Introduction_FMEAChineseversion.ppt

“Makingtodaybetterthanyesterday”,IntroductiontoFMEA,CarmelGlobalSummitMeeting,Sep2013,WhatIsLean?,Producingqualityproductwithminimalresources(Materials,Utilities,Labour,MachineandTime)tofulfillcustomerdemandbutthereisacontroltodetectthefailuremodeitself(seethenextslide).,ProcessControlExample,Inaninjectionmoldingprocess,injectionpressureofover6895pieze(kilo-pascals)leadstoasmalldimension.Atalaterstage,thismakesassemblydifficult.Aprocesscontrolonthecause(injectionpressure)mightbeahighpressurealarmonthehydrauliccircuit.Aprocesscontrolonthefailuremode(smalldimension)mightbeadimensionalinspectionofeachpart.,FMEA-Step10,10.Foreachprocesscontrol,estimatethedetection.,FMEA-Step10:DetectionGuidelines,FMEA-Step11,11.Foreachcauseoffailure,calculatetheRiskPriorityNumber.,RiskPriorityNumber(RPN),TheRPNnumberiscalculatedfromtheteamsestimatesofSeverity,OccurrenceandDetection.RPN=SxOxDIfyouareusinga1-10scaleforSeverity,OccurrenceandDetection,theworstRPN=1000(10 x10 x10),whilethebestwouldbeRPN=1(1x1x1).UseRPNnumberstoprioritizefailuremodesand/orcausesoffailuresinordertoworkonthehighestpriorityissues.,FMEATipsaboutStep11,11.Foreachcauseoffailure,calculatetheRiskPriorityNumber.,TipsaboutStep11:Anyfailuremodewithaseverityof9or10mustbeidentifiedashighpriorityregardlessoftheRPN.AddressingthehighestRPNsismoreimportantthansettinganactualtarget(allRPNs150,forexample).Teamsarealldifferent,sodifferentteamswillobtaindifferentRPNs.UsethehighRPNstoidentifycriticalissues(failuremodes,causesoffailures,keyprocessinputs).,FMEA-Step12,12.Forhighprioritycausesoffailureand/orfailuremodes,developrecommendedactions.,FMEATipsaboutStep12,12.Forhighprioritycausesoffailureand/orfailuremodes,developrecommendedactions.,TipsaboutStep12:Recommendedactionsshouldbelowcostandeffective.Useideasfromallteammemberstoimprovetheexistingorplannedproject.Trytothinkoflowcostactionsthatwillreducetheoccurrence.Reducingtheoccurrenceisthemostcosteffectivewaytoreducerisk.,FMEA-Step13,13.Foreachrecommendedaction,assignresponsibilityandcompletiondates.,FMEA-Step14,14.Foreachrecommendedaction,implementtheactionandnoteitseffect.,Process,Function,Requirements,Potential,Failure,Mode,Potential,Effect(s),ofFailure,Severity,Potential,Cause(s)/,Mechanism(s),ofFailure,Occurrence,Current,Process,Controls,Detection,RPN,Recommended,Action(s),Responsibility,&Target,CompletionDate,Actions,Taken,Spotweldnutto,pedestal,Nutpresent,Nutnotpresent,Cannotassembleseatbelt,restrainttopedestal,5,Weldercycleswithoutnut,present,8,100%VisualInspectionby,operatoraftercycle,4,160,Design,test&,installanut,presence,sensingcircuit.,Welderwillnot,cyclew/oweld,nut,a,Mark,4/15/96,c,Circuitinstalled,on4/12/96.,10,000welds-,noproblem.,Circuitaddedto,welderdesign,e,Operatorfailstoloadnut,intowelder,2,100%VisualInspectionby,operatoraftercycle,4,40,SeeNotea,Seeabove,notec,Seeabove,notee,Nutisloadedbutfallsout,beforeweldcycle,1,100%VisualInspectionby,operatoraftercycle,4,20,SeeNotea,Seeabove,notec,Seeabove,notee,ActionResults,FMEATipsaboutStep14,14.Foreachrecommendedaction,implementtheactionandnoteitseffect.,TipsaboutStep14:Itisessentialthattheteamnotonlyverifythattherecommendedactionwasimplemented,butthattheyalsodeterminehoweffectiveitwas.Wasitimplemented?YesorNo.Howeffectivewasit?Getdata.,FMEA-Step15,15.Foreachimplementedaction,re-estimatetheseverity,occurrenceanddetectionrankingsandrecalculatetheRPN.,FMEATipsaboutStep15,15.Foreachimplementedaction,re-estimatetheseverity,occurrenceanddetectionrankingsandrecalculatetheRPN.,TipsaboutStep15:NeverrecalculateanRPNwithoutimplementinganimprovement!Guessingisnotallowed!Usually,itisdifficulttoreducetheseverityofafailuremode.However,sometimesafailuremodecanbeeliminated.ThemosteffectiveRPNreductionisreducingthelikelihoodofoccurrence.Poka-Yokecanreducethedetectionrankingandreducecost!TheleasteffectiveRPNreductionisincreasinginspection(reducingthedetectionranking).,FMEA“Tips”,Makeita“teameffort.”Analyzenewprocessestoavoidproblemsbeforetheyhappen.Analyzeexistingprocessestofindandfixproblems.Analyzeexistingprocessestodiscoverthehighpriority(“key”)processinputvariables.Workdownthecolumns,notacross.Keepitm