Session 15

Recap of Lecture 14

Begin Module 1

Summary

Module 5

Steps in FMEA

Module 4

Failure Mode Effects Analysis FMEA

Module 3

Quality Function Deployment QFD

Module 2

Recap of Lecture 14

Module 1

Agenda

Rajiv Gupta
BITS Pilani
Lecture 15

MMVA ZG 522 Total Quality

Management

Quality Function Deployment

Begin Module 2

Lecture 15

End of Module 1

Lecture 15

In this lecture we discussed quality by design

Traditional approaches to design are sequential. This
causes gaps in communication, resulting in longer
product development cycles and high cost
Quality by design requires simultaneous or concurrent
design and development activities
We need to form multi-disciplinary teams of people
required in the design process to improve
communication
Ideally the teams should be co-located. However, virtual
teams may also be used.

Recap of Lecture 14

QFD
Approach

In general, it is not easy to incorporate the voice of

the customer completely in the product design.
The problem lies in different interpretations at each
level in the organization and the lack of clarity
regarding the impact of a decision on the customers
expectations.
The result is a frequent departure from what the
customer states as his requirements and what we
provide as the finished product.

Why QFD?

It is a product planning tool used to fulfill customer

expectations.
It is a disciplined approach to product design,
engineering, and production.
It can improve engineering knowledge, productivity
and quality and reduce costs, product development
time, and engineering changes.
It is employed to translate customer expectations
(voice of the customer) requirements to specific
product requirements in terms of engineering or
technical characteristics.

QFD

QFD Cascade

House of Quality

Cascading
Requirements
-- in Toyotas
paint rusting
problem

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Roof of
House of
Quality
(QFD)

Customer
Requirements
(What), Design
Requirements
(How),
Relationships and
Importance
Ratings

Prioritize Technical Descriptors

Prioritize Customer Requirements

Competitive Assessments

Develop Interrelationship (Hows)

Develop Relationship (Whats & Hows)

List Technical Descriptors (Hows)

List Customer Requirements (Whats)

Steps in Building the House of

Quality

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Lecture 15
End of Module 2

(from Textbook)

QFD Example
-- Bicycle
Handlebar
Stem Design

Plotting
Product
Ratings

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 Prevent system, product and process problems

before they occur
reduce costs by identifying system, product and
process improvements early in the development
cycle
Create more robust processes
Prioritize actions that decrease risk of failure
Evaluate the system, design and processes from a
new vantage point

FMEA is a tool that allows you to:

FMEA

It is a proactive and qualitative tool used by Quality,

Safety and Product/Process engineers to improve
reliability (eliminate failures thus, improve
quality/customer satisfaction).
It seeks to identify possible failure modes and
mechanisms, the effects or consequences that the
failures may have on performance, methods of
detecting the identified failure modes, and possible
means for prevention.
Very effective when performed early in
product/process development and by experienced
multi-functional teams.

Failure Modes and Effects Analysis

(FMEA)

Failure Mode Effects Analysis FMEA

Begin Module 3

Lecture 15

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Things that could go wrong

Failure has to take into account all possibilities,
including incorrect usage by the customer

Failure modes may be the result of upstream

operations or may cause downstream operations
to fail

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The way in which the component, subassembly,

product, input, or process could fail to perform its
intended function

A Failure Mode is:

Failure Mode

Reliability is a critical quality characteristic which

measures sustained product-process performance.
Reliability ,R(t), is defined as the probability of a
product (or process) to perform as expected for a
certain period of time (t), under given operating
conditions, and at a given set of product
performance characteristics (e.g. after 5,000
landings, 100,000 miles, etc.).

Reliability

Systematic evaluation of a product or process at

specified levels of system complexity.
Postulation of single point failures, identification of
possible failure mechanisms, examination of
associated effects, likelihood of occurrence, and
preventive measures.
Systematic documentation (Tabular format) of
potential product or process nonperformance.

FMEA encourages --

 End of Module 3

Lecture 15

Determining Risk Priority

What could go wrong? Failure Mode

What are the chances of the failure mode
occurring?
How severe will be the effect of the failure
mode? i.e., what will be the negative impact?
How easy/difficult is it to detect the failure
mode?

What is included in an FMEA

Table?

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Step 6 - Assign a detection rating for each

failure mode and/or effect
Step 7 - Calculate the risk priority number for
each effect
Step 8 - Prioritize the failure modes for action
Step 9 - Take action to eliminate or reduce the
high-risk failure modes
Step 10 - Recalculate the new RPN as the
failure modes are reduced or eliminated

Steps in FMEA (contd.)

Step 1 - Review the process

Step 2 - Brainstorm potential failure modes
Step 3 - List potential effects of each failure
mode
Step 4 - Assign a severity rating for each
failure mode
Step 5 Assign an occurrence rating for each
failure mode

Steps in FMEA

Steps in FMEA and FMEA Example

Begin Module 4

Lecture 15

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This step is very important as it affects the rest

of the FMEA process
Enough care must be taken to ensure that as
many effects are taken into account as
possible
It is helpful to think if this failure occurs,
what are the consequences?

Step 3 List Potential Effects of

Each Failure Mode

Team members should come prepared with ideas

During the brainstorming session, more ideas get
generated due to synergy
Due to product complexity, several brainstorming
sessions may be required, each focussing on one
element at a time
After the brainstorming session, the ideas should be
grouped into categories for ease of working through

Step 2 Brainstorm Potential

Failure Modes

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All the members on the FMEA team need to

understand the product/process.
It is important to have an accurate blueprint
before the process starts
Members should physically see the product, or its
prototype
An expert should be on the team to answer
questions

Step 1 Review the process

Step 1 Review the Process

Steps 4, 5, and 6 require that we assign

numerical values to the severity, occurrence,
and detection ratings

Steps 4, 5, 6

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The failure modes should be prioritized by the

RPN value
A Pareto diagram may help in visualizing the
different ratings
A cut off RPN value may be used to determine
which failure modes will be attended to

Step 8 Prioritize the Failure

Modes for Action

FMEA Form

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After action has been taken, the new RPN

values should be calculated
It is expected that the new value is
significantly less than the original value
Often at least a 50% reduction in RPN values
should be expected

The risk priority number (RPN) is calculated by

multiplying the severity rating by the
occurrence rating and by the detection rating
for all items.
RPN = Severity x Occurrence x Detection

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Step 10 Recalculate the new RPN

Values

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Step 7 Calculate the Risk Priority

Number for Each Failure Mode

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Using systematic problem solving techniques,

work to reduce or eliminate the potential
failure modes
Critical failure modes should be eliminated
Other failure modes may be reduced in terms
of their RPNs
Generally it is best to attack the likelihood of
occurrence, followed by severity and
detection

Step 9 Take Action to Eliminate or

Reduce Impact of Failure Modes

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In this lecture we discussed quality function

deployment QFD
QFD is a powerful, systematic tool to convert
the voice of the customer into product and
process design
QFD employs the house of quality to help
analyze customer requirements and convert
them into design features and process steps in
a systematic fashion

Summary of Lecture 15

Summary

Begin Module 5

Lecture 15

End of Module 4

Lecture 15

End of Module 6

Lecture 14

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We also discussed Failure Mode Effects Analysis

FMEA
FMEA is a proactive tool that allows us to look at
product and process designs to reduce the impact
of various failure modes
FMEA looks at the severity of the impact of a
failure mode, its likelihood of occurrence, and the
probability of detection

Summary of Lecture 15