FMEA F
FMEA F
FMEA F
FMEA Definition
A procedure & tool that help to identify every possible failure mode of a process or product;
To determine frequency and impact of the failure To determine its effect on other sub-items & on the required function of the product or process
Also used to rank & prioritize the possible causes of failures To develop and implement preventative actions For each failure identified (known or potential), an estimate is made of its occurrence, severity and detection
Failure Rate
Majority of products follow a familiar pattern Failure modes are classified into 3 categories
Debug- Due to flaws in design or Mfg, have high failure rate in the initial stages Chance- Due to accidents, poor maintenance, or limitations in the design Wear out- Failures after product/process life has ended
Periods of failure are modeled by exponential distr, prob of product/process survival may viewed as;
Rt = e-t = e-t/
Rt= Period of operation without failure t = Time specified for operation without failure = Failure rate, = mean time to failure
Types of FMEA
Design FMEA- Aids in the design process
Identifies known and foreseeable failure modes and then ranks them according to relative impact on product Helps to establish priorities based upon expected failures Reduces dev time, cost of Mfg process by eliminating potential failure modes prior to operation and specifying appropriate test to prove the product Documents the results for future references as well
System
Components Subsystems Main Systems
Design
Components Subsystems Main Systems
Process
Manpower Machine Method Material Measurement Environment Focus: Minimize failure effects on the Processes Objectives/Goal: Maximize Total Process Quality, reliability, Cost and maintenance
Focus: Minimize failure effects on the System Objectives/Goal: Maximize System Quality, reliability, Cost and maintenance
Focus: Minimize failure effects on the Design Objectives/Goal: Maximize Design Tools, Quality, reliability, Work Stations, Cost and Production Lines, maintenance Operator Training, Processes, Gauges
Machines
FMEA Documentation
FMEA practices always existed in the thinking process but now it helps to keep those ideas available for future use Reps from all affected areas are involved while documenting Block Diagram- Design FMEA always begin with it
Used to show different flows (info, fluid etc) involved with the component being analyzed and included in all phases of FMEA Purpose is to know the input of block, its function & output and to establish a logical order to the analysis It starts by listing the components of the system, their function and means of attachment/connection b/w them Then components are placed in blocks & their functional relationships are represented by lines connecting the block For complicated system of components, a hierarchical representation is used to aid in determining interconnection b/w components
FMEA Documentation
Other Documentation
The other three documents needed are the; Design or Process intent, The customer needs and wants and, The FMEA form
Specifying Possibilities
Functions, Possible Failure Modes, Root causes, Effects, Detection/Prevention
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Quantifying Risk
Probability of cause, Severity of defect, Effectiveness of control to prevent cause, Risk priority number
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Every FMEA should have an assumption document attached (electronically if possible) or the first line of the FMEA should detail the assumptions and ratings used for the FMEA
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Action Results R P N Responsib & Response & Recommended Target Traget Actions Complete Date Action Taken S E V O C C D E T R P N
Function-What is the part supposed to do in view of customer requirements? Describe what the system or component is designed to do
Include information regarding the environment in which the system operates Define temperature, pressure, and humidity ranges
Function
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
EXAMPLE: HVAC system must defog windows and heat or cool cabin to 70 degrees in all operating conditions (-40 degrees to 100 degrees) - within 3 to 5 minutes
Failure Mode
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Failure modes may be one of two things; method in which it fail to meet the design criteria or method that may cause potential failure in a higher level system or may be the result of failure of a lower level system Failure modes should be written as anti-functions e.g cracked, leaking, short cct etc EXAMPLES: HVAC system does not heat vehicle or defog windows HVAC system takes more than 5 minutes to heat vehicle HVAC system does heat cabin to 70 degrees in below zero temperatures HVAC system cools cabin to 50 degrees HVAC system activates rear window defogger
Usage
Above average life cycle Harsh environment Below average life cycle
Effect(s) of Failure
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Effects must be listed in a manner customer would describe them Effects must include (as appropriate) safety / regulatory body, end user, internal customers manufacturing, assembly, service Must also forecast what effects the particular failure may have on other sub/ systems in immediate contact with the system failure EXAMPLE: A part may fracture, which may cause vibration of the sub-system in contact with the fractured part, resulting in an intermittent system operation. This could cause performance to degrade leading to customer dissatisfaction Some typical effects of failure may include noise, erratic operation, poor appearance, lack of stability etc
Severity
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
It is the assessment of the seriousness of the effect of the potential failure mode to the next sub/component, system or customer if it occurs It applies only to the effect of failure and not the potential failure mode It is rated from 1 to 10 by the team and different for all designs, reduced only after direct design change EXAMPLE: Cannot see out of front window severity 9 Air conditioner makes cab too cold severity 5 Takes too long to heat up severity 4
Classification
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Classification should be used to define potential critical and significant characteristics Critical characteristics (9 or 10 in severity with 2 or more in occurrence) must have associated recommended actions Significant characteristics (4 thru 8 in severity with 4 or more in occurrence) should have associated recommended actions Classification should have defined criteria for application
Cause(s) of Failure
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Some potential failure modes may have more than one cause of failure for each failure mode Each of the causes must be identified for a failure mode with equal relative weight Causes at component level analysis should be identified as part or system characteristic (a feature that can be controlled at process) EXAMPLE: Incorrect material specified Over stressing and poor environment protection
Potential Cause
Tolerance build up Insufficient material Insufficient lubrication capacity Vibration Foreign material Interference Incorrect material thickness specified Exposed location Temperature expansion Inadequate diameter Inadequate maintenance instruction Over-stressing Over-load Imbalance Inadequate tolerance
Mechanism
Yield Fatigue Material instability Creep
Wear
Corrosion
Occurrence
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Occurrence are the chances that one of the specific causes/mechanisms will occur Occurrence ratings for design FMEA are based upon the likelihood that a cause may occur, based upon past failures, performance of similar systems in similar applications, or percent new content It is rated from 1 to 10 for every cause and reduced only after direct design change
EXAMPLE: Incorrect routing of vent hoses (too close to heat source) occurrence 6 Inadequate coolant capacity for application occurrence 2
Control must be allocated in the plan to be listed, otherwise its a recommended action There are three types of Controls 1. Prevention from occurring or reduction of rate 2. Detect cause mechanism and lead to corrective actions 3. Detect the failure mode, leading to corrective actions
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Preventive controls are those that help reduce the likelihood that a failure mode or cause will occur affects occurrence value Detective controls are those that find problems that have been designed into the product assigned detection value If detective and preventive controls are not listed in separate columns, they must include an indication of the type of control
EXAMPLE: Engineering specifications (P), Historical data (P) preventive control Functional testing (D) detective control General vehicle durability (D) detective control
Examples of Controls
Type 1 control
Warnings which alert product user to impending failure Fail/safe features Design procedures/ guidelines/ specifications
Detection
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
It is a relative measure of the assessment of the ability of the design control to detect either a potential cause or the failure mode before the completion of production
It is rated from 1 to 10 for every cause and reduced only after direct design change
EXAMPLE: Engineering specifications no detection value Historical data no detection value Functional testing detection 3 General vehicle durability detection 5
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
RPN threshold should not be used as the primary trigger for definition of recommended actions EXAMPLE: Cannot see out of front window severity 9, incorrect vent location 2, Functional testing detection 3, RPN - 54
RPN Considerations
Rating scale example:
Severity 10 indicates that the effect is very serious and is worse than Severity 1 Occurrence 10 indicates that the likelihood of occurrence is very high and is worse than Occurrence 1 Detection 10 indicates that the failure is not likely to be detected before it reaches the end user and is worse than Detection 1
10
10
Recommended actions
Control
Influence
Recommended Actions
After every concern is examined and given a risk priority number, the team should begin to examine the corrective actions that may be employed, beginning with the concern with the greatest RPN These are tasks recommended for purpose of reducing one or more of the criteria that constitute the RPN Only design revision can bring about a reduction in the severity ranking Examples of Recommended actions to reduce RPN are
Perform:
Reliability Testing Finite Element Analysis
Recommended Actions
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Recommended actions should be focused on design, and directed toward mitigating the cause of failure, or eliminating the failure mode If recommended actions cannot mitigate or eliminate the potential for failure, recommended actions must force characteristics to be forwarded to process FMEA for process mitigation
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
All recommended actions must have a person assigned responsibility for completion of the action Responsibility should be a name, not a title Person listed as responsible for an action must also be listed as a team member There must be a completion date accompanying each recommended action
Action Results
Item Potential Failure Mode
Function
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Action Results R P N Response & Recommended Target Actions Complete Date Action Taken S E V O C C D E T R P N
Action taken must detail what actions occurred, and the results of those action Actions must be completed by the target completion date Unless a failure mode has been eliminated, severity should not change Occurrence and detection may or may not be lowered based upon the results of actions If severity, occurrence or detection ratings are not improved, additional recommended actions must be defined If no actions are taken, this section should be left blank. If same RPN is written future users will think that actions were taken but the had no effect
PFMEA Assumptions
The design is valid Design failures are not covered in PFMEA, they be part of the design FMEA All incoming product is in compliance to design specifications Failures can but will not necessarily occur
Process Changes
Machining
Too narrow Too deep Angle incorrect Finish not to specification Flash or not cleaned
May have several effects but list them in same cell The worst case impact should be documented and rated in severity of effect It must also be stated that whether the failure will impact personal safety or break any product regulations
Potential Effects
End user
Noise Leakage Odor Poor appearance Endangers safety Loss of a primary function performance
Next operation
Cannot assemble Cannot tap or bore Cannot connect Cannot fasten Damages equipment Does not fit Does not match Endangers operator
Severity Ranking
How the effects of a potential failure mode may impact the customer Applies only to the effect and is assigned with regard to any other rating Potential effects of failure Cannot assemble bolt (5) Endangers operator (10) Vibration (6) Severity
Every failure mode may have multiple causes which creates a new row on the FMEA
DoE may be considered to determine which root causes are major contributors and can be controlled
Potential Causes
Equipment
Tool wear Inadequate pressure Worn locator Broken tool Gauging out of calibration Inadequate fluid levels
Operator
Improper torque Selected wrong part Incorrect tooling Incorrect feed or speed rate Mishandling Assembled upside down Assembled backwards
Occurrence Ranking
How frequent the cause is projected to occur Use other data available
Past assembly processes SPC Warranty
All controls should be listed, but ranking should occur on detection controls only List the controls chronologically
Don not include controls that are outside of your plant
Process Controls
Preventive
SPC Inspection verification Work instructions Maintenance Error proof by design Method sheets Set up verification Operator training
Detection
Functional test Visual inspection Touch for quality Gauging Final test
Detection
It is the detection of probability that defect will be detected by process controls before subsequent process, or before the part or component leaves the manufacturing or assembly location Assume that failure has occurred and then assess the capabilities of the current process control to prevent shipment of the part having this NC Each control receives its own detection ranking, Assess the ability of the process controls to detect low frequency failure modes or prevent them from going further in the process
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