9 Process FMEA.ppt

FailureModeandEffectsAnalysis FMEA FailureModeandEffectsAnalysisLearningObjectives Attheendofthissectiondelegateswillbeableto UnderstandtheroleofFailureModeandEffectsAnalysis FMEAwithintheDMAICImprovementProcessConductaProcessFMEAonanexisting newormodifiedtransactionalprocessUsetheProcessFMEAtoprioritiseareasforattentionUsetheProcessFMEAtosupportthegenerationofControlPlans FailureModeandEffectsAnalysis Agenda IntroductiontoFailureModeandEffectsAnalysisFMEAWithinDMAICFMEARoadmapFMEAFormandControlPlansImplementingFMEASummary Classic Failures Citytraderbuys15 000 000sharesinsteadof15 000LeapdayshutsdownbankcashmachinesNASAprobelostduetoMetric ImperialunitsconfusionWorldwidePerrierstockswithdrawnduetofilterfailurePilotshutsdownwrongaircraftengineCompanyemailsconfidentialaccountinformationtoanalystsandhastosuspendtrading IntroductiontoFMEA FailureModeandEffectsAnalysis FMEAis Asystematicmethodofidentifyingandinvestigatingpotentialdesignorprocessweaknesses Ameanstoevaluateandmanageproductrisks Ameansofevolvingorganizationalknowledge Developedintheaerospaceindustryinthemid1960 s FMEAPurpose Recogniseandevaluatethepotentialfailuremodesandcausesassociatedwiththedesignandmanufactureofaproductordesignandoperationofanyprocess Identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring Documenttheanalysisandchangesmade ApplicationofFMEAinSixSigma InDesignforSixSigma DesignFMEA toidentifypotentialfailuremodestoidentifypotentialcausesoffailuretoeliminate minimisethepotentialfailuremodeswithintheDesignprocessInTransactional OperationalSixSigma ProcessFMEA toanalysetheexistingprocesses identifypossiblex s toimprovetheprocess elimination reductionoffailuremodes toselectnewprocessalternativestodevelopcontrolplans ApplicationofPFMEAinDMAIC Measure PreliminaryrootcauseanalysisAnalyse Toanalysetheexistingprocessesandidentifypossiblex s causesoffailure Improve Toimprovetheprocess elimination reductionoffailuremodes ToselectnewprocessalternativesControl TodevelopcontrolplansItisonlynecessarytoconductPFMEAonthemodified changedareasoftheprocess LinksfromC EMatrix KPOVs KPIVs ProcessFMEARoadmap 1 DescribeProcess 3 IdentifyPotentialFailureModes 5 DetermineCauses 6 CurrentControls 9 AssessResults Step1 DescribeProcess Suppliers SalesStores Inputs OrderProductPackaging Customers SalesShippingEndcustomer Outputs PackagedProductShippingrequisitionOrderfulfilmentnote Step1 DescribeProcess OrderFulfilment Receiveorder Checkstock Pullproductandcheck Packageproduct Weighproduct Correctweight Orderstock NotifySales TransfertoGoodsOut Yes Yes No No Step2 DefineFunction 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 Step2 DefineFunction FunctionsReceiveorderChecksufficientstockNotifysalesOrderstockPullproductCheckproductEtc Receiveorder Checkstock Pullproductandcheck Allavailable Orderstock NotifySales Yes No Function DoesNotFunction ListofPotentialFailures Doesnot CannotToomuchToolittleTooearlyToolateDegradedIntermittentIncorrectUnwanted Function Step3 IdentifyPotentialFailureModes 3 IdentifyPotentialFailureModes ProcessFunction PotentialFailureModes ReceiveOrder DoesnotreceiveorderReceivesincorrectorderReceivestoomanyorders Checksufficientstock DoesnotchecksufficientstockIncorrectcheck wrongconclusion InsufficientstockwhensufficientSufficientstockwheninsufficient Step3 IdentifyPotentialFailureModes NotifySales DoesnotnotifysalesNotifiessalestoolateNotifiessaleswithincorrectinformation Assumethefailurecouldoccur whatwouldbetheeffect Consider Howitaffectstheprocess processor nextoperationsubsequentdownstreamoperationsHowitaffectstheenduser customer Immediate delayedimpact Berealistic Note Theremaybeseveralpotentialeffectsforeachfailure butthesearelistedtogetherasoneoveralleffect Step4 DescribeEffectsofFailure DoesnotReceiveOrder Incorrectstockcheck Concludesinsufficientwhensufficientavailable Step4 DescribeEffectsofFailure Assumethefailurecouldoccur whatwouldbetheeffect PotentialFailureModes PotentialEffects Ordernotfulfilled customerhastore submitorder Delayinfulfillingorder excessstock possiblelossoforder Incorrectstockcheck Concludessufficientstockwheninsufficientavailable Incompleteorder delay customerdissatisfaction NotifySalestoolate Customernotawareofdelay salestakesfurtherorders Whatcouldcausethepotentialfailuremodetooccur Process processorerrorsthatcouldleadtothefailureBespecific processorerror or equipmentfailure aretoovagueConsidertheworkingenvironmentoftheprocess conditionofequipment ITsystemsTherewilltypicallybeseveralcausesforeachfailuremodeIdentifyrootcausesforseverefailures Step5 DetermineCauses Step5 DetermineCauses Whatcouldcausethepotentialfailuremodetooccur PotentialCauses PotentialFailureModes IncorrectlyaddressedDeliveredtowrongdepartmentLostinpost Incorrectstockcheck ErrorininventorylevelsEnteredwrongpartcodeEnteredwrongquantityMultipleordersinprocess 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 processorerror istoovague Therewilltypicallybemorethanonecauseperfailuremode Prepareashortpresentationonyourteam sfindings Workshop1Time Workshop1 IdentifyPotentialFailuresModes ProcessFMEARoadmap 1 DescribeProcess 3 IdentifyPotentialFailureModes 5 DetermineCauses 6 CurrentControls 9 AssessResults Inorderofpreferencetherearethreetypesofcurrentcontrols PreventthecauseDetectthecause leadingtocorrectiveactionDetectthefailure defect Thesemightinclude ControlChartsCheckSheetsMistakeProofingTrainingInformationTechnology Identifythecurrentcontrolstoprevent detectthefailurebeforeitreachesthecustomer Step6 CurrentControls Step6 CurrentControls Incorrectstockcheck ErrorininventorylevelsEnteredwrongpartcodeEnteredwrongquantityMultipleordersinprocess Stocktake annual StockcontrolsystemDoubleentryrequiredDoubleentryrequiredNocontrols PotentialFailureModes Identifythecurrentcontrolstoprevent detectthefailurebeforeitreachesthecustomer PotentialCauses CurrentControls ProbabilityofOccurrence Detection CapabilityofCurrentControls RiskPriorityNumber X X Step7 CalculateRisk SeverityoftheEffect ProcessFMEASeverityRating Howseriousistheeffect Note Manyorganisationschoosetomodifythedescriptionstobestdescribetheirindustry Inconvenient serviceprovidedbutnotuptoexpectations Someprocessdisruption sometransactionalreworking ProcessFMEAOccurrenceRating Howlikelyisthecause Note Manyorganisationschoosetomodifythedescriptionstobestdescribetheirindustry Occ Probability Likelyfailurerates 11 Veryhigh persistentfailures 7 1in100transactions opportunities 4 Moderate occasionalfailures 2 Low relativelyfewfailures ProcessFMEADetectionRating HoweffectivearetheCurrentControls EffectIncompleteorder delay customerdissatisfaction CauseMultipleordersinprocess CurrentControlsNoControls Severity 4 Occurrence 4 Detection 11 RPN 4x4x11 176 Step7 CalculateRisk FailureModeIncorrectStockCheck CorrectiveActionEffectsOnRPNRating Note DonotmodifyRPNuntilcorrectiveactioniscompleted Step9 Step8 TakeAction EffectIncompleteorder delay customerdissatisfaction CauseMultipleordersinprocess CurrentControlsNoControls Severity 4 Occurrence 4 Detection 11 RPN 4x4x11 176 Step8 TakeAction FailureModeIncorrectStockCheck StockCheckisimproved ReviewcorrectiveactionsandmodifyRPNfigurebasedonresults Step9 AssessResults 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 Recogniseandevaluatethepotentialfailuremodesandcausesassociatedwithabusinessprocessormanufactureofaproduct Identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring Documenttheanalysisandchangesmade FMEAForm FMEABrainstorming MeasureStage FMEARiskAnalysis Analyzestage FMEAActionPlanning AnalyzeStage FMEAImplementActionPlan ImproveStage FMEAVerify beforeprojectclosure Workshop2 RiskAssessment Transferthefailuremodes effectsandcausesidentifiedinworkshop1tothelargeFMEAform UsingtheSeverityratingscale rateeachofthefailuremodeeffectsandrecordthenumberintheappropriatecolumn Wherethereareseveralpossibleeffectsforafailuremode taketheworstcasefortherating Thereshouldbeonlyoneseverityratingforeachfailuremode UsingtheOccurrenceratingscaleandyourteam sexpertise rateeachofthepotentialcausesoffailureandrecordthenumbersintheappropriatecolumn Forthepurposeoftheexercise assumetherearenoCurrentControls Detectionrating 11 calculatetheRiskPriorityNumbers RPN andrecordonthechart ThereshouldbeoneRPNscoreforeachcauselistedontheFMEAform ForthetopfiveRPN s identifypossibleactionstoreducetheRPNscores Identifywhichofthecategories Severity Occurrence andDetection wouldbereducedoncetheactionhasbeencompleted Prepareashortpresentationtosummariseyourteam sfindings ImplementingFMEA Improve Team notanindividualCrossfunctional opportunitytoimprovecommunicationandunderstandingIncludetheprocessors peoplewhoworkintheprocess Considerincludingthecustomerwhereappropriate WhoShouldDoFMEA 10KeysToFMEASuccess Supportbytop middlemanagementMotivatedteammembersCrossfunctionalrepresentationontheteamTreatas beforetheevent not afterthefact GeneratecompanyspecificratingscalesTreatasalivingdocument reflectlatestrevisionsExecuterecommendedactionsIntegrationintoyourdevelopmentprocessGenerate usealibraryofgenericFMEA sFollowthespirit nottheform CommonMistakes AppliedtoolatePoorteamwor