FMEA11401070

8/20/2019FMEAFailureMode&EffectsAnalysis8/20/2019ObjectivesLinkFMEAToMeasure-Analyze-Improve-ControlIntroduceTheStepsToCreateAFMEAShowExamplesPerformAnExercise8/20/2019ProcessMapMulti-VariStudiesExperimentationControlPlans/SPCOptimizedProcess+15Inputs8-104-82-4C&EMatrix1995Allied-Signal-Dr.SteveZinkgrafFoundCriticalX’sControllingCriticalX’s10-15AllX’s1st“HitList”ScreenedListDynamicsofTheMethodology-TheFunnelEffectFMEA8/20/2019PAPERWORKTURNSTEAMONTODICYTANKLOADDMFLOADDICYLOAD2MI1BILLOFMATERIALSISOPROCEDURESREWORKSCALEACCURACYPREHEATINGLOADACCURACYCLEANLINESSRAWMATERIALLOADACCURACYENVIRONMENT(HUMIDITY)RAWMATERIALMIXERSPEEDLOADACCURACYENVIRONMENT(HUMIDITY)RAWMATERIALMIXERSPEEDProcessMapIdentifiesallXsandYs1234567891011ProcessStepProcessInputsHeaviesinProductLightsinProductMoistureinProductAcidityinProductLowCapacityFromUnitExcessiveDowntimeMaterialLossesCorrosionofEquipmentPoorReactorPerformanceTotal139DayTanksAnalysis1010993359ReactorCat./HFRatio5871577ReactorRxrTemperature654714973LightsRemovalCondenserLeak4824114874LightsRemovalReboilerLeak48241148131PurificationLowStages88144144FinalStorageContainers3266140100NeutralizationpHValue66313816CatalystStripperPluggage3653137111DryingDecomposition2632213439DrierWaterCarryover465113234DrierMolecularSieve33272125CauseandEffectsMatrixPrioritizesXsandYsProcessStep/PartNumberPotentialFailureModePotentialFailureEffectsSEVPotentialCausesOCCCurrentControlsDETRPNActionsRecommendedResp.COATING&IMAGINGDIRTYPHOTOMASKMICROCRACKING,DELAMINATION,STREAKS8LOWFREQUENCYOFCLEANING8SOP,VISUALINSPECTION7448INCREASEFREQUENCYTOONCEEVERY20PANELSMGIMPROVECLEANINGMETHODPFPURCHASEOFF-LINECLEANINGSYSTEMMGTESTON-LINEMASKREPLACEMENTPFFMEAtakesthehighpriorityXsandbeginstoanalyzethemOUTPUTSINPUTSUsedWithPermissionAllied-Signal1995-Dr.SteveZinkgrafTheFlow8/20/2019ProcessorProductName:Preparedby:Responsible:FMEADate(Orig)______________(Rev)_____________ProcessStepKeyProcessInputPotentialFailureModePotentialFailureEffectsSEVPotentialCausesOCCCurrentControlsDETRPNWhatistheprocessstepWhatistheKeyProcessInput?InwhatwaysdoestheKeyInputgowrong?WhatistheimpactontheKeyOutputVariables(CustomerRequirements)orinternalrequirements?HowSevereistheeffecttothecusotmer?WhatcausestheKeyInputtogowrong?HowoftendoescauseorFMoccur?Whataretheexistingcontrolsandprocedures(inspectionandtest)thatpreventeiththecauseortheFailureMode?ShouldincludeanSOPnumber.HowwellcanyoudetectcauseorFM?000000000000Process/ProductFailureModesandEffectsAnalysis(FMEA)8/20/2019FMEAWHATDOESITDO?*Funnels“X’s”RanksTheItemsWeShouldWorkOnFirst*IdentifiesHolesInOurControlPlans*LeadsUsToAskMoreQuestionsAboutTheProcess8/20/2019Definition-FMEAASystematizedGroupofActivitiesThat:IdentifiesthewaysinwhichaprocesscanfailtomeetcriticalcustomerrequirementsEstimatestheriskofspecificcauseswithregardtothesefailuresEvaluatesthecurrentcontrolplanforpreventingthesefailuresfromoccurringPrioritizestheactionsthatshouldbetakentoimprovetheprocessShouldbeadynamicdocument,continuallyreviewed,amended,updatedUsedWithPermissionAllied-Signal1995-Dr.SteveZinkgraf8/20/2019HistoryFirstusedinthe1960’sintheAerospaceindustryduringtheApollomissions.In1974theNavydevelopedMIL-STD-1629regardingtheuseofFMEA.Inthelate1970’s,automotiveapplicationsdrivenbyliabilitycosts,begantoincorporateFMEAintothemanagementoftheirprocesses.Inthemid1980’s,automotiveinstitutedProcessFMEAtovalidatemanufacturingprocesses.In1991ISO9000recommendeduseofProductandProcessFMEA.8/20/2019TYPESOFFMEAsPRODUCTFMEA-FocusonproductandDesignProcess.Components/Parts/RawMaterials/SystemPROCESSFMEA-Focusontheprocess.ProcessFlow/ProcessSequence/ProcessSteps/OperatorsOrderentry/Invoicepayment/OntimeDeliveryAPPLICATIONFMEA•SuppliersSide-Upstream•CustomersSide-DownstreamSERVICEFMEA-FocusonFieldServiceafterSales•Reliability/Maintainability/Warranty/SpareParts8/20/2019APPLICATIONFMEASERVICEFMEAPRODUCTFMEAPROCESSFMEAOurareaoffocustoday!8/20/2019WhatisaFMEA?FMEAisadisciplinedprocedurethatallowsanindividualtoanticipatefailuresandpreventtheiroccurrence.Identifywaystheproductorprocesscanfail.Thenplantopreventthosefailures.Concept8/20/2019RoleofProcessFMEAKeytoolofateamtoimprovetheprocessinapreemptivemanner(beforefailuresoccur)UsedtoprioritizeresourcestoensureattentiontoprocessimprovementeffortsthatarebeneficialtocustomerUsedtodocumentcompletionofprojectsandresultantimprovementstoriskcalculationsShouldbeadynamicdocument,continuallyreviewed,amended,updatedUsedWithPermissionAlliedSignal1995-Dr.SteveZinkgraf8/20/2019PurposesofProcessFMEAAssistsintheanalysisofnewprocessesIdentifiesdeficienciesintheProcessControlPlansothatactionscanbetakentoimproveEstablishesthepriorityofactionsHelpsevaluatetheriskofprocesschangeIdentifiespotentialvariablestoconsiderinMulti-variandDOEstudiesGuidesthedevelopmentofnewprocessesbyhelpingteamsunderstandweaknessesofcurrentprocessesHelpssetthestageforbreakthroughstrategyUsedWithPermissionAllied-Signal1995-Dr.SteveZinkgraf8/20/2019Prevention(Proactive):PreventaFailureModef