FMEA F il Failure Mode

High Level Process Mapping

Who • FMEA Team • Process Owners

What • Identify Failure Modes

Why • Give FMEA Depth

FMEA Overview • What is FMEA? • AIAG (Automotive Industry Action Group) Defines FMEA in the 3rd edition of their FMEA manual as: An FMEA can be described as a systematic group of activities intended to: (a) Recognize and evaluate the potential failure of a product or process and the effects of that failure. (b) Identify actions that could eliminate or reduce the chance of the potential failure occuring. occuring (c) Document the entire process It is complementary p y to the p process of defining g what a design or process must do to satisfy the customer. Copyright © 2007 SigmaFlow. All rights reserved. CONFIDENTIAL content, not to be redistributed without express SigmaFlow permission.

FMEA Failure Modes • How do we find Failure Modes? • Common Types of Failure: – – – –

No Function Partial Function (Over Function, Degraded Function) Intermittent Function U i Unintended d dF Function i

• Look for the above in the Process Map p or SIPOC for each activity.

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FMEA-Process Map Linkage

•No Function •Partial Function (Over Function, Degraded Function) •Intermittent Function •Unintended Function Copyright © 2007 SigmaFlow. All rights reserved. CONFIDENTIAL content, not to be redistributed without express SigmaFlow permission.

Failure Mode “Tree”- Each Activity will Expand

Activity

Failure Mode

Failure Mode 1 Activity Failure Mode 2

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Effect

Severity

Effect 1

Severity Score

Effect 2

Severity S it Score

Effect 1

Severity Score

FMEA- Logic Path to Improvement

Activity

What can go wrong? (Failure Mode)

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What are the Effects?

How Bad is it

What can be done? (Action Plan)

FMEA- Logic Path to Improvement

Activity

What can go wrong? (Failure Mode)

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What are the Causes?

How often does it happen?

What can be done? (Action Plan)

FMEA- Logic Path to Improvement

Activity

What can go wrong? (Failure Mode)

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How can this be prevented and detected?

How good is this method of detection?

What can be done? (Action Plan)

High Level Process Mapping- Failure Modes/SIPOC •No Function of Supplier, Input? •Partial Function (Over Function, Degraded Function) •Intermittent Function of Supplier, Supplier Input? •Unintended Function of Supplier, Input?

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SIPOC- Process Map Linkage High Level Process

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Detailed Process

FMEA-Process Map Linkage- Prioritize

Sometimes we will need to prioritize the activities or factors we study. A cause and effect matrix will help us do that. Copyright © 2007 SigmaFlow. All rights reserved. CONFIDENTIAL content, not to be redistributed without express SigmaFlow permission.

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!

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