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Process Failure Modes & Effects Analysis (PFMEA)

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Minimise the potential process failure and its effects on your customer

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Process Failure Modes & Effects Analysis (PFMEA)

  1. 1. Process Failure Modes and Effects Analysis (PFMEA) Minimise the potential process failure and its effects on your customer Anand Subramaniam
  2. 2. <ul><li>“ In the field of observation, chance favors only the prepared mind .” </li></ul><ul><ul><li>- Louis Pasteur </li></ul></ul>
  3. 3. PFMEA - Overview <ul><li>Assumes that the design is sound </li></ul><ul><li>Analyses manufacturing & assembly processes at the system, subsystem or component levels </li></ul><ul><li>Focuses on potential failure modes of the process that are caused by manufacturing or assembly process deficiencies </li></ul><ul><li>Recommends actions targeted at eliminating the Root Cause of the potential failures </li></ul>
  4. 4. PFMEA – Sections / Groups <ul><li>Process Flow Diagram (PFD) </li></ul><ul><li>Process Failure Mode and Effects Analysis (PFMEA) </li></ul><ul><li>Process Control Plan (PCP) </li></ul>
  5. 5. PFMEA - Process Flow Diagrams <ul><li>It reflects the detailed process steps, including interfaces </li></ul><ul><li>It provides the structure to document what product characteristics and requirements (outputs) are affected by a given operation </li></ul><ul><li>It shows how the sources of variation are controlled (inputs) </li></ul><ul><li>It reflects every possible path a part can take through the anticipated manufacturing process </li></ul><ul><li>It assists in developing equipment specifications including material conformance, inspections, engineering change number etc </li></ul>
  6. 6. PFMEA - Assumptions <ul><li>The design is valid </li></ul><ul><li>Failures can but will not necessarily occur </li></ul><ul><li>All incoming product is to design specifications </li></ul><ul><li>Design failures are covered as part of the design FMEA </li></ul>
  7. 7. PFMEA - Inputs & Outputs <ul><li>Inputs </li></ul><ul><li>Process Flow Maps </li></ul><ul><li>Design FMEA </li></ul><ul><li>Technical procedures (drawings / formulas) </li></ul><ul><li>Process History (scrap, rework, warranty) </li></ul><ul><li>C&E Matrix </li></ul><ul><li>Outputs </li></ul><ul><li>Actions to prevent causes </li></ul><ul><li>Actions to detect failure modes </li></ul><ul><li>Document history of actions taken </li></ul>
  8. 8. PFMEA - Process Steps
  9. 9. PFMEA - Matrix Process steps / operation # from Process Flow Potential - Significant & Critical Characteristics from DFMEA High / Medium Interactions are causes / failure modes in PFMEA Characteristics Ranked in order of Importance Prioritised ranking of process steps relative to risk Severity Process Primary Process Steps Customer Assessment Direction of Improvement Potential Critical and Significant Weighted Importance Relative Importance M F H F H F M M G H M H H F H H F F M H H H H H G G M 5 3 9 3 9 9 5 0 81 81 72 0 9 41 0 0 27 54 261 3 0 54 81 3 0 0 0 27 0 45 9 9 0 0 0 0 0 0 0 Special Characteristics Matrix
  10. 10. PFMEA - Failure Categories <ul><li>Complete Failure </li></ul><ul><li>Partial Failure </li></ul><ul><li>Intermittent Failure </li></ul><ul><li>Failure over Time </li></ul><ul><li>Over- Performance of Function </li></ul>
  11. 11. PFMEA - Control Groups <ul><li>Type 1 – prevent the cause </li></ul><ul><li>Type 2 – detect the cause </li></ul><ul><li>Type 3 – detect the failure mode </li></ul>
  12. 12. PFMEA – Interface Process Interface Quality Audits Re-work Processes Part Buffers Product / Tooling Changeovers Alternative Processes Part Identity / Labeling Scrap Part Movement Gauging Stations Reject Handling
  13. 13. FMEA – Process Controls <ul><li>Preventative </li></ul><ul><li>SPC </li></ul><ul><ul><li>Maintenance </li></ul></ul><ul><ul><li>Method sheets </li></ul></ul><ul><ul><li>Operator training </li></ul></ul><ul><ul><li>Work instructions </li></ul></ul><ul><ul><li>Set up verification </li></ul></ul><ul><ul><li>Inspection verification </li></ul></ul><ul><ul><li>Error proof by design </li></ul></ul><ul><li>Detection </li></ul><ul><ul><li>Gauging </li></ul></ul><ul><ul><li>Final test </li></ul></ul><ul><li>Functional test </li></ul><ul><ul><li>Visual inspection </li></ul></ul><ul><ul><li>Touch for quality </li></ul></ul>
  14. 14. Process Control Plans <ul><li>Identify which controls relate to Product & Process </li></ul><ul><li>Note any Special Characteristics </li></ul><ul><li>Identify evaluation methods, frequency and control methods </li></ul>
  15. 15. PFMEA – Benefits PFMEA Benefits Improves processes before failure occur Tracks and documents completion of projects Improves performance monitoring, fault-sensing equipment and / or test points Effective preventive maintenance plans based on the significance of failure effects Creates robust designs that consider less than ideal operating environments and poor customer habits Prioritises resources to ensure process improvement efforts are beneficial to customers Decreases warranty costs, waste, non-value added tasks Increases safety and enhances customer satisfaction
  16. 16. <ul><li>“ Good design can't fix broken business models. ” </li></ul><ul><ul><li>- Jeffrey Veen </li></ul></ul>
  17. 17. <ul><li>Good Luck </li></ul><ul><li> </li></ul>