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Learning Objectives
Participants will be able to:
Prepared by _________________________
Potential
Failure
Mode
Potential
Effects of
Failure
C
Potential O
Current
S l
Causes/
a
c
Process
e
Mechanisms
Control
v s of Failure c
s
(Prevention)
Action Results
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Recommended
Actions
Responsibility
& Target
Completion Date
Actions
Taken
S O D
e c e
v c t
R.
P.
N.
Potential
Failure
Mode
Potential
Effects of
Failure
Function
Process Step
is simply
the focus of
the analysis
S
e
v
C
l
a
s
s
Potential
O
Causes/
Mechanisms c
c
of Failure
Current
Process
Control
(Prevention)
Identify potential
causes of the item
not performing its
intended function
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Potential
Failure
Mode
Potential
Effects of
Failure
Function
Severity
evaluates
the impact
of the effect.
S
e
v
C
l
a
s
s
Potential
O
Causes/
Mechanisms c
c
of Failure
Current
Process
Control
(Prevention)
Occurrence
rates how often
a specific cause is
likely to result in
the failure mode
being analyzed.
Classification is an optional
column commonly used
to identify safety risks.
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Detection
ranks our ability
to detect either a
cause or a resulting
failure mode. Use
best detection
available.
Design FMEA
Focuses on how product design might fail.
Process FMEA
Focuses on how processes that make the product might fail.
Machinery FMEA
Focuses on how machinery that perform processes might fail.
Design FMEA
Process & Machinery FMEA
Cause
Detection
Direct
Cause
Failure Mode
Detection
Failure
Mode
Immediate
Effect
Effects
Causes
Subsystem Level
Failure
Modes
Effects
Causes
Component Level
Failure
Modes
Effects
Causes
12
Customer
Plant
Customer Plant
Control Plan
Control
Plan
Tool
Tool Design
Design
Machinery FMEA
Machinery
FMEA
Internal
Internal Processes
Processes
Process FMEA
Process
FMEA
Internal
Internal Process
Process
Control Plan
Control
Plan
Life
Cycle
Cost
Customer
Satisfaction
Process
Process FMEA
Customer Plant
Control Plan
First-Time
Capability
R&M
Tool Design
Machinery FMEA
Internal Processes
Process FMEA
Internal Process
Control Plan
Product
Design FMEA
Process
Process FMEA
Identify and Manage
Deliverables
Customer
Required for Plant
Design
Review
Control
Plan
Tool Design
Machinery FMEA
Internal Processes
Process FMEA
Internal Process
Control Plan
Customer Plant
Control Plan
Phase 3
Control Plan
for
Production
Product
Design FMEA
Phase 2
Control Plan
Process
for
Process FMEA
Pre-Production
Tool Design
Machinery FMEA
Internal Processes
Process FMEA
Internal Process
Control Plan
Containment Considerations
Cost of Defects
Risk of Defects
Bracketing Strategies
Protecting On-Time Delivery
Cost of Stopping Production
Cost of Recall Campaigns
Benefits of Traceability
FMEA Teams
Multi-functional teams are essential.
Ensure expertise from manufacturing engineering, plant
operations, maintenance, and other appropriate sources.
Select team with ability to contribute:
Knowledge
Information
Experience
Equity
Empowerment
Pick the right team members, but limit the number of team
members based on the scope of the issues being addressed.
In addition to the FMEA team.
Call in Experts as Needed
End Users
OEM Plants
Supplier Plants
Government Agencies (safety and environment)
Defining Functions
Secure Part
Advance Part
Locate Part
Robot
Functions
Requirements
Potential
Failure
Mode
Potential
Effects of
Failure
S
e
v
C
l
a
s
s
Potential
O
Causes/
Mechanisms c
c
of Failure
Current
Process
Control
(Prevention)
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Functional
Requirements
Function
Not Done
Incorrect
Actions
Function
Done Poorly
Surprise
Results
Correct
Actions
Function
Dispense
Paint
Properly
Failure Modes
No Paint
Spitting Paint
Stream of Paint
Too Much Paint
Too Little Paint
Void in Fan
Failure Modes
No Feedback Signal
Intermittent Signal
Signal Too High
Send Accurate
Feedback Signal
Function
Clearance hole
for 12 mm bolt
- Hole size
Potential
Failure
Mode
No hole
Hole too
large
Hole too
small
Hole violates
MMC
boundary
- Hole Depth
- Hole location
- No burrs
Hole not
drilled
thru
Potential
Effects of
Failure
S
e
v
C
Potential
l
O
Causes/
a
Mechanisms c
s
c
of Failure
s
Current
Process
Control
(Prevention)
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Failure Mode
Identification Worksheet
Process Step:
Functional requirements
or specifications:
Causes
Causes
Precede the
Failure Mode
Direct
Cause
Direct
Cause
Direct
Cause
Failure
Mode
Immediate
Effect
Example of Causes
Example of Causes
Function
Clearance hole
for 12 mm bolt
- Hole size
Potential
Failure
Mode
Hole too
large
Potential
Effects of
Failure
S
e
v
C
Potential
l
O
Causes/
a
Mechanisms c
s
c
of Failure
s
Feed rate too
high
Spindle speed
too slow
Wrong drill
size
Drill improperly
sharpened
Wrong tool
geometry for
material
- Hole depth
Hole not
drilled thru
Missing drill
Current
Process
Control
(Prevention)
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Causes
Precede the
Failure Mode
Direct
Cause
Immediate
Effect
Failure
Mode
Immediate
Effect
Immediate
Effect
Example of Effects
Example of Effects
Potential
Failure
Mode
Potential
Effects of
Failure
Function
Clearance hole
for 12 mm bolt
- Hole size
Hole too
large
S
e
v
C
l
a
s
s
Potential
O
Causes/
Mechanisms c
c
of Failure
Feed rate too
high
Spindle speed
too slow
Wrong drill
size
Drill improperly
sharpened
Wrong tool
geometry for
material
- Hole depth
Hole not
drilled thru
Assemble with
missing
fastener
Missing drill
Current
Process
Control
(Prevention)
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Cause
Detection
Go/NoGo Gage
Direct
Cause
Wrong Nozzle in Bin
Failure
Mode
Wrong Paint Nozzle
Immediate
Effects
Paint Splatter
Too Much Paint
Too Little Paint
Potential
Failure
Mode
Potential
Effects of
Failure
Function
Clearance hole
for 12 mm bolt
- Hole size
Hole too
large
S
e
v
C
l
a
s
s
Potential
O
Causes/
Mechanisms c
c
of Failure
Current
Process
Control
(Prevention)
Current
Process
Control
(Detection)
DOE Results
Set Up
Verification
Violation of
specification
Spindle speed
too slow
DOE Results
Set Up
Verification
Wrong drill
size
First Piece
Inspection
Load Meter
Drill improperly
sharpened
Set Up
Verification
Wrong tool
geometry for
material
DOE Results
Set Up
verification
D
e
t
R.
P.
N.
Severity of Effect
Frequency of Occurrence
Potential
Failure
Mode
Potential
Effects of
Failure
Function
Severity
evaluates
the impact
of the effect.
S
e
v
C
l
a
s
s
Potential
O
Causes/
Mechanisms c
c
of Failure
Current
Process
Control
(Prevention)
Occurrence
rates how often
a specific cause is
likely to result in
the failure mode
being analyzed.
Current
Process
Control
(Detection)
D
e
t
Detection
ranks our ability
to detect either a
cause or a resulting
failure mode. Use
best detection
available.
R.
P.
N.
Prioritization of Risk
Several strategies exist for the mitigation of risk, for
example:
1. High Risk Priority Numbers
2. High Severity Risks (regardless of RPN)
3. High Design Risks (Severity x Occurrence)
4. Other Alternatives (S,O,D) and (S,D)
NOTE: The use of an RPN threshold is NOT a
recommended practice for the need for action.
Potential
Failure
Mode
Hole too
large
Potential
Effects of
Failure
S
e
v
C
Potential
l
O
Causes/
a
Mechanisms c
s
c
of Failure
s
Current
Process
Control
(Prevention)
Current
Process
Control
(Detection)
D
e
t
R.
P.
N.
Set Up
Verification
50
Violation of
specification
Set Up
Verification
50
Wrong drill
size
First Piece
Inspection
50
Load Meter
40
Drill improperly 2
sharpened
Set Up
Verification
50
Wrong tool
2 DOE Results
geometry for
material
Set Up
verification
50
9. Recommend Actions
The intent with recommended actions is to
reduce risk.
Recommended actions will be focused to:
Reduce Severity
Reduce Frequency of Occurrence
Improve Detection
Recommended Actions
Action Results
Recommended
Actions
Responsibility
& Target
Completion Date
Actions
Taken
S O D
e c e
v c t
R.
P.
N.
2.
3.
4.
5.
6.
Risk Priority Numbers provides a rank order to risks and action items.
7.
8.