Failure Mode and Effect Analysis
Download as PPTX, PDF0 likes434 views
The seminar on Failure Mode and Effect Analysis (FMEA) covers the identification and prioritization of potential product/process failures to reduce associated risks. FMEA, first utilized in the 1960s, has evolved into several types including Design and Process FMEA, offering benefits such as improved quality and customer satisfaction. The process involves a structured team approach to brainstorm failure modes, assign severity and detection rankings, and develop action plans to mitigate risks.
Failure Mode and Effect Analysis
- 1. Seminar On “Failure Mode And Effect Analysis (FMEA)” SIVA S 1AC15ME036 5TH SEM B.E. MECHANICAL ALPHA COLLEGE OF ENGINEERING Subject: Total Quality Managemenet (TQM)
- 2. INTRODUCTION • Identifying the ways in which a product / process can fail. • Estimating risk associated with specific causes. • Prioritizing the actions that should be taken to reduce risk.
- 3. HISTORY • First used in the 1960’s in the Aerospace industry during the Apollo missions. • In 1974, the Navy developed MIL-STD-1629 regarding the use of FMEA. • In the late 1970’s, the automotive industry was driven by liability costs to use FMEA.
- 4. TYPES OF FMEA 1. CONCEPT FMEA (CFMEA) 2. DESIGN FMEA (DFMEA) 3. PROCESS FMEA (PFMEA) 4. SERVICE FMEA 5. SOFTWARE FMEA
- 5. CONCEPT FMEA DESIGN FMEA SYSTEM (S) SUB-SYSTEM (SS) COMPONENTS (C) PROCESS FMEA ASSEMBLY (S),(SS),(C) MANUFACTURING (S),(SS),(C)
- 6. DESIGN FMEA (DFMEA) • The Design FMEA is used to analyze products before they are released to production. • It focuses on potential failure modes of products caused by design deficiencies. • Design FMEAs are normally done at three levels system, subsystem, and component levels.
- 7. PROCESS FMEA (PFMEA) • This type of FMEA focuses on potential failure modes of the process that are caused by manufacturing or assembly process deficiencies. • Minimize production process based ,failure effects on the system. • This approach is also commonly used in many industries to access certain processes involved in providing customer care.
- 8. BENIFITS • Improved product/process quality, reliability and safety. • Fewer late changes. • Increased customer satisfaction • Shorter time to market. • Early identification and elimination of potential product/process failure modes. • Determination of warranty on products. • Improved company image and competitiveness.
- 9. FMEA TERMINOLOGY Risk Priority Number (RPN) Severity ( Impact of the event). Occurrence ( probability of the event occurring). Detection (identification) RPN = (Severity ) x (Occurrence ) X (Detection )
- 10. SEVERITY (S) RATING MEANING I No relevant effect on safety or reliability. II Very minor , no damage, only results in maintenance action. III Minor, low damage, light injuries. IV Critical , loss of all safety margins , severe damage, possibility of death. V Catastrophic event will occur again, complete unsafe for operation, multiple death possible.
- 11. OCCURRENCE (O) RATING MEANING A Extremely unlikely B Remote C Occasional D Reasonably Possible E Frequent
- 12. DETECTION (D) RATING MEANING 1 Certain- fault can be caught in the test 2 Almost certain 3 High 4 Moderate 5 Low 6 Fault is undetected by operator or maintainers
- 13. FMEA TEAM MEMBERS • FMEA is meant to be a team process, and should be done by a team. • Each member of the team should bring her specific view to the hazard mitigation process. • The team needs to meet, discuss and address the problem in a collective manner. • Isolation of team members also prevents exchange of ideas within the team and the analysts understanding remains limited to his own scope.
- 14. DESIGN OF FMEA DOCUMENT • FMEA NUMBER • ITEM • DESIGN RESPONSIBILITY • PREPARED BY • MODEL NUMBER / YEAR • CORE TEAM • ITEM / FUNCTION • POTENTIAL CAUSE OF FAILURE/S • KEY DATE
- 15. Actual DESIGN FMEA FORM of Chrysler Ford, General Motors Supplier Quality Requirements Task Force
- 16. PROCESSING OF A FMEA Step 1: Review the process Step 2: Brainstorm potential failure modes Step 3: List potential effects of each failure Step 4: Assign Severity rankings Step 5: Assign Occurrence rankings Step 6: Assign Detection rankings Step 7: Calculate the RPN Step 8: Develop the action plan Step 9: Take action Step 10: Calculate the resulting RPN
- 17. CASE STUDY The Hercules Cycle And Motor Company Limited - MODEL HERCULUS TROOPER
- 18. 1. ITEM - Bicycle Hand Brake Subsystem
- 19. 2. FUNCTION 3. FAILURE MODE & EFECT
- 20. 5. Severity- 10 , Cause - cable breaks, Occurance – 4, 2 & 6
- 21. 6. CONTROLS - Hand Brake System (Manual) PREVENTION TYPE CONTROL - Cable Material Selection Based On ANSI #ABC DETECTION TYPE CONTROL - Bicycle System Durability Test #789
- 22. 7. DETECTION- 5 & 9 , RISK PRIORITY NUMBER (RPN) - 10 X 6 X 4 = 240
- 23. RECOMMENDED ACTIONS - Require Cable DFMEA/PFMEA From Cable Supplier Approved By All-terrain FMEA Team.
- 24. SOFTWARES USED FOR FMEA • ASENT FMEA Software • Byteworx • FMEA-Pro • Isograph Software • Item Software • Quality Plus • RAM Commander Software . • PTC/Relex Software • XMEA • Relyence Software .
- 25. ADVANTAGES OF FMEA • Improve the quality, reliability, and safety of a product/process • Increase user satisfaction • Maximize profit • Minimize late changes and associated cost. • Reduce impact on company profit margin. • Early identification and elimination of potential failure modes. • Emphasize problem prevention. • Reduce the possibility of same kind of failure in future
- 26. LIMITATIONS OF FMEA • Examination of human error is limited. • Examination of external influences is limited. • Focus is on single-event initiators of problems. • Results depend on the mode of operation. • Outputs are only as good as the inputs.
- 28. THANKS YOU ALL