FMEA Outline What is FMEA History Timing Benefits
FMEA
Outline • • • What is FMEA? History Timing Benefits Applications Stages of FMEA Team Procedure (RPN=S*O*D) Summary
What is FMEA? • FMEA stands for Failure Mode and Effect Analysis • Methodology of FMEA: – Identify the potential failure of a system and its effects – Assess the failures to determine actions that would eliminate the chance of occurrence – Document the potential failures
What is FMEA is a systematic way of assuring that every conceivable potential failure of a design/process has been considered.
History of FMEA • Created by the aerospace industry in the 1960 s. • Ford began using FMEA in 1972. • Automotive Industry Action Group and American Society for Quality Control copyright standards in 1993.
Timing • Integral part of the early design evaluation • During the design phase • Preliminary design or layout • Design improvement programmes • Perriodically updated
What are the Benefits? • Improvements in: – Safety – Quality – Reliability
Benefits • What other potential benefits can be identified? – Company image – User satisfaction – Lower development costs – Presence of a historical record
Applications • Concept • Design • Process • Service • Equipment
4 Stages of FMEA • 1. Specifying Possibilities (ROOT CAUSES/ EFFECTS) • 2. Quantifying Risk ( SEVERITY, OCCURENCE, DETECTION= RPN) • 3. Correcting High Risk Causes (DETAILING ACTION/ASSIGNING RESPONSIBILITIES) • 4. Re-Evaluation of Risk (RECALCULATIING OF RPN)
FMEA Team • It is a team effort RESPONSIBILITIES Determining the meeting time and place Communicating Coordinating Corrective Action/Assignments Follow up Participation from all Keeping the records/files/documents Keeping the process moving
FMEA Procedure • Assign a label to each system component • Describe the functions of each part • Identify potential failures for each function
Procedure • Determine the effects of the failures • Estimate the severity of the failure • Estimate the probability of occurrence
Procedure cont. • Determine the likelihood of detecting the failure • Determine which risks take priority • Address the highest risks – Assign a Risk Priority Number • Update the FMEA as action is taken
FMEA Flow Chart Assign a label to each process or system component List the function of each component List potential failure modes Describe effects of the failures Determine failure severity Determine probability of failure Determine detection rate of failure Assign RPN Take action to reduce the highest risk
SEVERITY • Severity is an assessment of the seriousness of the effect and refers directly to the potential failure mode being studied
OCCURENCE • The occurrence is the assessment of the probability that the specific cause of the failure mode will occur
DETECTION • This is an assessment of the probability that the proposed process controls will detect a potential cause of failure or a process weakness
Ranking for SEVERITY Rank 1 2 3 4 5 6 7 8 9 10 Effect None Very Minor Very Low Moderate High Very High Hazard with Warning Hazard without Warning
Ranking of OCCURENCE Rank 1 2 3 4 5 6 7 8 9 10 Evaluated Failure Rates 1 in 1, 500, 000 1 in 15, 000 1 in 2, 000 1 in 400 1 in 80 1 in 20 1 in 8 1 in 3 1 in 2
Ranking of DETECTION Rank 1 2 3 4 5 6 7 8 9 10 Detection Almost Certain Very High Moderately High Moderate Low Very Low Remote Very Remote Almost Impossible
RPN (RISK PRIORITY NUMBER) RPN = SEVERITY*OCCURENCE*DETEC TION (S*O*D) Value Ranges from 1 to 1000, 1 being the smallest possible risk.
FMEA Worksheet
Summary • FMEA is a procedure designed to identify and prevent potential failures • Provides cost savings and quality enhancing benefits • Should be used for all business aspects in both manufacturing and services
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