Failure Mode and Effects Analysis WithAdrian™ FMEA 2013 Adrian Beale
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Failure Mode and Effects Analysis purpose is to identify risk and eliminate it from the process.
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Failure Mode and Effects Analysis WithAdrian™ FMEA 2013 Adrian Beale
- 1. FAILURE MODE ANDFAILURE MODE AND EFFECTS ANALYSISEFFECTS ANALYSIS WithAdrian™
- 2. DEFINITION “Reliability engineering method for risk elimination.” “FMEA is a specific methodology to evaluate a system, design and process for possible ways in which failures can occur.” WithAdrian™
- 3. INTRODUCTION We need to eliminate risk if we are to eliminate Waste ! The concept of getting things right first time!!! WithAdrian™
- 4. INTRODUCTION U.K and USA Industry needs to change both PacePace and TuneTune if it is to survive Change brings risk !Change brings risk ! A forward thinking company will have considered risk management WithAdrian™
- 5. INTRODUCTION In industry today we can not tolerate wasteful activities if we are to compete in an ever increasing competitive market WithAdrian™
- 6. INTRODUCTION Quality Cost Delivery The elimination of risk will improve:- Improved Customer Satisfaction ! WithAdrian™
- 7. INTRODUCTION The elimination of risk should be a total commitment of the entire organisation. Before After SOLUTION OF A PROBLEM MONITORING OF WASTE QUANTIFICATION OF RELIABILITY PREVENTION OF A PROBLEM ELIMINATION OF WASTE REDUCTION OF UNRELIABILITY “If you do what you’ve always done, you will get what you’ve always got” WithAdrian™
- 8. GENERAL OVERVIEW The three types of FMEA SYSTEM FMEA DESIGN FMEA PROCESS FMEA MANPOWER MACHINE METHOD MATERIAL MEASUREMENT ENVIRONMENT MAIN SYSTEMS SUB SYSTEMS COMPONENTS MAIN SYSTEMS SUB SYSTEMS COMPONENTS WithAdrian™
- 9. GENERAL OVERVIEW When new systems, products, processes or services are designed When existing systems, designs, products, processes or services are about to change Continuously improving When is the FMEA started? WithAdrian™
- 10. GENERAL OVERVIEW System & Design FMEA - These are complete when the product is obsolete. Process FMEA - Complete when the product or process becomes obsolete. When is the FMEA complete? WithAdrian™
- 11. GENERAL OVERVIEW The process of conducting an FMEA, 4 Step Approach •Select team •Brainstorm process •Model process •Brain storm elements to define failure modes •Define occurrence, severity and detection ratings for failure modes. •Calculate risk priority number (RPN) •Define action to reduce rpn •Define person responsible for carrying out action •Next meeting record the result of the actions •Deduce the occurrence, severity and detection calculate the new RPN •Once the process has been analysed start again. Spend 50% of time }Step 1 PLAN Step 2 DO Step 3 CHECK Step 4 ACT WithAdrian™
- 12. GENERAL OVERVIEW A good FMEA:- Very well planned Identifies known and potential failures Identifies the cause and effects of each failure Prioritises the identified failure modes Provides a problem follow up and corrective action FMEA is one of the most effective early warning and preventative techniques available. WithAdrian™
- 13. FMEA VOCABULARY Failure Mode: A physical description of the manner in which a failure occurs. Cause of Failure: The root cause of the failure mode. Search for the complete elimination of the problem. Effect of Failure: The outcome of the failure mode. View both local and global effects (domino effect). Current Controls: Exists to prevent the cause of the failure from occurring. WithAdrian™
- 14. GUIDE TO RATINGS OCCURRENCE CRITERIA RATING REMOTE Remote probability of occurrence. 1 VERY HIGH Very high probability of occurrence. Process out of control failure is almost certain. 5 HIGH High probability of occurrence. Process in control with failures often occurring. 4 MODERATE Moderate probability of occurrence. Process in control with occasional failures. 3 LOW Low probability of occurrence. Process under control. 2 1:10000 1:1 1:10 1:100 1:1000 STATISTICAL WEIGHTING WithAdrian™
- 15. GUIDE TO RATINGS SEVERITY MINOR Negligible effect on performance of functional equipment under consideration. No noticeable effect on programme. 1 VERY HIGH Equipment failure or high degree of rework. Programme irrecoverable. 5 HIGH High degree of impact due to nature of failure. Rework required, significant programme setback. 4 MODERATE Significant degradation of functional equipment under consideration with some rework, small impact on programme. 3 LOW Minor degradation of functional equipment under consideration. Minor rework, insignificant impact on programme. 2 < 5 MINUTE < 1 WEEK < 24 HOURS < 4 HOURS < 30 MINUTE CRITERIA RATING STATISTICAL WEIGHTING for rework WithAdrian™
- 16. GUIDE TO RATINGS DETECTION VERY HIGH Current control will almost certainly detect the failure mode. Defect will be detected during own process or operation 1 VERY LOW Current control will not detect the failure mode. Defect will reach customer 5 LOW Current controls have a poor chance of detecting the existence of a failure mode. Defect may reach customer. 4 MODERATE Current controls may detect the failure mode. Defect should be detected during at a stage of build or test. 3 HIGH Current controls have a good chance of detecting the failure mode. Defect will be detected during own process or operation 2 1:1 1:10 000 1:1000 1:100 1:10 CRITERIA RATING STATISTICAL WEIGHTING WithAdrian™
- 17. COMPLETING THE FMEA FORM STEP BY STEP Process Description/ Process Purpose Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s) of Failure O C C S E V D E L T A Current Controls D E T R P N Recommended Action(s) Area/ Individual Responsible. Completion date Action Results Actions Taken S E V O C C D E T R. P. N. 1 2 3 4 5 6 7 8 9 10 11 12 13 Team Effort WithAdrian™
- 18. FMEA FORM EXAMPLE Process Description/ Process Purpose Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s) of Failure O C C S E V D E L T A Current Controls D E T R P N Recommended Action(s) Area/ Individual Responsible. Completion date Action Results Actions Taken S E V O C C D E T R. P. N. Fixing unit to jig plate Screws too short Thread breakout from jig, possible unit damaged or scraped Wrong torque applied to screws Unit may become loose. Damage to feet on device under test 5 5 Thread breakout from jig, possible unit damaged or scraped Operator picks wrong screw Wrong wrench used 2 2 Operator skill at recognising screws Operator checks torque wrench if not recognised as one used before 3 4 30 40 Revive storage bins for screws Label torque wrench John Jones Steve Smith Labeled storage bin for each type of screw, nut and washer. Screw thrown away after use Dated calibration labels stuck to torque wrenches. 15315 40425 WithAdrian™
- 19. TEAM AND TEAM MECHANICS To do a complete job with the best results the: FMEA must be written by a team Team must be multi-disciplined and cross functional Team must be committed to achieving common objectives Whole team must participate Team members must maintain a positive attitude Team must reach a consensus WithAdrian™
- 20. TEAM AND TEAM MECHANICS The Team Responsible Engineer Planner Manufacturing Engineer Quality Operator The team should be no more than 5 - 8 people WithAdrian™
- 21. TEAM AND TEAM MECHANICS Handling difficult people The Individuals Who Talk Too Much Members Who Talk Too Little Members Who Say The Wrong Things The facilitator must manage the situation WithAdrian™
- 22. TEAM AND TEAM MECHANICS Common Meeting Pitfalls: Competing for power, often by challenging the leader Joking and clowning excessively, which is a distraction Failing to agree on a problem or issue Arguing about others’ opinions and suggestions Wondering off the topic at hand WithAdrian™
- 25. WithAdrian™ Things I would like to do again Lead initiatives, spark creativity, explore insights, cultivate brands, strengthen companies, build teams, encourage others, challenge myself
- 26. WithAdrian™
Notas del editor
- This presentation will take approximately 1 hour After this you will be be able to : Understand the principles of FMEA. Completing an FMEA Select a team for an FMEA F.M.E.A. is as its name suggests a method for analyising potential failures. FMEA provides a forum to discuss and record new ideas to improve the products and processes, in so doing reducing risk. When looking back many failures are in hindsight obvious. Introduce presentation as part of FMEA course
- 3 TYPES OF FMEA’s A product development cycle covers three stages. System design, Design and manufacturing. The system FMEA is the highest level FMEA and analysis the system at the concept stage. The design FMEA analyses the subsystems down to component level. The process FMEA analyses the manufacturing processes, failure here will fall under :- Manpower Machine Method Material Measurement Environment
- By definition the FMEA is a methodology to maximise the satisfaction of the customer by eliminating potential problems. To do this the FMEA must start as soon as possible. An FMEA can be started at any point between design conception and manufacturing. Do not wait for all the info because it will never start, make do with what you have
- A very common question is “when is the FMEA Complete” It is important to keep re-addressing the FMEA all through the life cycle of the product, this is the only way the FMEA maintains its usefulness.
- To conduct an FMEA effectively one must follow a systematic approach The 4 step method follows the PLAN, DO, CHECK, ACT cycle PLAN Select a cross functional team. Model the process, this should be a step by step flow chart. Points to remember when modelling a process are: 1. Make sure the objectives for the model are clearly defined 2. Model boundary , disregard information which is outside the model purpose or redefine the model and start again. 3. Model view point, is the model considered from the view point of the customer, employee, environment etc. If the model definition is to loose arguments can arise as to the consequence of failures on the system. Use affinity diagrams to identify and arrange the process. Brain storm process to gather elements of process. Organise elements into groups, address ill defined areas, look for and hidden relationships. DO Brain storm each process element for failure modes. In each case consider Material, Man Power, Method, Machine Measurement & Environment, these identify the key areas where failures are found. Quantify these effects using occurrence, severity and detection ratings(these are defined later). Multiply these ratings together to deduce the Risk Priority Number (RPN). Use the RPN to decide the importance of the failure mode relative to the other failure modes. Define the corrective actions to reduce the RPN, the lower the RPN the lower the risk associated with the failure mode. Assign members of the team to be responsible for executing the actions. CHECK At subsequent meetings record the result of the action. Deduce the new Occurrence, severity and detection ratings, calculate the new RPN and compare it to the original. Ask the following questions: Is the situation better than before ?, worse than before ?, the same as before ?. ACT Continually repeat the FMEA. Each member must maintain enthusiasm to improve the process.
- FMEA helps map out the road to continuous improvement
- Low occurrence, low severity high detection will give a low RPN. This indicates a low priority failure mode. Inversely high occurrence, high severity and low detection will give a high RPN. This indicates a very high priority failure mode. It is important to remember that the statistical weighting is arbitrary. It has to be decided by the FMEA team. It is very important that once a statistical weighting has been decided the team should try to use it where possible. The ratings for all FMEAs are graded between 1 and 5.
- 1.Process description - Identify the process element under consideration from the process map. 2.Failure mode - The problem, the concern, the opportunity. There can be more than one. 3.Effect of failure - The potential effects of the failure is the consequence of a process failure. 4.Severity of effect - Severity is a rating indicating the seriousness of the effect. 5.Critical characteristic- Is the process element critical to the whole process, enter “ “ for yes. 6.Cause of failure - The cause of a process failure mode is the process deficiency that results in the failure mode. There could be more than one cause. 7.Occurrence - It is the rating value corresponding to the estimated frequency of failures. 8.Current controls - Identify current controls that help detect or prevent failure modes and help the estimation of the detection rating. 9.Detection - It is a rating corresponding to the likelihood that the current process controls will detect the cause of failure. 10.RPN - This number is the product of severity, occurrence and detection. 11.Recommend action - Reduces RPN, may be specific action or further study. 12.Area/Individual responsible - The owner of the risk who will carry out action. 13.Action results - After the actions are incorporated, the FMEA team should re-evaluate the severity, occurrence and detection.
- Sum of the group is greater than the sum of the individuals The team is the foundation for improvement When conducting FMEA the following types of people slow down the process 1. The individuals who talk too much. 2. Members who talk too little. 3. Members who say the wrong thing - do not stick to agenda. These are not necessarily negative people. The group must draw as much useful information as possible. Try to be constructive not punitive.
- Team should meet on regular basis, for example once a week to review the effectiveness of the corrective actions and to look at new failure modes.
- Adrian Beale USA Address: Date of Birth: 24/09/61 1106 Marital Status: Married Fern Hill Road Health: Excellent Mooresville Driving License: Full/Clean North Carolina Work: +44776337534 USA Mobile: 7049051291