Fmea

FAILURE MODES AND EFFECTS ANALYSIS (FMEA) Julie VanLaanen

Failure Modes and Effects Analysis (FMEA) ,[object Object]

How The FMEA Fits Into Your Final Proposal Proposal Sections: Letter of Intent ----------------->> Transmittal Title Page Executive Summary Table of Contents List of Figures Letter of Intent ------------------>> Introduction QFD/House of Quality ------>> Design Objectives FMEA Analysis ----------------->> Product, System, or Process Division of Responsibility Project Milestones------------- >> Project Schedule Budget Resume -------------------------->> Qualifications Bibliography QFD/House of Quality ------>> Appendices Detailed Project Schedule- >> Appendix Glossary

Was Failure a design requirement in your QFD? Should it have been? Can you design for failure?

Failure is ALWAYS a Design Constraint ,[object Object],[object Object],[object Object]

From: “Inviting Disaster – Lessons From the Edge of Technology” By James R. Chiles ,[object Object],[object Object]

How could your design fail? ,[object Object],[object Object],[object Object],[object Object]

When will my design fail? ,[object Object],[object Object]

When will my design fail? ,[object Object],[object Object],[object Object],[object Object]

Reliability Curve Assuming a part/product is designed correctly, statistically it should follow a standard bath-tub curve Infant Mortality – failures don’t usually affect the customer, except DOA Useful life – failures here are problems Wear Out – failures here are acceptable

Causes of Reliability Curve Failure

Tools used to Design for acceptable Product Failure ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Tools to used to Design for acceptable Product Failure (cont.) ,[object Object],[object Object]

Failure Modes and Effects Analysis (FMEA) ,[object Object],[object Object],[object Object]

Three Key Questions Posed by FMEA ,[object Object],[object Object],[object Object]

Design FMEA Analysis  = Critical characteristic which may effect safety, compliance with Gov. regulations, or require special controls. SEV = Severity rating (1 to 10) OCC = Occurrence frequency (1 to 10) DET = Detection Rating (1 to 10) RPN = Risk Priority Number (1 to 1000)

Rifle Bolt Example D E T Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Item and Function ,[object Object],D E T ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Identify and List Potential Failure Modes ,[object Object],[object Object],[object Object],[object Object],[object Object]

Identify and List Potential Failure Modes Jamming Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

List Potential Effects from Failure ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Potential Effects from Failure Failure of weapon to function Jamming Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Critical Potential Effects from Failure ,[object Object],[object Object],[object Object],[object Object],[object Object]

Identifying Critical Failures Failure of weapon to function Jamming Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Specifying Severity of Failure (SEV) ,[object Object]

Specifying Severity of Failure (SEV) 8 Failure of weapon to function Jamming 10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Potential Cause of Failure ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Potential Cause of Failure ,[object Object],[object Object],8 Failure of weapon to function Jamming ,[object Object],[object Object],10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Likelihood of Occurrence (OCC) ,[object Object]

Likelihood of Occurrence (OCC) 5 ,[object Object],[object Object],8 Failure of weapon to function Jamming 6 ,[object Object],[object Object],10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Detection Methods & Quality Controls ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Detection Methods & Quality Controls ,[object Object],[object Object],5 ,[object Object],[object Object],8 Failure of weapon to function Jamming ,[object Object],[object Object],6 ,[object Object],[object Object],10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Likelihood of Detection (DET) ,[object Object]

Likelihood of Detection (DET) 3 5 D E T ,[object Object],[object Object],5 ,[object Object],[object Object],8 Failure of weapon to function Jamming ,[object Object],[object Object],6 ,[object Object],[object Object],10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Calculate a Risk Priority Number (RPN) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Calculate a Risk Priority Number (RPN) 3 5 D E T 1 2 0 ,[object Object],[object Object],5 ,[object Object],[object Object],8 Failure of weapon to function Jamming 300 ,[object Object],[object Object],6 ,[object Object],[object Object],10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Develop Recommended Actions ,[object Object],[object Object],[object Object],[object Object],[object Object]

Develop Recommended Actions 3 5 D E T Initiate SPC program to check and maintain bolt dimensions 1 2 0 ,[object Object],[object Object],5 ,[object Object],[object Object],8 Failure of weapon to function Jamming Initiate radiographic testing of all rifle bolts 300 ,[object Object],[object Object],6 ,[object Object],[object Object],10 Catastrophic failure with destruction of weapon and injury to personnel Fracture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Recommended Actions R P N Detection Method & Quality Controls O C C Potential Cause(s) of Failure S E V Potential Effects of Failure Potential Failure Mode Part and Function

Acknowledgement ,[object Object],[object Object],[object Object],[object Object]

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