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Failure Modes and Effects Analysis (FMEA) Present by Mr. Kittiwat Sirikasemsuk

Created by Kittiwat Sirikasemsuk ,CU-KMITL

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FMEA Form – 6 Sigma

In what ways does the Key What is the impact on the Key Input go wrong? Output Variables (Customer Requirements) or internal requirements?

S E V

Potential Causes

What causes the Key Input to go wrong?

O C C

Definition of FMEA

Current Controls

What are the existing controls and procedures (inspection and test) that prevent eith the cause or the Failure Mode? Should include an SOP number.

D E T

R P N

How well can you detect cause or FM?

Potential Failure Effects

How often does cause or FM occur?

What is the process step/ Input under investigation?

Potential Failure Mode

How Severe is the effect to the cusotmer?

Process Step/Input

Created by Kittiwat Sirikasemsuk ,CU-KMITL

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„ FMEA

is a systematic technique for assessing the risks associated with defective products reaching the marks.

Actions Recommended What are the actions for reducing the occurrance of the Cause, or improving detection? Should have actions only on high RPN's or easy fixes.

0 0

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Objective.

Usefulness „

„

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Overall Aspect : For quality assurance early , which prevent or reduce failure modes and cause of defective. Product/Process Aspect : A disciplined review and analysis of a new or revised product/process is promoted to anticipate, resolve or monitor potential problems within the product or process. Created by Kittiwat Sirikasemsuk ,CU-KMITL

1. Review and analysis product / process when revise or make new. 2. Anticipate failure and cause which may occur from experience and team work. 3. Specify risk and priority RPN. 4. Reduce RPN by eliminated that cause formerly. 5. Provides a discipline/methodology for documenting Created by Kittiwat Sirikasemsuk

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Characteristics of FMEA

Characteristics of FMEA

1. Prioritizes Potential Failures according to their risk and drives actions to eliminate or reduce their likelihood of occurrence.

3. By its self, an FMEA is not a problem solve. It is used in combination with other problem solving tools “The FMEA presents the opportunity but does not solve the problem.”

2. Provides a discipline/methodology for documenting this analysis for future use and continuous process improvement. Created by Kittiwat Sirikasemsuk ,CU-KMITL

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In reality, FMEA is such a basic tool that any model to investigate Reliability, Reliability Maintainability or Safety cannot be completed without FMEA at some stage.

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An FMEA utilizes occurrence and detection probability in conjunction with severity criteria to develop a Risk Priority Number(RPN) for prioritization of corrective action considerations.

RPN = S x O x D 11

Analysis

Risk

Effects of failure

Severity

Causes

Occurrence

Current controls or design verification

Detection Created by Kittiwat Sirikasemsuk ,CU-KMITL

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Implementation

Note „

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Special Characteristics

Involution „

Process Flowchart , C&E Diagram , Pareto Diagram , Action Plan , Team Work Management, Risk Management

Created by Kittiwat Sirikasemsuk ,CU-KMITL

Choice 1 : Correction => Problem Solving Choice 2 : Prevention => None of Problem yet. Note to achieve the maximum benefit, organization need to conduct FMEAs before a failure is unknowingly instituted Created by Kittiwat Sirikasemsuk into a process or design.

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Where is FMEA used? „

QS 9000 , Big Three(Chryler, Ford Motor, General Motors)

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APQP Manual (Advanced Product Quality Planning)

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ISO/TS 16949 , IATF (International Automotive Task Force)

The Role of FMEA in a QS 13

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DMAIC , Six Sigma

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Product / Process Design

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Tool

QS9000

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„

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APQP ISO/TS16949

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Types of FMEA

S4

System

Design

Components

Components

Manpower

Man / HR

Subsystems

Subsystems

Machine

Machine

Mainsystem

Mainsystem

Method

Method

Material

Material

Measurement

Measurement

Environment

Environment

Focus : Minimize failures

Created by Kittiwat Sirikasemsuk ,CU-KMITL

Phase of Smart Six Sigma Solution.(S4)

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Note The most people separate FMEA to be two 20 type in Automotive. (DFMEA & PFMEA)

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FMEA for System :

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is used to analysis mainsystem and subsystem in step early. FMEA for Design :

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is used to analysis product before do manufacturing. FMEA for Process :

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Automotive FMEA Timeline

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Design goahead

Automotive FMEA Timeline DFMEA :

Start early in process.Complete by the time preliminary drawing are done but before any tooling is initiated. „ PFMEA :

Process FMEA

Design Prototype completion build

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„

Concept

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Do not mix : DFMEA with PFMEA

is used to analysis process manufacturing and assembly. Created by Kittiwat Sirikasemsuk

Design FMEA

Service

Caution!

Add explanation

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Process

Eng./Mfg. Sign off

Start as soon as basic manufacturing methods have been discussed. Complete prior to finalizing production plans and releasing for production.

Production start

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Relationship of system, design, and process FMEA. Failure Modes

Effect

cause

The ramifications of the problem.

The Problem

The causes of the problem.

The causes of the problem from the system FMEA..

The effects from the system FMEA with a better definition.

New root causes for the design failure modes.

Process The causes of the

The same effects as the design FMEA

Specific root causes of the process failure modes.

System FMEA

Design FMEA

FMEA

problem from the design FMEA..

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Origins

Origins

FMECA

mid-1960’s

Created by Kittiwat Sirikasemsuk ,CU-KMITL

FMECA 26 : Failure Mode Effects and Criticality Analysis.

Criticality Matrix. •About using Criticality Matrix.

mid-1960’s

FMECA

•Aerospace of NASA in Apollo and Navy US. Military.

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•Addressed safety issues.

end-1980’s

FMEA

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•About using RPN

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•using in Automotive Industrial. •For the reliability analysis.

now

FMEA

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•using almost all Industrial Type.

FMECA 27 : Failure Mode Effects and Criticality Analysis.

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Set Team before make FMEA. „

Team should / may consist of Design Engineer, Manufacturing Engineer, „ Assembly Engineer, „ Quality Engineer, „ Reliability Engineer, „ and else which people are related with it. „ „

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Creating an FMEA

Perspective

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Perspective

Created by Kittiwat Sirikasemsuk ,CU-KMITL

Creating an FMEA (continue)

1. Set the level of the analysis. 2. Learn about the design/process. - draw functional diagram/process flowchart. 3. Describe the desired functions or process. 4. List / Identify the Item-Function for DFMEA or Process Function-Requirements for PFMEA. 5. List all potential failure modes. 6. Identify the effect(s) of each failure mode.

Title DFMEA

7. List all possible causes of each failure mode. 8. List the current controls of each cause, if have. 9. Give severity, occurrence and detection rating. 10. Multiply these together to give RPN 11. Rank by RPN and state recommended action, and responsibilities. 12. Revise RPN in line with completed actions. 33

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DFMEA Title

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PFMEA

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PFMEA Title

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Setting the level of analysis.

1. Setting the level of analysis.

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Setting the level of analysis.

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•The fundamental problem with FMEA is that, being a “Bottom-Up” technique. System Level

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Failure Mode Failure Effect Subsystem Level

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2

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Failure Mode Failure Effect Component Level Created by Kittiwat Sirikasemsuk ,CU-KMITL

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Failure Mode

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FailureMode Mode Failure

Created by Kittiwat Sirikasemsuk ,CU-KMITL

Design Block Diagram Example System

Body

Sub-System

Doors

If the product function is complex, break it down.

Exterior

Window

2. Learn about the design/process.

Interior - draw functional diagram/process flowchart.

Component

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Door Inner Panel

Glass

Sealing with Strip

Latch / Lock

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Mechanical System evaporator

Circuit Diagram

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Assembly Drawing I

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Assembly Drawing II

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Process Flow Chart / Mapping

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9. Give severity, occurrence and detection rating.

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Severity

Note : Severity will not change when 49 do FMEA finish.

Occurrence

Created by Kittiwat Sirikasemsuk ,CU-KMITL

Detection

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Example RPN S

O

D

9

1

1

1

9

1

1

1

9

Note : Select RPN more than 90 to correct. 51

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: RPN Maximum is 1000.

Created by Kittiwat Sirikasemsuk ,CU-KMITL

This case Process Flow Chart

Example PFMEA

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Show detail or function. 1. Receive material is the first step for this process. When we receive ingot of Aluminium grade Si 9 % ,Cu 3 %, next we will check quality of material to ahead for standard and check quantity to follow ordering. 2. Melting is procedure to transform ingot to be liquefy of Aluminium by melting by a electricity blast furnace, then do cleaning Aluminium by filling flux Subsequent, is transportation to next station.

4. Decorate is procedure for beautify work product after injection which have three step so that file, trimming hole and shot blast. 5. Packing will bring finish product into the tray and will check quality lastly and quantity 6. Stock is an arrangement of finish product to go at inventory. 7. Delivery is transfer of finish product into customer.

3. Diecasting is procedure to inject liquid to be work product by injection machinery no. DC 350 T. Created by Kittiwat Sirikasemsuk ,CU-KMITL

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EX. C&E Diagram Station2. Al Melting &Molten Al transferred

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Created by Kittiwat Sirikasemsuk ,CU-KMITL

Addition

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:http://www.fmeca.com/ffsoft/download.htm

Created by Kittiwat Sirikasemsuk ,CU-KMITL

FMEA : ( AFTER ACTION TAKEN )

FMEA : ( BEFORE ACTION TAKEN )

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Reference

Show PFMEA

1. 2. 3. 4. 5. 6. 7.

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“Failure Modes and Effects Analysis Reference Manual”, Big Three “Failure Mode and Effect Analysis”, บ.แอลวีเอ็ม (เอเชีย) จํากัด , กรุงเทพฯ “Six Sigma for Shopfloor Management”, บ.ซีเกทเทคโนโลยี (ประเทศไทย) จํากัด สาขาโคราช “Failure Mode and Effect Analysis”, www.16949.com Breyfogle, Forrest W., “Implementing Six Sigma : Smarter Solutions Using Statistical Methods”, John Wiley & Sons, Canada, c1946 รศ. ดํารง ทวีแสงสกุลไทย , “Failure Mode and Effect Analysis”, ซีตประกอบการ สอนวิชา Quality Engineering Techniques รศ.ดร. ปารเมศ ชุติมา , “Failure Mode and Effect Analysis”, ซีตประกอบการสอน วิชา PPD Created by Kittiwat Sirikasemsuk ,CU-KMITL

Deming Prize Thank you for listening.

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