FAILUREEFFECTS,CompanySwitchforxxxxasbeforeSameTeamsasbeforeNominateanewteamleaderStarttocompletetheblankDesignFMEAPreparelistofPotentialFailureModesPreparelistofPotentialEffectsoffailure,30,POTENTIALEFFECT(S)OFFAILURE,2,TypicalFailureEffects,11,NoiseOperationalImpairedRoughIntermittentOperationUnstableUnpleasantOdorInoperativePoorAppearanceErraticOperation,31,POTENTIALEFFECT(S)OFFAILURE,Asexperiencedbysubsequentoperation(s)CannotfastenlidCannotmountpartDoesnotfitfixtureEndangeroperator,11subsequentoperation,32,33,THEFMEAFORM,12Severity13Classification,34,SEVERITYS,12,EffectonthecustomerifitoccursEffectonthenextcomponent,subsystemorsystemDesignchangeisrequiredtoreducetheSeverityRankingindex.,Theassessmentoftheseriousnessofaneffect(listedincolumn11)ofapotentialfailuremode,35,SEVERITYINDEX,12,themethodofrankingseriousnessEffectonthecustomerifitoccursEffectonthenextcomponent,subsystemorsystemDesignchangeisrequiredtoreducetheSeverityRankingindex.,36,SuggestedEvaluationCriteria,37,SuggestedEvaluationCriteria,38,SuggestedEvaluationCriteria,39,SuggestedEvaluationCriteria,40,WORKSHOP3SEVERITYINDEX,RankingSeriousness,CompanySwitchforxxxxSameTeamsNominateanewteamleaderUsethe“SeverityCriteriaTable”todevelopalistofSeverityEvaluationCriteria,41,WORKSHOP3SEVERITYINDEX,RankingSeriousness,Column1EffectColumn2CriteriaColumn3Ranking,SimplestatementofeffectDescriptivetexttodefineandestablishspecificcriteriafortheseverityoftheresultsofafailureNumberthatrelatestotheseriousnessoftheeffect,42,CLASSIFICATION,13,Characteristicsthatmaketheproductcritical,key,majororsignificantSafetyorGovernmentalPerformance,FitorAppearanceifidentifiedintheDesignFMEAandaddressedintheProcessFMEA,Toclassifyanycharacteristicsthatmayrequireadditionalcontrols,43,CLASSIFICATION,Thiscolumnisnormallyaddressedaftercolumn9-15arecompleted.Whenafailuremodehasaseverityrating8,thenapotentialCriticalCharacteristicmayexist.,44,CLASSIFICATION,Whenafailuremodehasaseverityratingbetween5B.Standardlabtest,performancetest;C.CorrectionwithdesignchangesD.Verificationby3rdpartytestinglab,85,86,87,88,DESIGNFMEAREVIEW,89,DesignFMEAReview,AFormalReviewwiththeFMEATeamisstronglyencouragedtoEnsureeveryactiontoaddresspotentialdesignfailurearediscussedandcarryoutindesignactionorforfollow-up.,90,DesignFMEAReview,TheReviewhighlightachievementmadeandthecelebrationofteamwork.Itisthebeginnin