Failure Modes and Effects Analysis (FMEA) Present by Mr. Kittiwat Sirikasemsuk
Created by Kittiwat Sirikasemsuk ,CU-KMITL
1
FMEA Form – 6 Sigma
In what ways does the Key What is the impact on the Key Input go wrong? Output Variables (Customer Requirements) or internal requirements?
S E V
Potential Causes
What causes the Key Input to go wrong?
O C C
Definition of FMEA
Current Controls
What are the existing controls and procedures (inspection and test) that prevent eith the cause or the Failure Mode? Should include an SOP number.
D E T
R P N
How well can you detect cause or FM?
Potential Failure Effects
How often does cause or FM occur?
What is the process step/ Input under investigation?
Potential Failure Mode
How Severe is the effect to the cusotmer?
Process Step/Input
Created by Kittiwat Sirikasemsuk ,CU-KMITL
2
FMEA
is a systematic technique for assessing the risks associated with defective products reaching the marks.
Actions Recommended What are the actions for reducing the occurrance of the Cause, or improving detection? Should have actions only on high RPN's or easy fixes.
0 0
0
Created by Kittiwat Sirikasemsuk ,CU-KMITL
3
Objective.
Usefulness
5
Created by Kittiwat Sirikasemsuk ,CU-KMITL
4
Overall Aspect : For quality assurance early , which prevent or reduce failure modes and cause of defective. Product/Process Aspect : A disciplined review and analysis of a new or revised product/process is promoted to anticipate, resolve or monitor potential problems within the product or process. Created by Kittiwat Sirikasemsuk ,CU-KMITL
1. Review and analysis product / process when revise or make new. 2. Anticipate failure and cause which may occur from experience and team work. 3. Specify risk and priority RPN. 4. Reduce RPN by eliminated that cause formerly. 5. Provides a discipline/methodology for documenting Created by Kittiwat Sirikasemsuk
6
,CU-KMITL
1
Characteristics of FMEA
Characteristics of FMEA
1. Prioritizes Potential Failures according to their risk and drives actions to eliminate or reduce their likelihood of occurrence.
3. By its self, an FMEA is not a problem solve. It is used in combination with other problem solving tools “The FMEA presents the opportunity but does not solve the problem.”
2. Provides a discipline/methodology for documenting this analysis for future use and continuous process improvement. Created by Kittiwat Sirikasemsuk ,CU-KMITL
7
In reality, FMEA is such a basic tool that any model to investigate Reliability, Reliability Maintainability or Safety cannot be completed without FMEA at some stage.
Created by Kittiwat Sirikasemsuk ,CU-KMITL
9
An FMEA utilizes occurrence and detection probability in conjunction with severity criteria to develop a Risk Priority Number(RPN) for prioritization of corrective action considerations.
RPN = S x O x D 11
Analysis
Risk
Effects of failure
Severity
Causes
Occurrence
Current controls or design verification
Detection Created by Kittiwat Sirikasemsuk ,CU-KMITL
10
Implementation
Note
Created by Kittiwat Sirikasemsuk ,CU-KMITL
8
Special Characteristics
Involution
Process Flowchart , C&E Diagram , Pareto Diagram , Action Plan , Team Work Management, Risk Management
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Choice 1 : Correction => Problem Solving Choice 2 : Prevention => None of Problem yet. Note to achieve the maximum benefit, organization need to conduct FMEAs before a failure is unknowingly instituted Created by Kittiwat Sirikasemsuk into a process or design.
12
,CU-KMITL
2
Where is FMEA used?
QS 9000 , Big Three(Chryler, Ford Motor, General Motors)
APQP Manual (Advanced Product Quality Planning)
ISO/TS 16949 , IATF (International Automotive Task Force)
The Role of FMEA in a QS 13
Created by Kittiwat Sirikasemsuk ,CU-KMITL
DMAIC , Six Sigma
Product / Process Design
14
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Tool
QS9000
15
Created by Kittiwat Sirikasemsuk ,CU-KMITL
APQP ISO/TS16949
18
Created by Kittiwat Sirikasemsuk ,CU-KMITL
3
Types of FMEA
S4
System
Design
Components
Components
Manpower
Man / HR
Subsystems
Subsystems
Machine
Machine
Mainsystem
Mainsystem
Method
Method
Material
Material
Measurement
Measurement
Environment
Environment
Focus : Minimize failures
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Phase of Smart Six Sigma Solution.(S4)
19
Note The most people separate FMEA to be two 20 type in Automotive. (DFMEA & PFMEA)
FMEA for System :
is used to analysis mainsystem and subsystem in step early. FMEA for Design :
is used to analysis product before do manufacturing. FMEA for Process :
,CU-KMITL
Automotive FMEA Timeline
23
Design goahead
Automotive FMEA Timeline DFMEA :
Start early in process.Complete by the time preliminary drawing are done but before any tooling is initiated. PFMEA :
Process FMEA
Design Prototype completion build
Created by Kittiwat Sirikasemsuk ,CU-KMITL
22
Concept
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Do not mix : DFMEA with PFMEA
is used to analysis process manufacturing and assembly. Created by Kittiwat Sirikasemsuk
Design FMEA
Service
Caution!
Add explanation
21
Process
Eng./Mfg. Sign off
Start as soon as basic manufacturing methods have been discussed. Complete prior to finalizing production plans and releasing for production.
Production start
Created by Kittiwat Sirikasemsuk ,CU-KMITL
24
Created by Kittiwat Sirikasemsuk ,CU-KMITL
4
Relationship of system, design, and process FMEA. Failure Modes
Effect
cause
The ramifications of the problem.
The Problem
The causes of the problem.
The causes of the problem from the system FMEA..
The effects from the system FMEA with a better definition.
New root causes for the design failure modes.
Process The causes of the
The same effects as the design FMEA
Specific root causes of the process failure modes.
System FMEA
Design FMEA
FMEA
problem from the design FMEA..
Created by Kittiwat Sirikasemsuk ,CU-KMITL
25
Origins
Origins
FMECA
mid-1960’s
Created by Kittiwat Sirikasemsuk ,CU-KMITL
FMECA 26 : Failure Mode Effects and Criticality Analysis.
Criticality Matrix. •About using Criticality Matrix.
mid-1960’s
FMECA
•Aerospace of NASA in Apollo and Navy US. Military.
4
•Addressed safety issues.
end-1980’s
FMEA
3
•About using RPN
2
•using in Automotive Industrial. •For the reliability analysis.
now
FMEA
O
•using almost all Industrial Type.
FMECA 27 : Failure Mode Effects and Criticality Analysis.
Created by Kittiwat Sirikasemsuk ,CU-KMITL
1
1
2
3
4
5
S Created by Kittiwat Sirikasemsuk ,CU-KMITL
28
Set Team before make FMEA.
Team should / may consist of Design Engineer, Manufacturing Engineer, Assembly Engineer, Quality Engineer, Reliability Engineer, and else which people are related with it.
29
Created by Kittiwat Sirikasemsuk ,CU-KMITL
30
Created by Kittiwat Sirikasemsuk ,CU-KMITL
5
Creating an FMEA
Perspective
31
Perspective
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Creating an FMEA (continue)
1. Set the level of the analysis. 2. Learn about the design/process. - draw functional diagram/process flowchart. 3. Describe the desired functions or process. 4. List / Identify the Item-Function for DFMEA or Process Function-Requirements for PFMEA. 5. List all potential failure modes. 6. Identify the effect(s) of each failure mode.
Title DFMEA
7. List all possible causes of each failure mode. 8. List the current controls of each cause, if have. 9. Give severity, occurrence and detection rating. 10. Multiply these together to give RPN 11. Rank by RPN and state recommended action, and responsibilities. 12. Revise RPN in line with completed actions. 33
Created by Kittiwat Sirikasemsuk ,CU-KMITL
DFMEA Title
35
Created by Kittiwat Sirikasemsuk ,CU-KMITL
32
PFMEA
34
Created by Kittiwat Sirikasemsuk ,CU-KMITL
PFMEA Title
Created by Kittiwat Sirikasemsuk ,CU-KMITL
36
Created by Kittiwat Sirikasemsuk ,CU-KMITL
6
Setting the level of analysis.
1. Setting the level of analysis.
Created by Kittiwat Sirikasemsuk ,CU-KMITL
37
Setting the level of analysis.
Created by Kittiwat Sirikasemsuk ,CU-KMITL
38
•The fundamental problem with FMEA is that, being a “Bottom-Up” technique. System Level
1
2
3
4
Failure Mode Failure Effect Subsystem Level
1
2
3
Failure Mode Failure Effect Component Level Created by Kittiwat Sirikasemsuk ,CU-KMITL
39
40
1
2
Failure Mode
3
FailureMode Mode Failure
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Design Block Diagram Example System
Body
Sub-System
Doors
If the product function is complex, break it down.
Exterior
Window
2. Learn about the design/process.
Interior - draw functional diagram/process flowchart.
Component
41
Door Inner Panel
Glass
Sealing with Strip
Latch / Lock
Created by Kittiwat Sirikasemsuk ,CU-KMITL
42
Created by Kittiwat Sirikasemsuk ,CU-KMITL
7
Mechanical System evaporator
Circuit Diagram
43
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Assembly Drawing I
45
Assembly Drawing II
Created by Kittiwat Sirikasemsuk ,CU-KMITL
46
Process Flow Chart / Mapping
47
Created by Kittiwat Sirikasemsuk ,CU-KMITL
44
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Created by Kittiwat Sirikasemsuk ,CU-KMITL
9. Give severity, occurrence and detection rating.
48
Created by Kittiwat Sirikasemsuk ,CU-KMITL
8
Severity
Note : Severity will not change when 49 do FMEA finish.
Occurrence
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Detection
Created by Kittiwat Sirikasemsuk ,CU-KMITL
50
Example RPN S
O
D
9
1
1
1
9
1
1
1
9
Note : Select RPN more than 90 to correct. 51
Created by Kittiwat Sirikasemsuk ,CU-KMITL
52
: RPN Maximum is 1000.
Created by Kittiwat Sirikasemsuk ,CU-KMITL
This case Process Flow Chart
Example PFMEA
53
Created by Kittiwat Sirikasemsuk ,CU-KMITL
54
Created by Kittiwat Sirikasemsuk ,CU-KMITL
9
Show detail or function. 1. Receive material is the first step for this process. When we receive ingot of Aluminium grade Si 9 % ,Cu 3 %, next we will check quality of material to ahead for standard and check quantity to follow ordering. 2. Melting is procedure to transform ingot to be liquefy of Aluminium by melting by a electricity blast furnace, then do cleaning Aluminium by filling flux Subsequent, is transportation to next station.
4. Decorate is procedure for beautify work product after injection which have three step so that file, trimming hole and shot blast. 5. Packing will bring finish product into the tray and will check quality lastly and quantity 6. Stock is an arrangement of finish product to go at inventory. 7. Delivery is transfer of finish product into customer.
3. Diecasting is procedure to inject liquid to be work product by injection machinery no. DC 350 T. Created by Kittiwat Sirikasemsuk ,CU-KMITL
55
56
EX. C&E Diagram Station2. Al Melting &Molten Al transferred
57
Created by Kittiwat Sirikasemsuk ,CU-KMITL
Addition
58
Created by Kittiwat Sirikasemsuk ,CU-KMITL
:http://www.fmeca.com/ffsoft/download.htm
Created by Kittiwat Sirikasemsuk ,CU-KMITL
FMEA : ( AFTER ACTION TAKEN )
FMEA : ( BEFORE ACTION TAKEN )
59
Created by Kittiwat Sirikasemsuk ,CU-KMITL
60
Created by Kittiwat Sirikasemsuk ,CU-KMITL
10
Reference
Show PFMEA
1. 2. 3. 4. 5. 6. 7.
61
Created by Kittiwat Sirikasemsuk ,CU-KMITL
62
“Failure Modes and Effects Analysis Reference Manual”, Big Three “Failure Mode and Effect Analysis”, บ.แอลวีเอ็ม (เอเชีย) จํากัด , กรุงเทพฯ “Six Sigma for Shopfloor Management”, บ.ซีเกทเทคโนโลยี (ประเทศไทย) จํากัด สาขาโคราช “Failure Mode and Effect Analysis”, www.16949.com Breyfogle, Forrest W., “Implementing Six Sigma : Smarter Solutions Using Statistical Methods”, John Wiley & Sons, Canada, c1946 รศ. ดํารง ทวีแสงสกุลไทย , “Failure Mode and Effect Analysis”, ซีตประกอบการ สอนวิชา Quality Engineering Techniques รศ.ดร. ปารเมศ ชุติมา , “Failure Mode and Effect Analysis”, ซีตประกอบการสอน วิชา PPD Created by Kittiwat Sirikasemsuk ,CU-KMITL
Deming Prize Thank you for listening.
63
Created by Kittiwat Sirikasemsuk ,CU-KMITL
64
Created by Kittiwat Sirikasemsuk ,CU-KMITL
11