Transcript Financial Review - FMEA Info Centre Home Page Failure Mode

Welcome -- Day 1
Failure Mode and Effects Analysis
1.1
FTEP Modules
Quick QFD
Systems
Engineering
Fundamentals
Global 8D
Process
Control Methods
Ford
Technical
Education
Program
FMEA
Experimental
Design
Reliability
Tolerance
Design
Parameter
Design
1.2
Warm-Up -- Day 1
Place Self Others
Purpose
Team
Agenda
1.3
Course Purpose
These three days are designed to ...
help you function effectively
as an FMEA team member,
but not to leave as an FMEA
team leader or an FMEA expert
1.5
Participant Materials
Questionnaire


Only one correct answer is possible
Do NOT guess if unsure of answer
1.6
FMEA -- An Introduction


Introduction



Why Do FMEAs?
Definition, Purpose,
Types, Benefits
FMEA Working Model
Generating / Managing
Team Approach
1.7
Ford 2000 Strategies
Empowered
People
Achieve
Worldwide Growth
Nimble Through
Process Leadership
Ford
Lead in Customer
Satisfaction
Lead in Corporate
Citizenship
The World’s
Leading
Automotive
Company
Achieve Worldwide
Product Excellence
The Low Cost
Producer
1.8
1.9
Why Do FMEAs?


Appropriate recommended
actions may not have been
taken
Significant savings in
engineering time -reduction in changes
immediately before and after
Job 1
1.10
FMEA -- Definition
Structured group of activities which ...



2-2
Recognize and evaluate the potential
failure of a product or process and
its effects
Identify actions which could
eliminate or reduce the chance of
the potential failure occurring
Document the process
1.11
FMEA Purposes
Origin of
Failures
Failures
Elimination of
Failures
FMEA
JOB 1
Time
1.12
Customer Orientation
QFD
FMEA Purposes
Unreliable
Products
Excellent
Products
Disaster
Reliable
Products
Customer
Doesn't Want
Design and Process Orientation
FMEA
1.13
FMEA -- Purposes
FMEAs are intended to ...




2-2
Identify potential failure modes and rate
severity of effects
Identify critical and significant
characteristics
Help engineers prioritize and focus on
eliminating product and process concerns
and helps prevent problems from occurring
Test adequacy of controls from DCP process
1.14
FMEA -- Types
System
Concept
FMEA
Design
FMEA
Sub-System
Component
System
Process
FMEA
Assembly
Sub-System
Component
System
Manufacturing
Sub-System
Component
2-4
1.15
Benefits -- Concept FMEAs
Design
Concept
Process






2-5
Helps select optimum concept
Identifies potential failure
modes
Considers potential effects
Helps generate occurrence
ratings
Identifies testing requirements
Helps determine if hardware
system redundancy is required
1.16
Benefits -- Design FMEAs
Design
Concept
Process





2-5

Aids in evaluating requirements
and alternatives
Aids in initial design for DFM
Increases probability of detecting
failure modes and their effects
Provides additional information
for testing requirements
Helps identify critical and
significant characteristics
Helps validate DVPs and SDSs
1.17
Benefits -- Process FMEAs
Design
Concept
Process





2-6
Identifies potential product related
failure modes
Assesses effects on all customers
Identifies potential Manufacturing
and Assembly causes to focus
controls on reducing occurrence
and/or increasing detection
Establishes a priority system for
considering corrective actions
Identifies confirmed critical and
significant characteristics
1.18
FMEA Working Model
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.19
Generating FMEAs
Who initiates?
When to
discard?
How is FMEA
documented?
When is FMEA
complete?
2-9
Who prepares?
Who updates?
Failure
Mode
and
FMEAs
Effects
Analysis
Who is FMEA
customer?
When started
and updated?
Relationship
to FPDS?
1.20
Managing FMEAs
FMEAs are living documents,
and are updated when ...



Modification to a component,
process or system is planned
Component is to be used in new
environment
Customer concern arises: Global 8D
1.21
FMEAs and Systems Engineering
Customer
Musts / Wants
CFMEA
Vehicle Level Inputs
Customer
Requirements
• Purchaser / owner / operator
• Regulatory (FMVSS, EPA, ...)
• Corporate (WCR, ABS, Manuf, ...)
Purchase, Operate
& Maintain
Disposal
Feasibility
Feedback
Requirements
Cascade
Vehicle Level Requirements
• Vehicle Attributes
• Vehicle System Specification - VDS
DFMEA
Customer
Satisfaction
Customer Focus
Customer Experience & Feedback
Vehicle
Verification
DVM / DVP
Production
Feasibility
Feedback
Requirements
Cascade
System / Subsystem Level
• System &
• Subsystem Design Specifications SDS
DVM / DVP
System
Verification
Feasibility
Feedback
Requirements
Cascade
PFMEA
Part /
Component Fabrication /
Part/
Verification
Component Design
• Component Design Specification - CDS
2-13
KO
SI
SC
PA
PR
J1
1.22
Team Approach -- FMEA
Core
Team
Support
Team
3-5
1.23
Section Summary


Introduction



Why Do FMEAs?
Definition, Purpose,
Types, Benefits
FMEA Working Model
Generating / Managing
Team Approach
1.24
Break
1.25
Design FMEA -- An Introduction
Design FMEA
Introduction

Identify FMEA Team

Establish Scope

Describe Function
» Brainstorming
» Function Trees

Practice Exercise 1
1.26
Design FMEA
Potential
Failure Mode and Effects Analysis
Scope
Team
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
Potential
Failure
Mode
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.27
Design FMEA -- Team
Facilitator or Application Engineer
Technical Affairs
Design Engineer
Manufacturing /
Process Engineer
3-5
Representatives
from:
Support
Team • Customer
Service
CORE
Team
• Suppliers
• Global Test
Operations
• Corporate
Quality
1.28
Design FMEA -- Scope
Once core team is established...



3-8
Create a block diagram
Identify the boundary for analysis
Confirm composition of the support
team
1.29
Constructing Block Diagrams
Assembly
Service
Part
X
Screw
Component/
Assembly
Weld
Part
Y
User
3-10
Other
Systems
Adhesive
Part
Z
1.30
Block Diagram -- Example
Headlamp Assembly
1.31
Block Diagram -- Example
Vertical Trimmer Assembly
1.32
Block Diagram -- Example
Hood
(Clearance)
Vehicle Body
Upper Cross
Member
Lateral
Location
Screw
Adjuster
Socket
Vertical
Trimmer
Assembly
User
Clips
2
Reflector
1.33
Determine Function
Potential
Failure Mode and Effects Analysis
Scope
Team
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
Potential
Failure
Mode
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.34
What is Function ?



5-6
Design intent or engineering
requirement
Must be measurable or set at an
actionable level
Representation of all wants, needs
and requirements, both spoken and
unspoken
1.35
Describe Function
Verb
Indicates action,
occurrence, being
5-7
Generate
Control
Dispense
Retain
Prevent
Noun
Indicates what the
action relates to
Light
Speed
Fuel
Seat Track
Rust
1.36
Describe Function
Thought Starters ...






Satisfy user
Attract user
Assure convenience
Assure dependability
Governmental requirements
Safety requirements
1.37
Brainstorming
Exercise in creative thinking
Method to generate ideas
1.38
Brainstorming -- Guidelines

Warm up

Suspend judgment

Anything goes

Quantity counts

Springboard

Persevere

Warm down
1.39
Brainstorming -- Pitfalls

Low team trust

Broad task definition

Criticism, competition, defensiveness

Silliness, lack of focus

Questions and explanations

Organizing ideas during creative stage
1.40
Brainstorming -- Agreement

Everyone explains view(s)

Identify needs of individuals

If you can’t meet a need, say so

Check out feelings -- yours / others

Don’t compromise, average,
or ‘split the difference’
1.41
Function Trees



Provide an organized approach to
identify the essential features of a
product (or process sometimes)
Help ensure that ‘unspoken’ and
‘spoken’ requirements are defined
Provide a graphical representation
of functions to ensure clear, total
team understanding
1.42
Constructing Function Trees
HOW ?
WHY ?
Secondary
Level
Primary
Level
Tertiary
Level
1.43
Vertical Trimmer Function Tree
HOW ?
Permit / Maintain
Horizontal
Adjustment
Adjust
Headlamp
WHY ?
Adjust Light Beam X Both Directions
Locate Headlamp Laterally 10 Years,
150,000 Miles
Retain Setting 10 Years,
150,000 Miles
Permit / Maintain
Vertical Adjustment
Retain Setting 10 Years,
150,000 Miles
Adjust Light Beam X Both Directions
Locate Headlamp Vertically 10 Years,
150,000 Miles
1.44
Guidelines





Brainstorm all functions (VERB - NOUN)
Document individual functions by
asking “HOW is function achieved?”
Repeat left to right, until actionable level
Use worksheet to check that actionable
level is measurable
Work right to left and check structure by
asking “WHY is function included?”
1.45
Practice Exercise 1
Block diagram
Brainstorming
Function Tree
1.46
1.47
Presentation -- Practice 1
Technical
Debrief
Team
Debrief
1.48
Design FMEA Functions
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
Function
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
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c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
Function
1
Function
2
Function
3
SubFunction
Sub-SubFunction
SubFunction
Sub-SubFunction
SubFunction
Sub-SubFunction
Function
n
Function
1.49
Section Summary
Design FMEA
Introduction

Identify FMEA Team

Establish Scope

Describe Function
» Brainstorming
» Function Trees

Practice Exercise 1
1.50
Design FMEA Path 1
DFMEA -- Path
1

Failure Modes

Effects -- Severity

Recommended Actions

Potential Special
Characteristics

Practice Exercise 2
1.51
Design FMEA -- Path 1
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.52
Potential Failure Modes
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
Function
1
Function
2
Function
3
Function
4
Function
n
5-8
Potential Failure Modes:
• No function
• Partial function
• Intermittent function
• Unintended function
1.53
Potential Failure Modes
Failure Mode Type
Potential Failure Mode
No function
Not operational
Partial function
Not all of function operating
Intermittent function
Occasionally does not
function
Unintended
function
Unexpected function occurs
3-21
1.54
Failure Modes -- Vertical Trimmer
Failure Mode: Adjust Light Beam X in Both Directions
Failure Mode Type
Potential Failure Mode
No function
No adjustment
Partial function
Adjustment in one direction
Intermittent function
Adjustment sometimes and
not at others
Unintended function
Trimmer itself produces light
1.55
Effects of Failure Modes
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
5-10
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.56
Effects of Failure Modes
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Potential
Failure
Mode
Potential
Effect(s)
of Failure
Function
Function
1
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
Failure
Mode 1
Failure
Mode n
Potential Effects of Failure Modes:
Function
2
Function
n
5-11
•
•
•
•
•
•
Part / Sub-component
Assembly
System
Vehicle
Government Regulations
Customer (Internal and End User)
1.57
Design FMEA -- Effects Table
Vertical Trimmer
Failure
Mode
Doesn’t
Retain
Setting
Part / SC
Assbly
System
Vehicle
Gov’t
Custmr
Trimmer
Headlamp
Lt System
(-)
Regs
Driver
May Be
Stripped By
Adjustment
Attempt
Cannot be
Adjusted
Misaligned
Lightbeam
Impaired
Night/Fog
Perforsmanc
e
Road
Vehicle
Light Regs
‘89
F/CMVSS
NonCompliance
Impaired
Night/Fog
Vision
1.58
Design FMEA -- Severity
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
5-13
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.59
Suggested Severity Evaluation Criteria
Effect
Criteria: Severity of Effect
Ranking
Hazardous
Without
Warning
... affects safe vehicle operation and/or
government regulation without warning
10
Hazardous
With Warning
... affects safe vehicle operation and/or
government regulation with warning
9
Low
… operable at reduced level of
performance. Customer experience some
dissatisfaction
5
None
No Effect
1
1.60
DFMEA Severity Rating Example
Item
Function
Vertical
Trimmer/
Retains
Setting
Potential
Failure
Mode
Does not
maintain
adjustment
S
E
V
Potential
Effects of Failure
Part: May be stripped during
adjustment
(7)
Assembly: Headlamp
cannot be adjusted
(6)
System: Misaligned lightbeam
(8)
Vehicle: Impaired night/fog
performance
(7)
Govt Regs: Non-compliance
Customer: Impaired night/ fog
10
(10)
(7)
1.61
DFMEA -- Recommended Actions
Potential
Failure Mode and Effects Analysis
___ System
___ Subsystem
___ Component
Model Year / Vehicle(s):
Core Team:
Item
Function
5-32
Potential
Failure
Mode
FMEA Number:
Page 1 of 1
Prepared by:
FMEA Date ( Orig):
Design Responsibility:
Key Date:
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanisms
Failure
O
c
c
u
r
Current
Design
Controls
D
e
t
e
c
R
P
N
Recommended
Action(s)
Responsibility &
Target
Completion Date
(Rev)
Action Results
S O
e c
Actions
v c
Taken
D R
e P
t N
1.62
Select and Manage Actions
To Reduce:
Severity
3-37
Consider This Action:
Change the design ...
To Accomplish This:
Eliminate failure
mode(s) ...
1.63
Identify Potential Special Characteristics
Design FMEA
S=9
S=10
YC
7-11
1.64
Practice Exercise 2
Failure Modes
Effects
Severity
Recommended
Actions
Classifications
1.65
Break
1.66
Managing FMEAs
FMEAplus
1.67
Presentation -- Practice 2
Technical
Debrief
Team
Debrief
1.68
Section Summary
DFMEA -- Path
1

Failure Modes

Effects -- Severity

Recommended Actions

Potential Special
Characteristics

Practice Exercise 2
1.69
Warm-Down -- Day 1
Place Self
Purpose
Others
Team
Agenda
1.70
Course Purpose
These three days are designed to ...
help you function effectively
as an FMEA team member,
but not to leave as an FMEA
team leader or an FMEA expert
1.71
Day 1
Failure Mode and Effects Analysis
1.72