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1、FailureMode EffectAnalysis ExplanationandUseofFMEA WhatisFMEA FMEAisaproblemsolvingprocessadoptedbySnap onasakeycomponentoftheQualityForwardSystem Generally FMEAisdonebyanon sitemultifunctionalteamfacilitatedlocallyorbyanSEQGroupAdvancedQualityEngineer Objectiveistoidentifyallofthereasonswhyqualityo
2、faprocessorproductdoesnotmeetexpectations Usesseverity occurrenceanddetectionratingstodeterminecorrectiveactionpriorityforeachpossiblefailurereason WhenshouldaFMEAstudybeconducted AspartofaDesign Developmentphase Whencorrectiveactionisneededduetounfavorableperformancedata performancebasedonQFSmetric
3、sdoesnotmeetgoals WhenaneedtomakeincrementalimprovementisidentifiedbyfacilitymanagementortheSEQGroup FMEATeamStart Up TeamSelection donebylocalqualitycoordinator businessunitmanageror onrequest SEQGroupAdvancedQualityEngineer ProblemStatement Aconciseandfocuseddescriptionofthequalityproblemoropportu
4、nityforimprovement whatwentwrong or whatneedsfixing GoalStatement adescriptionofwhatistobeaccomplishedbytheteam inquantifiableterms reduceby increaseby eliminate etc Goodmetricstouseincludescrapcost reworkcost orDefectsPerMillionOpportunities DPMO etc Forexample agoalstatementcouldbe ToreduceDPMOonp
5、roductfamilyXfrom3000to2000byyearend CompleteFMEATeamStart UpWorksheet examplelocatedinprocedureSEQ80 10 Figure1 ProblemStatement GoalStatement ProblemStatementandGoalStatementshouldconsider Whatwentwrong Whatisthegapbetweenthedesiredqualitylevelandtheactualqualitylevel Whichprocessorprocessesareinv
6、olved Whichdepartmentorcellisthedeficiencyoccurringin Istheproblemcyclic canitbeattributedtospecificevents Whataretheappropriatemetricstomeasure Whatistheimpactonoperationalfitnessandprofitability Whatistheimpactonthebottomline reduced increased eliminated Arethereconstraintsrecognizedearlyintheproc
7、ess Ifso havetheybeenexploredandclarifiedwiththeappropriatemanagementlevel FMEAProcess FMEA suncoverprocessproblemsrelatedtothemanufactureofproduct Examples apieceofautomatedassemblyequipmentmaymisfeedpartsresultinginproductsnotbeingassembledcorrectly or inachemicalmanufacturingprocess temperatureor
8、mixingtimecouldbesourcesofpotentialfailuresresultinginunusableproduct Thinkintermsofthefiveelementsofaprocess people materials equipment methodsandenvironment Withthesefiveelementsinmind ask Howcanprocessfailureaffecttheproduct processingefficiencyorsafety NinestepsinFMEAprocess Step 1 ReviewtheProc
9、ess EnsurethateveryoneontheFMEAteamhasthesameunderstandingoftheprocessbeingworkedon Reviewblueprint engineeringdrawingofproduct ifconductingFMEAonproduct and oradetailedflowchartoftheprocess Ifthesearenotavailable theteamwillneedtocreateone Usingtheblueprintand orflowchart teammembersshouldfamiliari
10、zethemselveswiththeproductorprocess Theyshouldphysicallyseetheproductoraprototypeoftheproduct andphysicallywalkthroughtheprocessexactlyastheprocessflows Itishelpfultohavean expert ontheproductorprocessavailabletoansweranyquestionstheteammighthave Step 2 BrainstormPotentialFailureModes Methodofgenera
11、tinganddocumentingideasofpotentialfailuremodes Ifproductorprocessiscomplex aseriesofbrainstormingsessions eachfocusedonadifferentelement i e people methods equipment materials environment maybeneededtogenerateamorethoroughlistofpotentialfailuremodes Facilitatorshouldwritedownallideasgeneratedinbrain
12、stormingsessions Oncebrainstormingiscomplete ideasshouldbegroupedintolikecategories asdeterminedbytheteam Groupscanbetypeoffailure whereontheproductfailureoccurred estimatedseriousnessofthefailure etc Failuremodesmayalsobecombinediftheyarethesameorverysimilar Oncefailuremodeshavebeengrouped combined
13、 theyshouldbetransferredtothePotentialFailureModeandEffectAnalysisSheet exampleinSEQ80 10 Figure2 Step 2 continued BrainstormingGuidelines Donotmakeanyjudgmentonideas Teammembersshouldnotcommentonwhetheranideaisgoodorbad Thinkingshouldbeunconventional imaginative orevenoutrageous Aimforalargenumbero
14、fideasintheshortestpossibletime Teammembersshould hitchhike onotherideas byexpandingthem modifyingthem orproducingnewonesbyassociation Allteammembersshouldparticipateinbrainstormingprocess Step 3 ListPotentialEffectsofEachFailureMode AfterthefailuremodesarelistedontheFMEAworksheetform theFMEAteamnee
15、dstorevieweachfailuremodeandidentifythepotentialeffectsofthefailureshoulditoccur Forsomefailuremodes theremaybeonlyoneeffect whileotherfailuremodesmayhaveseveraleffects Thisstepmustbethorough thisinformationwilldetermineassignmentofriskratingsforeachofthefailures Itishelpfultothinkofthisstepasanif t
16、henprocess Ifthefailureoccurs thenwhataretheconsequences Step 4 AssignSeverityRating Theseverityratingisanestimateofhowserioustheeffectswouldbeifagivenfailuredidoccur Maybebasedonpastexperience oranestimatebasedontheknowledgeandexpertiseoftheteammembers Becauseeachfailuremayhaveseveraldifferenteffects andeacheffectmayhaveadifferentlevelofseverity theeffect notthefailure mustberated Eacheffectshouldbegivenitsownseverityrating Ratingsbasedon10 pointscale with1beingthelowestratingand10beingthehighe
