49 Hierarchical Levels and FMEA Scope What is

49 Hierarchical Levels and FMEA Scope What is your FMEA Level and Position? What is your FMEA Scope? Hierarchical Levels Content Produced by Joseph M. Adams

50 A Look at Various Maps in “Layer” Views Each “Layer” or type of map contains information specific to its purpose. When “Layers” are laid upon another better understanding results. An example: When the addresses of customers is “Layered” onto a street map, you may see a pattern arise. When the “Above Layer” example is “Layered” onto a land usage “Layer”, you might discover a river interrupts the delivery of products/service. Viewing Multiple “Layers” helps turn “Layer” information into knowledge. Hierarchical Levels Content Produced by Joseph M. Adams

51 Hierarchical Levels of Interest Each Map “Layer” or Level has a group of specialized people creating and updating the “Layer” or Level for which they are responsible. 2 Levels Above the Level of Interest Level X+2 1 Levels Above the Level of Interest Level X+1 Level of Interest Level X Hierarchical Levels Content Produced by Joseph M. Adams 1 Levels Below the Level of Interest Level X-1 2 Levels Below the Level of Interest Level X-2 3 Levels Below the Level of Interest Level X-3

52 Hierarchical Level X of Design Records – Levels Paper Design Sequence / C. A. D. Layers Key/Critical Customer Design Function Features Process Safety Datum's = Primary, Secondary, Tertiary Related Features Level X-1 Significant Customer Fit & Form Design Function Features Significant/Major Process Requirement Design Function Features Level X-2 Important Customer Fit & Form Design Function Features Important/ Minor Process Requirement Design Function Features Level X-3 Low Level/Unimportant Customer Design Function Features Low Level/Unimportant Process Requirement Design Function Features Hierarchical Levels Content Produced by Joseph M. Adams

AIAG FMEA pg. 10 Hierarchical Levels Company or Group “C” Company or Group “A” 53 of Systems, Sub-Systems, and Components Company or Group “B” Company or Group “D” Level X? Level X-2 ? System Level D&P FMEA’s X ? Level X+1 ? Level X-1 ? Sub-System D&P FMEA’s System Level D&P FMEA’s X ? Level X-2 ? X-4 ? Level X+2 ? System Level D&P FMEA’s X ? Level Component X-2 ? D&P FMEA’s Sub-System D&P FMEA’s Level X-1 ? X-3 ? Level X+3 ? Sub-System D&P FMEA’s Level X+4 ? X-2 ? Level X-3 ? X-5 ? Level Component X-2 ? D&P FMEA’s Component D&P FMEA’s Level X+5 ? Hierarchical Levels System Level D&P FMEA’s X ? Level X-2 ? Sub-System D&P FMEA’s Level X-1 ? Level X-2 ? Content Produced by Joseph M. Adams Component D&P FMEA’s Level X?

54 Hierarchical Levels of Systems, Sub-Systems, and Components for a Construction Company Hierarchical Levels Content Produced by Joseph M. Adams

55 Hierarchical Levels The Systems, Sub-Systems, and Components Hierarchy View looks much like a Bill of Material, BOM, View Here? The big question is, “Where is your FMEA’s Level X? ” Hierarchical Levels Here? Content Produced by Joseph M. Adams or a Procedures Cascade View

56 AIAG APQP pg. 8 & 47 The Timing/Project Management, WBS, View of APQP Concept DFMEA Concept PFMEA Project DFMEA Project PFMEA Prod. – C. I. - DFMEA Prod. – C. I. - PFMEA The big questions are, “Where is your FMEA on the Timing Chart? Is the FMEA on-track to meet its Due Date? ” Internal Audit of APQP for PPAP Due Date Prototype Control Plan Hierarchical Levels Content Produced by Joseph M. Adams Pre-Launch Cnt’l Plan Production Control Plan

57 The P-D-C-A - APQP Phase / Event / Technical The big questions are, “Where is your FMEA on the P-D-C-A Chart? Is the Memory View of APQP FMEA on-track to meet its Due Date? ” Hierarchical Levels Content Produced by Joseph M. Adams

58 The Sequence - Data / Information Flow View of APQP Advance Product Quality Planning, APQP ¨¨¨ Product / Process Information Flow ¨¨¨ The big questions are, “Where is your FMEA on the Sequence - Data / Information Flow Chart? Is the FMEA on-track to meet its Due Date? ” Dynamic Control Planning, DCP * Only 3 rd Party Auditors draw a line in the sand Hierarchical Levels Content Produced by Joseph M. Adams

59 QFDs / D&P-FMEAs and the “V-Model” More on this later. The big questions are, “Where is your FMEA on the V-model? Is the FMEA on-track to meet its Due Date? ” Project Timing Highly serial ‘V’ with very little concurrency Hierarchical Levels Highly concurrent ‘V’ Content Produced by Joseph M. Adams

60 Why is the Phase 2 QFD House Properties and the “V” Model Important to the DFMEA? Its Linkage to Sub-Teams and Customer Teams. Linkage to Higher Level Teams Scope Boundary Linkage to Lower Level Teams Hierarchical Levels Content Produced by Joseph M. Adams

61 Wow! This QFD, FMEA, C. P. methodology seems to be complicated. Well, maybe for a completely new product or a totally new process. But completely new products and totally new processes are developed over a long period of time compared to “same-as-except” products and processes, relatively speaking. You have many documents and histories from which to draw. • Execution Excellence & Existing Body of Knowledge • Bill of Process (Bo. P) • Flow Charts • Standard Process FMEA’s • Error Proofing Matrices • Gauging Histories • Standard Operating Procedures • Equipment Set-up Instruction Histories • Operating Process Setting Histories • Inspection Instruction Histories • Operator Work Instruction Histories • In-station Control Plan • Work Instructions • Other documents (Easiest job to do is “copy, paste, and review. ” Hierarchical Levels Content Produced by Joseph M. Adams

62 End of the Hierarchical Levels and FMEA Scope 1) What interested you the most? 2) What was your Key take away? 3) What did you have difficulty understanding? 4) Anything we should put on our “Sticky Note” lists? 5) What should I improve? Hierarchical Levels Content Produced by Joseph M. Adams

63 Hierarchical Levels Content Produced by Joseph M. Adams

AIAG APQP pg. xx AIAG PPAP pg. xx SAE pg. xx Concept Initiation/Approval Program Approval Prototype Pilot Launch Planning Product Design And Development Process Design and Development Product and Process Validation Production Feedback Assessment and Corrective Action Plan and Define Program Hierarchical Levels Product Design and Development Verification Process Design and Development Verification Product And Process Validation Content Produced by Joseph M. Adams Feedback Assessment and Corrective Action AIAG FMEA pg. xx 64