FMEA-02

Rolls-RoyceProprietary1Howcouldthingsgowrong?Wherearethebiggestrisks?Howcouldthingsgowrong?Wherearethebiggestrisks?Rolls-RoyceProprietary2FMEAOriginationThedifferenttypesFMEAFMEA’sLinkwithContinuousImprovementOurfocusisonProcessFMEAFMEAWorksheetWhyweuseFMEAWhentouseFMEAPotentialApplicationsofFMEAStepsoncompletingFMEARolls-RoyceProprietary3WheredoesFMEAcomefrom?WheredoesFMEAcomefrom?WheredoesFMEAcomefrom?DevelopedbytheAerospaceindustryinthe1960sSpreadtotheAutomotiveindustryNowusedextensivelyacrossallindustrysectorsReferenceSAEJ-1739DevelopedbytheAerospaceindustryinthe1960sSpreadtotheAutomotiveindustryNowusedextensivelyacrossallindustrysectorsReferenceSAEJ-1739Rolls-RoyceProprietary4DifferentTypesofFMEADifferentTypesofFMEADifferentTypesofFMEADesignAnanalyticaltechniqueusedprimarilybyDesignResponsibleEngineer/Teamasameanstoassurepotentialfailuremodes,causesandeffectshavebeenaddressedfordesignrelatedcharacteristicsProcessAnanalyticaltechniqueusedprimarilybyaManufacturingEngineer/Teamasameanstoassurepotentialfailuremodes,causesandeffectshavebeenaddressedforprocessrelatedcharacteristicsRolls-RoyceProprietary5LinkwithContinuousImprovementLinkwithContinuousImprovementLinkwithContinuousImprovementMistakeProofingTechniquesMistakeProofingTechniquesContinuousImprovementProgramsContinuousImprovementProgramsComponentProvingProcessComponentProvingProcessRolls-RoyceProprietary6OurFocusisonProcessFMEAOurFocusisonProcessFMEAOurFocusisonProcessFMEAAstructuredapproachto:IdentifyingthewayinwhichaprocesscanfailtomeetcriticalcustomerrequirementsEstimatingtheriskofspecificcauseswithregardtothesefailuresEvaluatingthecurrentcontrolplanforpreventingthesefailuresfromoccurringPrioritisingtheactionsthatshouldbetakentoimprovetheprocessConcept:Toidentifywaystheproductorprocesscanfailandthenplantopreventthosefailures,utilisingmistakeproofingtoolsandtechniques.Rolls-RoyceProprietary7ExampleofanProcessFMEATableExampleofanProcessFMEATableExampleofanProcessFMEATableProblem:IssuedBy:Notes:TeamMembers:Scores:Occurrence:HighNo.(10)Frequently/withcertaintyRPN=Occ.xSev.xDet.lowNo.(1)RarelyAssumptions:Severity:HighNo.(10)Dangerous/warrantystatisticLowNo.(1)NotSignificantDetection:HighNo.(10)DetectionveryunlikelyLowNo.(1)EasilydetectedRef.PartNo.FunctionorFailureEffectOfCauseOfCurrentCurrentStatusRecommendedNo.NameProcessModeFailureFailureControlsCorrectiveActionComp'lCommentsIssueSevOccDetRPNByDate000000000000000000000ProcessFailureModeandEffectsAnalysisSortFMEAbyHighestRPNNumbersRevision:Date:Rolls-RoyceProprietary8WhyweuseFMEA?WhyweuseFMEA?WhyweuseFMEA?ratherthancure.IncreaseprobabilityofDETECTIONIdentifybiggestcontributortofailuresandeliminatethemReduceprobabilityoffailureoccurringBuildqualityintotheproduct&processRolls-RoyceProprietary9WhentouseFMEA?WhentouseFMEA?WhentouseFMEA?FMEAismostbeneficialasa“before-the-event”actionDesignFMEAshouldbedoneduringinitialdesignofproductProcessFMEAshouldbedoneduringdesignofmanufacturingprocessProcessFMEAcanbedoneforlegacyproduct/processesRolls-RoyceProprietary10PotentialApplicationsforPFMEAPotentialApplicationsforPFMEAPotentialApplicationsforPFMEAComponentProvingProcessOutsourcing/ResourcingofproductDevelopSupplierstoachieveQualityRenaissance/ScorecardTargetsMajorProcess/Equipment/TechnologyChangesJustificationofFastTrackRESA?CostReductionsNewProduct/DesignAnalysisAssistinanalysisofaflatparetochartRolls-RoyceProprietary11GuidetodoProcessFMEAGuidetodoProcessFMEAGuidetodoProcessFMEABrainstormallpotentialfailuremodesBrainstormallpotentialfailuremodesIdentifypotentialeffectsoffailuresIdentifypotentialeffectsoffailuresIdentifycausesoffailuresIdentifycausesoffailuresDefinecurrentcontrolmethodsDefinecurrentcontrolmethodsCalculateRiskPriorityNumbersCalculateRiskPriorityNumbersPrioritisecorrectiveactionsPrioritisecorrectiveactionsDetermineSeverityRankingsDetermineSeverityRankingsScopeProjectScopeProjectDetermineOccurrenceRankingsDetermineOccurrenceRankingsDetermineDetectionRankingsDetermineDetectionRankingsSTEP1STEP1STEP2STEP2STEP5STEP5STEP6STEP6STEP4STEP4STEP3STEP3STEP7STEP7STEP8STEP8STEP9STEP9STEP10STEP10Rolls-RoyceProprietary12ComplexPartComplexPartComplexPartRolls-RoyceProprietary13Step1-ScopeProcessStep1Step1--ScopeProcessScopeProcessFormulatecrossfunctionalteamUnderstandcustomer/processrequirementsDefinestartandendofprocessAllteammemberswalkandobservetheprocessGetthe‘processworker’toexplaintheoperation/processunderreview.Makenotes/observationsDefiningScopeofFMEAisCRITICAL!DefiningScopeofFMEAisCRITICAL!Rolls-RoyceProprietary14ProcessMapExampleProcessMapExampleProcessMapExampleFlowchartObservationsQualitydata10IssueMaterialQualityaudit-materialcert.Notstamped20MillProfileRough&Finishcutters.Mistakeprooffixture30HeatTreatmentOneovenused.Wallclockused.CalibratedthermocoupleBatchscrapped-duetoincorrecttimeinoven40DrillandTapholeOperatorconcernedwithfixture-nopositivelocation.50FinalInspect60Mark,Pack&DispatchPartsnotrecheckedbyinspectionCustomercomplaint-incorrectp