failure mode effect analysis (fmea)
Post on 13-Sep-2014
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DESCRIPTION
ABOUT THE TRAINING PROGRAM :- Failure Mode and Effects Analysis or FMEA is a structured technique to analyze a process to determine shortcomings and opportunities for improvement. By assessing the severity of a potential failure, the likelihood that the failure will occur, and the chance of detecting the failure, dozens or even hundreds of potential issues can be prioritized for improvement. DESIGNED FOR :- Sr. Engineer, Engineer, Supervisor and Foreman engaged in maintenance, operation, Store, Supply chain, Quality, Safety and Engineering activities. OBJECTIVE :- Employees completing this training will be able to effectively participate on an FMEA team and can make immediate contributions to quality and productivity improvement efforts.TRANSCRIPT
Prepared by :- Mr. Deepak Sahoo , Consultant
Training Program on
FMEAFailure Mode and Effects Analysis
Presented by : - Mr. Deepak Sahoo
Prepared by :- Mr. Deepak Sahoo , Consultant
Day Plan @ 5th Jan 2013.
Start time – 10.15 AM End Time : 1 PM
FMEA Part 1 – 10.15 AM – 11.45 PM
FMEA Part 2 – 12.15 PM - 01.00 PM
Break time @ 11.45 PM for 30 minutes
FMEA Part - 1 FMEA Part - 2Break
Prepared by :- Mr. Deepak Sahoo , Consultant
Agenda
FMEA History
What is FMEA
Definitions
What it Can Do For You
Types of FMEA
Team Members Roles
FMEA Terminology
Getting Started with an FMEA
The Worksheet
FMEA Scoring
Prepared by :- Mr. Deepak Sahoo , Consultant
Why we need FMEA video
Prepared by :- Mr. Deepak Sahoo , Consultant
Do it right the first time.
Why does it always seem we
have plenty of time to fix our problems, but never enough
time to prevent the problems by
doing it right the first time?
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Accident Rate in Aviation industry.
The 2011 global accident rate (measured in hull losses per million flights) was 0.37, the equivalent of one accident every 2.7 million flights.
0.1 0.45 0.34 0.8 0.72
1.87
7.41
0
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N O R T H A M E R I C A
E U R O P E N O R T H A S I A
A S I A -P A C I F I C
M I D D L E E A S T A N D
N O R T H A F R I C A
L A T I N A M E R I C A
A F R I C A
ACCIDENT RATE IN AVIATION INDUSTRY
Data collected from IATA.http://www.iata.org/pressroom/pr/pages/2011-02-23-01.aspx
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Murphy’s Law
“Everything that can fail, shall fail”
This is known as Murphy’s Law and is one of the main reasons behind the FMEA technique.
Consequently, during the design of a system or product, the designer must always think in terms of:
What could go wrong with the system or process?
How badly might it go wrong?
What needs to be done to prevent failures?
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The Bathtub curve
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FMEA Video - 1
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How it Origin ?
• This “type” of thinking has been around for hundreds of years. It was first formalized in the aerospace industry during the Apollo program in the 1960’s.
• Department of Defense developed and revised the MIL-STD-1629A guidelines during the 1970s.
• Ford Motor Company published instruction manuals in the 1980s and the automotive industry collectively developed standards in the 1990s.
Prepared by :- Mr. Deepak Sahoo , Consultant
What is FMEA ?
• FMEA Stands for Failure mode effect Analysis.
• FMEA is a tool that allows you to:
• Prevent System, Product and Process problems before they occur
• Reduce costs by identifying system, product and process improvements early in the development cycle
• Create more robust processes
• Prioritize actions that decrease risk of failure
• Evaluate the system, design and processes from a new vantage point
Prepared by :- Mr. Deepak Sahoo , Consultant
A Systematic Process
FMEA provides a systematic process to:
Identify and evaluate
potential failure modes
potential causes of the failure mode
Identify and quantify the impact of potential failures
Identify and prioritize actions to reduce or eliminate the potential failure
Implement action plan based on assigned responsibilities and completion dates
Document the associated activities
Prepared by :- Mr. Deepak Sahoo , Consultant
Published Guidelines
• J1739 from the SAE for the automotive industry.
• AIAG FMEA-3 from the Automotive Industry Action Group for the automotive industry.
• ARP5580 from the SAE for non-automotive applications.
Other industry and company-specific guidelines exist. For example:
• EIA/JEP131 provides guidelines for the electronics industry, from the JEDEC/EIA.
• P-302-720 provides guidelines for NASA’s GSFC spacecraft and instruments.
• SEMATECH 92020963A-ENG for the semiconductor equipment industry.
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Rule of Ten (10)
If the issue costs $10,000 when it is discovered in the field,
then…
It may cost $1000 if discovered during the final test…
But it may cost $100 if discovered during an incoming inspection.
Even better it may cost $10 if discovered during the design or process engineering phase.
Prepared by :- Mr. Deepak Sahoo , Consultant
Benefits of FMEA.
Contributes to improved designs for products and processes.
Higher reliability
Better quality
Increased safety
Enhanced customer satisfaction
Contributes to cost savings.
Decreases development time and re-design costs
Decreases warranty costs
Decreases waste, non-value added operations
Contributes to continuous improvement
Prepared by :- Mr. Deepak Sahoo , Consultant
Type of FMEAs.
System/Concept “S/CFMEA”- (Driven by System functions) A system is a organized set of parts or subsystems to accomplish one or more functions. System FMEAs are typically very early, before specific hardware has been determined.
Design “DFMEA”- (Driven by part or component functions) A Design / Part is a unit of physical hardware that is considered a single replaceable part with respect to repair. Design FMEAs are typically done later in the development process when specific hardware has been determined.
Process “PFMEA”- (Driven by process functions & part characteristics) A Process is a sequence of tasks that is organized to produce a product or provide a service. A Process FMEA can involve fabrication, assembly, transactions or services.
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FMEA Terminology 1
1.) Failure Modes: (Specific loss of a function) is a concise description of how a part , system, or manufacturing process may potentially fail to perform its functions.
2.) Failure Mode “Effect”: A description of the consequence or Ramification of a system or part failure. A typical failure mode may have several “effects” depending on which customer you consider.
3.) Severity Rating: (Seriousness of the Effect) Severity is the numerical rating of the impact on customers.
4.) Failure Mode “Causes”: A description of the design or process deficiency (global cause or root level cause) that results in the failure mode.
5.) Occurrence Rating: Is an estimate number of frequencies or cumulative number of failures (based on experience) that will occur (in our design concept) for a given cause over the intended “life of the design”.
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FMEA Terminology 2
6.) Failure Mode “Controls”: The mechanisms, methods, tests, procedures, or controls that we have in place to PREVENT the Cause of the Failure Mode or DETECT the Failure Mode or Cause should it occur.
7.) Detection Rating: A numerical rating of the probability that a given set of controls WILL DISCOVER a specific Cause of Failure Mode to prevent bad parts leaving the facility or getting to the ultimate customer.
8.) Risk Priority Number (RPN): Is the product of Severity, Occurrence, & Detection.
Risk= RPN= S x O x D
9.) Action Planning: A thoroughly thought out and well developed FMEA With High Risk Patterns that is not followed with corrective actions has little or no value, other than having a chart for an audit
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FMEA Video - 2
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FMEA Process
Step 1 - Select a process to evaluate
Step 2 - Recruit a multidisciplinary Team
Step 3 - Have the team meet to list all the steps in the process
Step 4 - Have the team list failure modes and causes
Step 5 For each failure mode have the team assign a numeric value (Risk Priority Number (RPN)) for likelihood of
occurrence, likelihood of detection and severity.
Step 6 - Evaluate the results - Identify the failure modes with the top 10 highest RPNs.
Step 7 - Use RPNs to plan improvement efforts
Prepared by :- Mr. Deepak Sahoo , Consultant21
FMEA Core Team4 – 6 Members
Expertise in Product / ProcessCross functional
Honest CommunicationActive participation
Positive attitudeRespects other opinions
Participates in team decisions
Champion / SponsorProvides resources & support
Attends some meetingsPromotes team efforts
Shares authority / power with teamKicks off team
Implements recommendations
RecorderKeeps documentation of teams efforts
FMEA chart keeperCoordinates meeting rooms/time
Distributes meeting rooms & agendas
Facilitator“Watchdog“ of the process
Keeps team on trackFMEA Process expertise
Encourages / develops team dynamicsCommunicates assertively
Ensures everyone participates
Team Leader“Watchdog” of the project
Good leadership skillsRespected & relaxed
Leads but doesn’t dominateMaintains full team participation
Typically lead engineer
The FMEA Team Roles
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Risk Priority Number(RPN)
RPN = Severity x Occurrence x Detection
RPN is used to prioritize concerns/actions
The greater the value of the RPN the greater the concern
RPN ranges from 1-1000
The team must make efforts to reduce higher RPNs through corrective action
General guideline is over 100 = recommended action
Prepared by :- Mr. Deepak Sahoo , Consultant
RPN Considerations
Rating scale example:
Severity = 10 indicates that the effect is very serious and is “worse” than Severity = 1.
Occurrence = 10 indicates that the likelihood of occurrence is very high and is “worse” than Occurrence = 1.
Detection = 10 indicates that the failure is not likely to be detected before it reaches the end user and is “worse” than Detection = 1.
RPN ratings are relative to a particular analysis.
An RPN in one analysis is comparable to other RPNs in the same analysis …but an RPN may NOT be comparable to RPNs in another analysis.
Prepared by :- Mr. Deepak Sahoo , Consultant
Risk Guidelines
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Occurrence Ranking
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Detection Ranking
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FMEA Video - 3
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Exercise (Perform A DFMEA on a pressure cooker)
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Pressure Cooker Safety Features
1. Safety valve relieves pressure before it reaches dangerous levels.
2. Thermostat opens circuit through heating coil when the temperature rises above 250° C.
3. Pressure gage is divided into green and red sections. "Danger" is indicated when the pointer is in the red section.
Pressure Cooker FMEA
Define Scope:
1. Resolution - The analysis will be restricted to the four major subsystems (electrical system, safety valve, thermostat, and pressure gage).
2. Focus - Safety
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Pressure cooker block diagram
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Inputs for FMEA
Process flow diagram
Assembly instructions
Design FMEA
Current engineering drawings and specifications
Data from similar processes Scrap Rework Downtime Warranty
Process Function Requirement
Brief description of the manufacturing process or operation
The PFMEA should follow the actual work process or sequence, same as the process flow diagram etc.
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Team Members for a FMEA
Process engineer
Manufacturing supervisor
Operators
Quality
Safety
Product engineer
Customers
Suppliers
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Assumptions & Potential Failure Mode
The design is valid
All incoming product is to design specifications
Failures can but will not necessarily occur
Potential Failure Mode
How the process or product may fail to meet design or quality requirements
Many process steps or operations will have multiple failure modes
Think about what has gone wrong from past experience and what could go wrong
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Common & Potential Failure ModesAssembly
Missing parts
Damaged
Orientation
Contamination
Off location
Torque
Loose or over torque
Missing fastener
Cross threaded
Machining
Too narrow
Too deep
Angle incorrect
Finish not to specification
Flash or not cleaned
Sealant
Missing
Wrong material applied
Insufficient or excessive material
Dry
Drilling holes
Missing
Location
Deep or shallow
Over/under size
Concentricity
angle
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Potential Effects
• End user• Noise
• Leakage
• Odor
• Poor appearance
• Endangers safety
• Loss of a primary function
• performance
• Next operation• Cannot assemble
• Cannot tap or bore
• Cannot connect
• Cannot fasten
• Damages equipment
• Does not fit
• Does not match
• Endangers operator
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Severity Ranking
How the effects of a potential failure mode may impact the customer
Only applies to the effect and is assigned with regard to any other rating
Potential effects of failure
Severity
Cannot assemble bolt(5)
Endangers operator(10)
Vibration (6)
Take the highest effect ranking (10)
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Potential Causes
Equipment• Tool wear
• Inadequate pressure
• Worn locator
• Broken tool
• Gauging out of calibration
• Inadequate fluid levels
Operator• Improper torque
• Selected wrong part
• Incorrect tooling
• Incorrect feed or speed rate
• Mishandling
• Assembled upside down
• Assembled backwards
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Occurrence Ranking
How frequent the cause is likely to occur
Use other data available Past assembly processes
SPC
Warranty
Each cause should be ranked according to the guideline
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Detection
Probability the defect will be detected by process controls before next or subsequent process, or before the part or component leaves the manufacturing or assembly location
Likely hood the defect will escape the manufacturing location
Each control receives its own detection ranking, use the lowest rating for detection
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RPN
RPN provides a method for a prioritizing process concerns
High RPN’s warrant corrective actions
Despite of RPN, special consideration should be given when severity is high especially in regards to safety
An RPN is like a medical diagnostic, predicting the health of the patient
At times a persons temperature, blood pressure, or an EKG can indicate potential concerns which could have severe impacts or implications
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Recommended actions
Control
Influence
Can’t control or influence at this time
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Recommended actions
Definition: tasks recommended for the purpose of reducing any or all of the rankings
Examples of Recommended actions
Perform:
Process instructions
Training
Can’t assemble at next station
Visual Inspection
Torque Audit
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FMEA Video - 4
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FMEA Video - 5
Prepared by :- Mr. Deepak Sahoo , Consultant
Thank You !!!!
Connect With Me @
Mobile :- +974 – 3370 8982
Email :- [email protected]
LinkedIn :- www.linkedin.com/in/dksahoo
AnyQuestions?