Transcript Failure Mode and Effects Analysis

Project Management, Process
Mapping, and Failure Mode and
Effects Analysis
Leon Spackman
PMP, LSS Master Black Belt
Kirtland Federal Credit Union
Agenda
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Project Management
Process mapping
What is FMEA?
When do you use it?
How do you use it?
How do you interpret a FMEA?
Pareto Charts--show results
2
Project Management
• Initiate—Select project, define initial scope
• Plan—Establish schedule, budget, team, risk,
communications, project management plan
• Execute—Work the plan
• Monitor and Control—Quality control, monitor
schedule/budget, corrective actions
• Close—Verify scope, deliver results, close
contracts and project
3
Project Definition
• Temporary endeavor with beginning and
end
• Creates unique product or service
• Know more about the project as it
progresses
4
Project Management
• Multiple processes in project management
• PMI defines the high level process
• Project processes should be defined
clearly and understood by all on the
project team
• Lean efficient processes result in
successful projects
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Integration Management Process (1)
• Develop project charter
• Develop preliminary project scope
statement
• Develop project management plan
• Direct and manage project execution
• Monitor and control project work
• Integrated change control
• Close project
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Scope Management Process (2)
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Scope planning
Scope definition
Create Work Breakdown Structure
Scope verification
Scope control
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Time Management Process (3)
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Activity definition
Activity sequencing
Activity resource estimating
Activity duration estimating
Schedule development
Schedule control
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Cost Management Process (4)
• Cost estimating
• Cost budgeting
• Cost control
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Quality Management Process (5)
• Quality planning
• Perform quality assurance
• Perform quality control
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HR Management Process (6)
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Human resource planning
Acquire project team
Develop project team
Manage project team
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Communications Management
Process (7)
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Communications planning
Information distribution
Performance reporting
Manage stakeholders
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Risk Management Process (8)
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Risk management planning
Risk identification
Qualitative risk analysis
Quantitative risk analysis
Risk response planning
Risk monitoring and control
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Procurement Management Process (9)
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Plan purchases and acquisitions
Plan contracting
Request seller responses
Select sellers
Contract administration
Contract closure
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Project Management Tools
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Charter
WBS
Network Diagrams
Earned Value
Bar/Milestone Charts
Monte Carlo Analysis
Communication matrix
Fishbone Diagram
Risk Plan/Matrix
Contracting Tools/types
• Fast Tracking
• Crashing
• Cost Estimating
– Analogous
– Bottom-up
– Parametric
• Control Charts
• Scatter Diagram
• Design of Experiments
• Motivation Theories
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Lessons Learned
• Lean Six Sigma projects must use sound project
management principles
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Initiating—project selection criteria
Planning—often not done
Team building tools
Communication—more is needed
Risk Management—often not done
Stakeholder management
Milestones (schedule management)
Close—wrap up, have a party, release resources
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Lessons Learned
• Project Managers must eliminate waste, and improve
their processes
– Clearly define how projects will be selected—
establish and map the process
– Establish templates and mistake-proof processes as
much as possible
– Emphasize doing it right the first time (First Pass
Yield)
– Eliminate waste in the project—Look for clutter,
rework, bottlenecks, and uneven work load
– Gather metrics and use statistical tools if appropriate
17
Lessons Learned
• Project Managers must eliminate waste, and
improve their processes
– Spend time finding root causes—don’t just
use a band-aid fix
– Manage using process mentality
(Remember:Y=f(x))
– Map processes
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Process Mapping
• Before we can manage processes, we
must identify, define, and centralize them
• Provides a clear, visual way to examine
processes
• Helps identify redundancies, waste, and
weaknesses
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Why Map Processes?
The way you think it is.
What the customer expects, and is willing to pay for.
The way it really functions.
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Micro-Level Processes
Payroll
Collect
Emp. Data
Collect
Timesheet
Info
Calculate
Pay,
Benefits, etc
Cut Check
or Direct
Deposit
Update Vac,
sick time,
YTD info
Send/make
pay info
available
End
Process
Detailed steps that must be followed in
order to produce a product/result.
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Macro-Level Processes
Mid level detail
showing how an
overall task or
deliverable is
accomplished.
Business
Deployment
Management
Responsibility
Gather inputs
from One-Page
Strategy and
Quarterly Plan
Quarterly Plan
Updated
Incentive Goals
negotiated with
Managers
Incentive Plan
goals scored
quarterly
Incentive Goals
negotiated with
all other
employees
Incentive Plan
Progress
reviewed monthly
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Business System--High Level Relationships
Across Functions
Organization
Human
Resources
Engineering
Finance
Marketing
Operations
Department
Department
Department
Department
Department
Department
Department
Department
Department
Department
Department
Department
Department
Department
Department
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Process Symbols
Boundary
Reference
Document
Task
Multiple
Documents
Decision
Data
Base
Embedded
Process
Connector
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Putting It All Together
No
Data
Base
Yes
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Interactive Electronic Map
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Online Electronic Document
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What is FMEA?
• FMEA--a tool to identify risks in your process
• Can be used in multiple places in process
improvement
– Determine where problems are
– Help identify cause/effect relationships
– Highlight risks in solutions and actions to take
• Starts with input from processes
• Identifies three risk categories
– Severity of impact
– Probability of occurrence
– Ability to detect the occurrence
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When to Use
• Early stages (Define) to understand
process and identify problem areas
• Analyze data (Analyze) to help identify
root causes
• Determine best solutions (Improve) with
lowest risk
• Close out stage (Control) to document
improvement and identify actions needed
to continue to reduce risk
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FMEA Worksheet
Process or
Product Name
Prepared by:
Person
Responsible
Date (Orig) ___________ Revised __________
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Potential
Causes
O Current
c Controls
c
Page _____ of ______
D R Actions
e P Recommended
t N
S
e
v
O D R
c e P
c t N
Sev - Severity of the failure (what impact will it have on our process?)
Occ – How likely is the event to occur (probability of occurrence)
Det – How likely can the event be detected in time to do something about it
RPN – Risk Priority Number (multiply Sev, Occ, and Det)
30
How To Complete the FMEA
General Suggestions
• Use large white board or flip chart with a FMEA
form drawn on it during the generation phase
• Focus the team on the specific area of study
(product or process).
• Have process map available
• Have all subassemblies and component part of
a product.
31
Process for FMEA
Process to Change Oil in a Car
3000 miles
driven
Fill with
new oil
Drive car
on lift
Take Car
off lift
Drain Oil
Replace
Filter
Process
Complete
32
How to Complete the FMEA
Step 1. Complete header information
Step 2. Identify steps in the process
Step 3. Brainstorm potential ways the area
of study could theoretically fail
(failure modes)
Suggestion: Use Affinity Diagram
as a brainstorming tool
33
FMEA Worksheet
Process or
Product Name
Change Oil in Car
Prepared by: Leon
Person
Responsible
Leon Mechanic
Date (Orig) __27 Sep 2007___ Revised __________
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
Fill
with
new
oil
New
Oil—
Mech
anic
Wrong
type of
oil
Engine
wear
No oil
added
Engine
Failure
S
e
v
Potential
Causes
O Current
c Controls
c
Sev - Severity of the failure (what impact will it have on our process?)
Occ – How likely is the event to occur (probability of occurrence)
Det – How likely can the event be detected in time to do something about it
RPN – Risk Priority Number (multiply Sev, Occ, and Det)
Page _1____ of __1____
D R Actions
e P Recommended
t N
S
e
v
O D R
c e P
c t N
34
How to Complete a FMEA
•
•
Step 4
For each failure mode, determine impact
or effect on the product or operation using
criteria table (next slide)
Rate this impact in the column labeled SEV
(severity)
35
Severity (SEV) Rating
SEV
Severity
Product/Process Criteria
1
None
No effect
2
Very Minor
Defect would be noticed by most discriminating customers. A portion of the product may have to be
reworked on line but out of station
3
Minor
Defect would be noticed by average customers. A portion of the product (<100%) may have to be
reworked on line but out of station
4
Very Low
Defect would be noticed by most customers. 100% of the product may have to be sorted and a
portion (<100%) reworked
5
Low
Comfort/convenience item(s) would be operable at a reduced level of performance. 100% of the
product may have to be reworked
6
Moderate
Comfort/convenience item(s) would be inoperable. A portion (<100%) of the product may have to
be scrapped
7
High
Product would be operable with reduced primary function. Product may have to be sorted and a
portion (<100%) scrapped.
8
Very High
Product would experience complete loss of primary function. 100% of the product may have to be
scrapped
9
Hazardous
Warning
Failure would endanger machine or operator with a warning
10
Hazardous
w/out
Warning
Failure would endanger machine or operator without a warning
36
FMEA Worksheet
Process or
Product Name
Change Oil in Car
Prepared by: Leon
Person
Responsible
Leon Mechanic
Date (Orig) __27 Sep 2007___ Revised __________
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Fill
with
new
oil
New
Oil—
Mech
anic
Wrong
type of
oil
Engine
wear
2
No oil
added
Engine
Failure
1
0
Potential
Causes
O Current
c Controls
c
Sev - Severity of the failure (what impact will it have on our process?)
Occ – How likely is the event to occur (probability of occurrence)
Det – How likely can the event be detected in time to do something about it
RPN – Risk Priority Number (multiply Sev, Occ, and Det)
Page _____ of ______
D R Actions
e P Recommended
t N
S
e
v
O D R
c e P
c t N
37
How to Complete a FMEA
•
•
•
Step 5
For each potential failure mode identify one or
more potential causes (Could use Affinity
Diagram again to brainstorm ideas)
Rate the probability of each potential cause
occurring based on criteria table (next slide)
Place the rating in the column labeled OCC
(occurrence).
38
FMEA Occurrence (OCC Rating)
OCC
Occurrence
Criteria
1
Remote
1 in 1,500,000 Very unlikely to occur
2
Low
1 in 150,000
3
Low
1 in 15,000 Unlikely to occur
4
Moderate
1 in 2,000
5
Moderate
1 in 400 Moderate chance to occur
6
Moderate
1 in 80
7
High
1 in 20 High probability that the event will occur
8
High
1 in 8
9
Very High
1 in 3 Almost certain to occur
10
Very High
> 1 in 2
39
FMEA Worksheet
Process or
Product Name
Change Oil in Car
Prepared by: Leon
Person
Responsible
Leon Mechanic
Date (Orig) __27 Sep 2007___ Revised __________
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Potential
Causes
O Current
c Controls
c
Fill
with
new
oil
New
Oil—
Mech
anic
Wrong
type of
oil
Engine
wear
2 Mislabeled
3
No oil
added
Engine
Failure
1 Hurrying
0
3
Sev - Severity of the failure (what impact will it have on our process?)
Occ – How likely is the event to occur (probability of occurrence)
Det – How likely can the event be detected in time to do something about it
RPN – Risk Priority Number (multiply Sev, Occ, and Det)
Page _____ of ______
D R Actions
e P Recommended
t N
S
e
v
O D R
c e P
c t N
40
How to Complete the FMEA
•
•
•
Step 6
Identify current controls or detection
Rate ability of each current control to prevent or
detect the failure mode once it occurs using
criteria table (next slide)
Place rating in Det column
41
FMEA Detection (DET) Rating
DET Detection
Criteria
1
Almost
Certain
Current Controls are almost certain to detect/prevent the failure mode
2
Very High
Very high likelihood that current controls will detect/prevent the failure
mode
3
High
High Likelihood that current controls will detect/prevent the failure mode
4
Mod. High
Moderately High likelihood that current controls will detect/prevent the
failure mode
5
Moderate
High Likelihood that current controls will detect/prevent the failure mode
6
Low
Low likelihood that current controls will detect/prevent failure mode
7
Very Low
Very Low likelihood that current controls will detect /prevent the failure
mode
8
Remote
Remote likelihood that current controls will detect/prevent the failure
mode
9
Very
Remote
Very remote likelihood that current controls will detect/prevent the failure
mode
42
FMEA Worksheet
Process or
Product Name
Change Oil in Car
Prepared by: Leon
Person
Responsible
Leon Mechanic
Date (Orig) __27 Sep 2007___ Revised __________
Page _____ of ______
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Potential
Causes
O Current
c Controls
c
D RPN
e
t
Fill
with
new oil
New
Oil
from
supplier
Wrong
type of
oil
Engine
wear
2
Misread oil
chart for
vehicle
3
None
9
No oil
added
Engine
Failure
1
0
Hurrying
3
Engine light
3
Sev - Severity of the failure (what impact will it have on our process?)
Occ – How likely is the event to occur (probability of occurrence)
Det – How likely can the event be detected in time to do something about it
RPN – Risk Priority Number (multiply Sev, Occ, and Det)
Actions
Recommended
S
e
v
O D R
c e P
c t N
43
How to Complete the FMEA
Step 7
Multiply SEV, OCC and DET ratings and place the value in the
RPN (risk priority number) column. The largest RPN numbers
should get the greatest focus. For those RPN numbers which
warrant corrective action, recommended actions and the
person responsible for implementation should be listed.
SEV * OCC * DET = RPN
( 2 * 3 * 9 = 54 )
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Potential
Causes
O
c
c
Current
Controls
D
e
t
RPN
Fill with
new oil
New Oil
from
supplier
Wrong
type of
oil
Engine
wear
2
Misread
oil chart
for
vehicle
3
None
9
54
No oil
added
Engine
Failure
1
0
Hurrying
3
Engine light
3
90
Actions
Recommended
S
e
v
O
c
c
D
e
t
44
R
P
N
FMEA Rankings
Rating
High 10
Low
1
Severity
Occurrence
Detection
Hazardous without
warning
Very high and almost Cannot detect or
inevitable
detection with very
low probability
Loss of primary
function
High repeated
failures
Remote or low
chance of detection
Loss of secondary
function
Moderate failures
Low detection
probability
Minor defect
Occasional failures
Moderate detection
probability
No effect
Failure Unlikely
Almost certain
detection
Source: The Black Belt Memory Jogger, Six Sigma Academy
45
Action Results
Step 8
• After corrective action has been taken, place
summary of the results in the ‘Actions
Recommended’ block
• Assign new value for:
– Severity
– Occurrence
– Detection
• Calculate new RPN number
46
FMEA Worksheet
Process or
Product Name
Change Oil in Car
Prepared by: Leon
Person
Responsible
Leon Mechanic
Date (Orig) __27 Sep 2007___ Revised __________
Page _____ of ______
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Potential
Causes
O Current
c Controls
c
D RPN
e
t
Fill
with
new oil
New
Oil
from
supplier
Wrong
type of
oil
Engine
wear
2
Misread oil
chart for
vehicle
3
None
9 54
No oil
added
Engine
Failure
1
0
Hurrying
3
Engine light
3 90
Sev - Severity of the failure (what impact will it have on our process?)
Occ – How likely is the event to occur (probability of occurrence)
Det – How likely can the event be detected in time to do something about it
RPN – Risk Priority Number (multiply Sev, Occ, and Det)
Actions
Recommended
S
e
v
O
c
c
D R
e P
t N
Oil level
checked by
partner
1
0
3
1
47
3
0
FMEA Example
Process or Product
Name:
Hotel Service at Special Olympics
Prepared by:
Person Responsible:
Joe Quality
Date (Orig) ___________ Revised __________
Page _____ of ______
Process
Step
Key
Process
Input
Potential
Failure
Mode
Potential
Failure
Effect
S
e
v
Potential
Causes
O
c
c
Current
Controls
D
e
t
R
P
N
Register
guest
Service
Desk
Cannot
Register
in time
Complaints
5
Lack of
language
and
communicat
ion skills,
support of
volunteers
not
sufficient
4
No plan on
training
content;
training and
volunteer
support
sufficient
3
72
Provide
Guest
Services
Guest
Support
Lack of
barrierfree
facility
Inconvenien
ce and
injury
10
Cannot
provide
barrier-free
facility
3
Providing
barrier-free
facility
7
210
Provide
Meals
Food
Service
Food
goes bad
Disease or
injury
10
Past shelf
life
6
No control of
raw material
8
240
Provide
Medical
Service
Medical
Service
Service
not in
time
Illness
changes for
worse
10
No 24 Hour
service
6
12 hour
service
3
180
Actions
Recommended
S
e
v
Source: Quality Digest/ August 2006 Quality Service at the Special Olympics World Games, Tang Xiaofen
O
c
c
D
e
t
48
R
P
N
Summary
• FMEA identifies risk in our processes
– Impact/Severity
– Probability of Occurrence
– Detection
• Helps identify what can go wrong and
what we should fix
• Can be used in multiple stages of process
improvement
49
Continuous Improvement
• Process improvement not a linear process
• Never really ends
• Journey not a destination
Define
Control
Improve
Measure
Analyze
50
Challenge
“We are what we repeatedly do.
Excellence, therefore, is not an act
but a habit.”
-- Aristotle
51
Questions
Leon Spackman
[email protected]
(505) 254-4330 (Work)
(505) 401-8850 (Cell)
Group Exercise
• Build a FMEA to identify problem areas to
be addressed in your process (Cake
Baking)
– Identify process step(s) to analyze
– Use Affinity Diagram to brainstorm for
possible failure modes, effects, causes and
detection controls
– Rate severity, occurrence, and detection
– Analyze results with a Pareto Chart
• Report to the group
53
Baking a Cake
Birthday
Arrives
Add Liquid
Ingredients
Select
Type of cake
Bake
Get Recipe
Frost and
Decorate
Mix Dry
Ingredients
Serve at
Party
54
Pareto Chart
• Sorted Bar Chart with the bars arranged in
descending order from left to right
• Useful in taking a spreadsheet of data and
showing which category stands out from
the rest.
• Identify where the biggest “pain” occurs in
process
• Help determine where to focus our efforts
• Based on 80/20 rule
55
Pareto Chart—Example
Risk Priority Number
Pareto Chart--Special Olympics
300
250
200
150
100
50
0
Food goes
bad
Lack of
barrier-free
facility
Medical
service not
in time
Cannot
Register in
Time
Failure Modes
56
Pareto Chart--Example
57
Pareto Chart Hints
• Must have category/attribute data
• List categories in descending order on
horizontal line & frequencies on vertical line
• Break down tall pole into another Pareto
Chart for further analysis
• Involve customer/sponsor in selecting area
to focus on
58