111. 222 individually given your sample of m&ms, build a pareto diagram by color before you...
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222
Individually Given your sample of M&Ms, build a
Pareto diagram by color Before you destroy the evidence, be
sure you have an accurate count of each color and the total number of M&Ms.
Brown =Red =Yellow =Blue =Orange =Green =
------------------------ Total=
Exercise
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Pareto Chart Exercise
30 100%
2890%
26
24 80%
2270%
20
18 60%
1650%
14
12 40%
1030%
8
6 20%
410%
2
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A finished document (i.e., unit) contains a total of 4 critical entries (i.e., a critical entry is an opportunity for a defect, mistake, or error). An inspection of 3,000 documents revealed a total of 195 errors, and 94% of the documents were good (i.e., defect free).
Calculate the following:
dpu =
dpm =
dpmo =
Total Number of Defective Documents =
Total Number of Defect-Free Documents =
FPY =
σ capability =
Yield exercise
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Failure Mode – The manner in which a part or process can fail to meet specification. It is usually associated with a defect or nonconformance.
Effect – The impact on a customer if a failure mode is not prevented or corrected. The customer can be an immediate one or one downstream.
Cause – A deficiency that results in a failure mode. Causes are sources of variability associated with key process input variables.
A FMEA is best when a team prepares it. The team should be made up of people from all areas impacted by the process. The FMEA is useful in a number of applications: in determining X’s, helping to define process improvements and controls, and others.
Reference◦ AIAG – Potential Failure Mode and Effects Analysis, FMEA◦ SAE J1739- Potential Failure Mode and Effects Analysis in
Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)
Failure Mode and Effects Analysis Terms
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System FMEA is used to analyze systems and subsystems in early concept and design stages. It focuses on potential failure modes associated with the functions of a system caused by design.
Design FMEA is used to analyze products before they are release to production.
Process FMEA is used to analyze manufacturing, assembly, and transactional processes.
Product FMEA is used to analyze failure modes that could occur to the product once it gets into the customers hands.
Types of FMEA’s
FMEA: Identify ways of eliminating or reducing the specific causes and document a plan to prevent the
failures.
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Preliminary Steps in the FMEA Process
Preparation A FMEA begins with a process map.
Identify the process and map its key steps.
List the key process outputs to satisfy customer requirements.
List the key process inputs for each process step.
Define a matrix relating product outputs to process inputs.
Rank inputs according to their importance.
The goal in your preparation is to have a complete understanding of the process you are analyzing. What are its steps? What are its inputs and outputs? How do they relate?
**Information for this section taken from: GE Six Sigma Playbook and the AIAG Reference Manual.**
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Start with the high level process map for an accounts receivable process:
FMEA Example
ReceivePayment
IdentifyCustomer
IdentifyInvoice
ApplyPayment to Invoice
Start
End
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For each Process Input Variable (PIV), determine the ways in which the input can go wrong (failure modes).
There is at least one way that each input can fail.
FMEA - Step 1
Process StepKey Process
InputPotential Failure
Mode
Potential Failure Effects
SEV
Potential Causes
OCC
Current Controls
DET
RPN
Receive Payment Checks Delay internal mail
Identify Customer Wire Transfer reference line
Information not supplied
Identify Invoice Checks Incorrect invoice supplied
Identify Invoice Checks Invoice number not supplied
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For each failure mode associated with the inputs, determine effects.
These effects are internal requirements for the next process as well as customer effects.
FMEA - Step 2
Process StepKey Process
InputPotential
Failure ModePotential
Failure Effects
SEV
Potential Causes
OCC
Current Controls
DET
RPN
Receive Payment Checks Delay internal mail
AR balance does not go down
Identify Customer Wire Transfer reference line
Information not supplied
AR balance is past due
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
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Identify potential causes of each failure mode.
In most cases, there will be more than one cause for a failure mode.
FMEA - Step 3
Process StepKey Process
InputPotential
Failure ModePotential Failure
Effects
SEV
Potential CausesOCC
Current ControlsDET
RPN
Receive Payment Checks Delay internal mail
AR balance does not go down
Inadequate staffing in mail room
Identify Customer Wire Transfer reference line
Information not supplied
AR balance is past due
Customer or bank did not include name and/or account info on wire transfer
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
Customer error
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
Customer error
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List the current controls for each cause.
For each cause, we list how we are either preventing or detecting it. List the document number for any SOP’s.
FMEA - Step 4
Process StepKey
Process Input
Potential Failure Mode
Potential Failure Effects
SEV
Potential CausesOCC
Current ControlsDET
RPN
Receive Payment Checks Delay internal mail
AR balance does not go down
Inadequate staffing in mail room
None
Identify Customer Wire Transfer reference line
Information not supplied
AR balance is past due
Customer or bank did not include name and/or account info on wire transfer
Acct identifies problem when trying to apply payment
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
Customer error Customer might catch it when reviewing the next statement
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
Customer error Acct identifies problem when trying to apply payment
This is how the FMEA identifies initial holes in the current control plan. V-66
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The risk priority number (RPN) is the product of the rankings for:◦ Severity (SEV)◦ Probability of Occurrence (OCC)◦ Difficulty to Detect (DET)
High RPN’s are flags to take effort to reduce the calculated risk
Regardless of RPN, high severity scores (9-10) must be given special attention
Risk Priority Numbers, RPN
RPN = SEV x OCC x DET
Effects Causes
Controls
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Generic FMEA Rating table Create a rating system that
makes sense for your project, the process, and the defects
you’re trying to prevent.
Create a rating system that makes sense for your project, the process, and the defects
you’re trying to prevent.
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Assign severity, occurrence and detection ratings to each cause.
We are now ready to assign appropriate criteria. The team then starts scoring each cause to compute a risk priority number (RPN).
FMEA - Step 5
Process StepKey Process
InputPotential Failure
ModePotential Failure
Effects
SEV
Potential CausesOCC
Current ControlsDET
RPN
Receive Payment Checks Delay internal mail
AR balance does not go down
7
Inadequate staffing in mail room
7
None
10 490
Identify Customer Wire Transfer reference line
Information not supplied
AR balance is past due
10
Customer or bank did not include name and/or account info on wire transfer
5
Acct identifies problem when trying to apply payment
5 250
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
5
Customer might catch it when reviewing the next statement 10 250
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
10
Acct identifies problem when trying to apply payment
5 250
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Calculate the RPN’s and determine recommended actions to reduce high RPN’s.
High severity scores (9-10) must be given special attention.
Which issues may we want to address first?
FMEA - Steps 6
Process StepKey Process
InputPotential Failure
ModePotential Failure
Effects
SEV
Potential CausesOCC
Current ControlsDET
RPN
Receive Payment Checks Delay internal mail
AR balance does not go down
7
Inadequate staffing in mail room
7
None
10 490
Identify Customer Wire Transfer reference line
Information not supplied
AR balance is past due
10
Customer or bank did not include name and/or account info on wire transfer
5
Acct identifies problem when trying to apply payment
5 250
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
5
Customer might catch it when reviewing the next statement 10 250
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
10
Acct identifies problem when trying to apply payment
5 250
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Determine recommended actions to reduce high RPN’s.
Now fill in recommended actions for high RPN’s.
Ease of Completion (EOC) for each action is optional.
FMEA - Step 7
Process StepKey
Process Input
Potential Failure Mode
Potential Failure Effects
SEV
Potential CausesOCC
Current ControlsDET
RPN
EOC
Actions Recommended
Receive Payment
Checks Delay internal mail
AR balance does not go down
7
Inadequate staffing in mail room 7
None
10 490
Investigate mail room staffing and associated processes
Identify Customer
Wire Transfer reference line
Information not supplied
AR balance is past due
10
Customer or bank did not include name and/or account info on wire transfer
5
Acct identifies problem when trying to apply payment
5 250
Poka-Yoke wire transer process
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
5
Customer might catch it when reviewing the next statement 10 250
Provide payment stub with statement for each invoice
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
10
Acct identifies problem when trying to apply payment 5 250
Provide payment stub with statement for each invoice
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Person or group responsible should take on the Actions Recommended and document those actions. Now recalculate your RPN’s.
FMEA - Steps 8 And 9
Process StepKey
Process Input
Potential Failure Mode
Potential Failure Effects
SEV
Potential CausesOCC
Current ControlsDET
RPN
EOC
Actions Recommended
Resp. Actions TakenSEV
OCC
DET
RPN
Receive Payment
Checks Delay internal mail
AR balance does not go down
7
Inadequate staffing in mail room 7
None
10 490
Investigate mail room staffing and associated processes
G. Lee Added another mail clerk. Adjusted dock schedule. 7 1 10 70
Identify Customer
Wire Transfer reference line
Information not supplied
AR balance is past due
10
Customer or bank did not include name and/or account info on wire transfer
5
Acct identifies problem when trying to apply payment
5 250
Poka-Yoke wire transer process
N. Peart Contacted banks and established wire transfer procedure (DI 2112) 10 1 3 30
Identify Invoice Checks Incorrect invoice supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
5
Customer might catch it when reviewing the next statement 10 250
Provide payment stub with statement for each invoice
A. Lifeson Revised statement to include payment stub with each invoice. 5 1 5 25
Identify Invoice Checks Invoice number not supplied
Invoice shows outstanding (AR balance does go down)
5
Customer error
10
Acct identifies problem when trying to apply payment 5 250
Provide payment stub with statement for each invoice
S. Hagar Revised statement to include payment stub with each invoice. 5 1 5 25
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