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TQM Unit 4 FMEA Lecture 6

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18 views

TQM Unit 4 FMEA Lecture 6

Uploaded by

tamilselvansambath
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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FMEA

• Failure Mode and Effect Analysis is also known as risk


analysis.
• It is a preventive measure to systematically display the causes,
effects and possible actions regarding observed failures.
• It is an engineering technique used to define, identify and
eliminate known or potential failures, problems and errors.
• It is before-the-event action
• Is a never ending process improvement tool.
• FMEA is a qualitative and systematic tool,
usually created within a spreadsheet, to help
practitioners anticipate what might go wrong
with a product or process.
• In addition to identifying how a product or
process might fail and the effects of that
failure, FMEA also helps find the possible
causes of failures and the likelihood of failures
being detected before occurrence.
• Used across many industries, FMEA is one of
the best ways of analyzing potential reliability
problems early in the development cycle,
making it easier for manufacturers to take
quick action and mitigate failure.
• The ability to anticipate issues early allows
practitioners to design out failures and design
in reliable, safe and customer-pleasing
features.
FMEA - OBJECTIVES

1. Find failures and prevent them.


2. Prioritize failures and attempts to eliminate them.
TYPES OF FMEA

1. System FMEA -
2. Design FMEA - Design FMEA
3. Process FMEA -
4. Service FMEA -
5. Equipment FMEA - Process FMEA
6. Maintenance FMEA -
7. Concept FMEA - Design FMEA
8. Environmental FMEA- Process FMEA
BENEFITS OF FMEA

1. Improve product/process reliability and quality.


2. Increase customer satisfaction.
3. Early identification/elimination of failure modes.
4. Prioritize product/process deficiencies.
5. Capture engineering/organisation knowledge
6. Document and track the action taken to reduce risk
7. Focus for improved testing and development
8. Act as catalyst.
INPUTS FOR FMEA

1. People inputs: FMEA is a team work. The team should have


assembly engineer, manufacturing engineer, material
engineer, quality engineer, service engineer, suppliers and the
customer.

2. Data inputs: Product and process specifications, reliability


data, customer priority data, process variability data, process
descriptions and inspection data.
STAGES OF FMEA

Stage 1: Specifying Possibilities


i) Functions
ii) ii) Possible failure mode
iii) iii) Root causes
iv) Effects
v) Detection/Prevention.

Stage 2: Quantifying Risks


iv) Probability of cause
v) ii) Severity of effect
iii) Effectiveness of control to prevent cause
iv) Risk Priority Number (RPN)
STAGES OF FMEA

Stage 3: Correcting High Risk Causes


i) Prioritizing work
ii) Detailing action
iii) Assigning action responsibility
iv) Check points on completion

Stage 4: Re-evaluation of Risk


i) Recalculation of risk priority number
FMEA PROCEDURE

1. Describe the product/process and its function


2. Create a block diagram of the product/process
3. Complete the header of the FMEA form worksheet
4. List product/process functions
5. Identify failure modes
failure modes include corrosion failure, fatigue, deformation,
cracking, electrical short etc..
6. Describe the potential failure effects
defined as the result of a failure mode on the function of the
product/process
ex: injury to the user, impaired operation, poor appearance,
odour, noise etc..
FMEA PROCEDURE

7. Establish a numerical ranking for the Severity(S) of the effect


S is the assessment of the seriousness of the failure effect
standard scale uses 1 for no effect and 10 for very serious
effect.
8. The CLASS column is filled
Used to classify any special product characteristics for
components that may require additional process controls.
9. Identify the potential causes/mechanisms of failure
10. The probability factor “Occurrence” (O)
It is the chance that one of the specific causes will occur.
Standard scale uses 1 to represent not likely and 10 to
indicate inevitable.
FMEA PROCEDURE

11. Identify current controls (design or process)


12. Determine the likelihood of detection (D)
It is the assessment of the likelihood that the current controls
will detect the cause of failure mode
1 used for certain of detection and 10 for uncertainty of
detection.
13. Review Risk Priority Number (RPN)
RPN = S x O x D
14. Determine recommended actions
15. Assign responsibility and target completion date
16. Indicate action taken
After action, re-assess the severity, occurrence and detection
and revise the RPN
17. Update the FMEA
• After ranking the severity, occurrence and detection levels
for each failure mode, the team will be able to calculate a
risk priority number (RPN).
• The formula for the RPN is:
• RPN = severity x occurrence x detection
• In the FMEA in Figure 1, for example, a flat tire severely
affects the customer driving the car (rating of 10), but has
a low level of occurrence (2) and can be detected fairly
easily (3).
• Therefore, the RPN for this failure mode is 10 x 2 x 3 = 60.

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