FMEA Concepts
FMEA Overview • What is FMEA? • AIAG (Automotive Industry Action Group) Defines FMEA in the 3rd edition of their FMEA manual as: An FM...
FMEA Overview • How are we going to use FMEA? • We are going to doing what is called a Process FMEA – Focused on improving a process by identifying the Potential Failures, Causes and opportunities for detection/identification. – Done when we can “map” map the process and break each piece into the components of our FMEA.
Getting Started- Scoping to Find Actions High Level Process Map (Scope)
The High Level •The Process Mapping will scope our Study. • We want to cast as wide a net as our resources will permit. • The fish this net will catch are the action items for improvement.
FMEA and Scoping • How do we cover a wide enough area to be thorough, yet narrow enough to have the resources needed to prod produce ce actionable res results? lts? • P Prioritizei iti W should We h ld prioritize i iti th the activities ti iti or ffactors t that are most in need of attention first. • Pace- Study activities at an appropriate level of detail that allows us to complete the entire study and have time and d resources tto workk on action ti items. it
Pace Yourself- Identification vs. Action • Imagine you were going to run a marathon, would you sprint the first mile and walk the rest? • Th The energy and dd detail t il we apply l tto thi this analysis l i should h ld b be consistent throughout. • Using the High Level Process Map to divide the process process, we will evenly distribute the detail in the activities to make sure we can “finish” the race.
• Prioritizing the activities is insurance in case you do still start to fast!
Bringing it Together- Risk Priority Number • To prioritize the Failures we should focus on first we use a Risk Priority Number (RPN). The highest RPN represents: represents • The Most severe Effect • That Occurs Most Often • That we can’t Detect RPN= Severity(S) x Occurrence (O) x Detection (D) Example: RPN (210)= S(6) x O(7) x D(5)
Making Improvements- Action Items and PRPN • Actions Identified in each logic path should be reviewed. • Careful consideration given that Critical Factors have been addressed. • Other Oth Considerations; C id ti • Severity should be addressed first, then Occurrence and finally Detection Detection. • Design/Process changes to reduce Severity and Occurrence ratings. • Mistake Proofing with focus on prevention not detection for Detection Ratings.
PRPN- Post Risk Priority Number • Following the identification of Action items the PRPN should be calculated. The PRPN is an assessment of the e expected pected impro improvement ement if the actions are taken. • The easiest improvements that produce the greatest change may be your first targets targets. • Critical Factors should always be addressed first since they represent potential safety issues.
