The Silesian University of Technology Faculty of Organisation

The Silesian University of Technology Faculty of Organisation and Management Department of Quality Management of Processes and Products ADVANCED FMEA BASED ON COSTS – C-FMEA Authors: Magdalena Wierzbicka Jacek Mazurkiewicz Katarzyna Gmitrzak

STANDARD AND ADVANCED FMEA - DIFFERENCES FMEA method bases on three estimated factors: • Severity of Effect SEV (marks 1 -10) • Probability of Occurrence OCC (marks 1 -10) • Probability of Detection DET (marks 1 -10) SEV · OCC · DET = RPN (Risk Priority Number) C-FMEA method bases on: • Probability of Detection • Cumulated costs (Kjc) DET · Kjc = C-FMEA factor

PARTICIPATION OF EACH DEFECT (DET) unfilled section, (underfill) shape defects inappropriate dimensions nonconformin g calibration overlap (cold shut) inner defects cracks A) receiving and controld of material - - - 3, 92 0, 88 B) cutting material 0, 01 - 0, 02 - - - C) rotary furnance - - 0, 02 - 0, 15 - 0, 88 1, 29 0, 13 2, 38 - 7, 20 - 83, 34 E) inner control - - - 0, 69 - - 0, 88 F) heat treatment - - 0, 02 - - - 1, 76 G) control and examination - - - 0, 01 - H) customer control and final acceptance - - 0, 02 0, 08 - 0, 01 - Type of defect Oprations D) press-rolling mill Magdalena Wierzbicka 2006 Makon 3

PARTICIPATION OF EACH DEFECT (DET) Magdalena Wierzbicka 2006 Makon 4

RESULTS - FMEA Magdalena Wierzbicka 2006 Makon 5

RESULTS – C-FMEA Magdalena Wierzbicka 2006 Makon 6

COMPARING RESULTS Magdalena Wierzbicka 2006 Makon 7

CONCLUSIONS WHY C-FMEA seams to be better ü The choice of Severity gives too much freedom (increase in variation of RPN) – subjectivity in results ü results of FMEA are very fuzzy, there is no significant defect to be taken attention to ü FMEA does not take any costs into account so it cannot assure efficiency ü C-FMEA bases on real data (cost + probability) Magdalena Wierzbicka 2006 Makon 8

THANK YOU FOR YOUR ATTENTION Magdalena Wierzbicka 2006 Makon 9