FMEAtrainingversionWtBIII

FRENCKENGROUPLIMITEDINCORPORATEDINSINGAPORETrainerWilteBoekhorstSeniorQualityOfficerFrenckenMechatronicsEindhovenCommunicationNewlessonlearneddd.19-10-2011Don’tdoassumptionincommunicationDon’texpectthatlanguagecontrolisthesameallovertheworldVerifyinanearlystagewhatlanguageproblemscanbeexpectedinforeigncountry’sStartpreparinginamoreearlystageIntheendweallarewinnersFMEAFailureModeEffectsAnalysisAGENDA•Opening•DFMEA•PFMEA•PrepareforPFMEAExercise•ClosingandSurveyQualityandReliability•Qualityisarelativetermoftenbasedoncustomerperceptionorthedegreetowhichaproductmeetscustomerexpectations•Manufacturershavelongrecognizedthatproductscanmeetspecificationsandstillfailtosatisfycustomerexpectationsdueto:–Errorsindesign–Flawsinducedbythemanufacturingprocess–Environment–Productmiss-use–NotunderstandingcustomerrequirementsQuality,ReliabilityandFailurePrevention•Traditionallyqualityactivitieshavefocusedondetectingmanufacturingandmaterialdefectsthatcausefailuresearlyinthelifecycle•Today,activitiesfocusonfailuresthatoccurbeforewestartproductionafterwedesignedtheprocess•EmphasisonFailurePreventionFailureMode&EffectsAnalysis(FMEA)•FMEAisasystematicmethodofidentifyingandpreventingsystem,productandprocessproblemsbeforetheyoccur•FMEAisfocusedonpreventingproblems,enhancingsafety,andincreasingcustomersatisfaction•Ideally,FMEA’sareconductedintheproductdesignorprocessdevelopmentstages,althoughconductinganFMEAonexistingproductsorprocessesmayalsoyieldbenefitsFMEA/FMECAHistory•ThehistoryofFMEA/FMECAgoesbacktotheearly1950sand1960s.–U.S.NavyBureauofAeronautics,followedbytheBureauofNavalWeapons:–NationalAeronauticsandSpaceAdministration(NASA):•DepartmentofDefensedevelopedandrevisedtheMIL-STD-1629Aguidelinesduringthe1970s.FMEA/FMECAHistory(continued)•FordMotorCompanypublishedinstructionmanualsinthe1980sandtheautomotiveindustrycollectivelydevelopedstandardsinthe1990s.•Engineersinavarietyofindustrieshaveadoptedandadaptedthetoolovertheyears.FMEAisaTool•FMEAisatoolthatallowsyouto:–PreventSystem,ProductandProcessproblemsbeforetheyoccur–reducecostsbyidentifyingsystem,productandprocessimprovementsearlyinthedevelopmentcycle–Createmorerobustprocesses–Prioritizeactionsthatdecreaseriskoffailure–Evaluatethesystem,designandprocessesfromanewvantagepointASystematicProcess•FMEAprovidesasystematicprocessto:–Identifyandevaluate•potentialfailuremodes•potentialcausesofthefailuremode–Identifyandquantifytheimpactofpotentialfailures–Identifyandprioritizeactionstoreduceoreliminatethepotentialfailure–Implementactionplanbasedonassignedresponsibilitiesandcompletiondates–DocumenttheassociatedactivitiesPurpose/Benefit•costeffectivetoolformaximizinganddocumentingthecollectiveknowledge,experience,andinsightsoftheengineeringandmanufacturingcommunity•formatforcommunicationacrossthedifferentdisciplines•provideslogical,sequentialstepsforspecifyingproductandprocessareasofconcernBenefitsofFMEA•Contributestoimproveddesignsforproductsandprocesses.–Higherreliability–Betterquality–Increasedsafety–Enhancedcustomersatisfaction•Contributestocostsavings.–Decreasesdevelopmenttimeandre-designcosts–Decreaseswarrantycosts–Decreaseswaste,non-valueaddedoperations•ContributestocontinuousimprovementBenefits•CostbenefitsassociatedwithFMEAareusuallyexpectedtocomefromtheabilitytoidentifyfailuremodesearlierintheprocess,whentheyarelessexpensivetoaddress.–“ruleoften”•Iftheissuecosts$100whenitisdiscoveredinthefield,then…•Itmaycost$10ifdiscoveredduringthefinaltest…•Butitmaycost$1ifdiscoveredduringanincominginspection.•Evenbetteritmaycost$0.10ifdiscoveredduringthedesignorprocessengineeringphase.FMEAasHistoricalRecord•Communicatethelogicoftheengineersandrelateddesignandprocessconsiderations•Areindispensableresourcesfornewengineersandfuturedesignandprocessdecisions.SystemDesignProcessComponentsSubsystemsMainSystemsComponentsSubsystemsMainSystemsManpowerMachineMethodMaterialMeasurementEnvironmentMachinesTools,WorkStations,ProductionLines,OperatorTraining,Processes,GaugesFocus:MinimizefailureeffectsontheSystemObjectives/Goal:MaximizeSystemQuality,reliability,CostandmaintenanceFocus:MinimizefailureeffectsontheDesignObjectives/Goal:MaximizeDesignQuality,reliability,CostandmaintenanceFocus:MinimizefailureeffectsontheProcessesObjectives/Goal:MaximizeTotalProcessQuality,reliability,CostandmaintenanceWhydoFMEA’s?•Examinethesystemforfailures.•Ensurethespecsareclearandassuretheproductworkscorrectly•ISOrequirement-QualityPlanning–“ensuringthecompatibilityofthedesign,theproductionprocess,installation,servicing,inspectionandtestprocedures,andtheapplicabledocumentation”Whattoolsareavailabletomeetourobjective?•Benchmarking•customerwarrantyreports•designchecklistorguidelines•fieldcomplaints•internalfailureanalysis•internalteststandards•lessonslearned•returnedmaterialreports•ExpertknowledgeWhatarepossibleoutcomes?•Actual/potentialfailuremodes•customerandlegaldesignrequirements•dutycyclerequirements•productfunctions•keyproductcharacteristics•ProductVerificationandValidationHowtoFMEA…ThePre-TeamMeeting•Priortoassemblingthe