Quality Progress - June 2014 - (Page 42)

3.4 PER MILLION BY T.M. KUBIAK Conducting FMEAs for Results Tips and techniques for properly using the risk management tool TODAY'S WORLD IS fraught with risk. A as the tool is, however, it is often used product, assembly, subassembly or part. By failure mode and effects analysis (FMEA) incorrectly. Users who invest significant contrast, the PFMEA uses a process. There- is a prevention-based, risk management time and effort in the tool often do not fore, the first column contains the process tool that focuses the user or team on reap all it has to offer. steps. As such, a process map, cause and This column details FMEA and systematically: effect matrix, suppliers, inputs, process, provides useful tips for gaining the most failures. outputs and customers (SIPOC) diagram, benefit from the use of this tool. * Identifying and anticipating potential value stream map, cause and effect diagram, or something similar, usually feed it. * Identifying potential causes for the Types of FMEAs failures. * Prioritizing failures. The lean Six Sigma practitioner is likely to The PFMEA document * Taking action to reduce, mitigate or encounter two types of FMEAs: Of the two primary types of FMEA docu- 1. Design FMEA (DFMEA)-an analy- ments, the lean Six Sigma practitioner eliminate failures. The real value of the FMEA is reflected sis process used to identify and evalu- likely will deal with the PFMEA the most. in its use as a long-term, living document. ate the relative risk associated with a The PFMEA document's columns include: It is essential that the document is owned particular hardware design. 1. Process step-Identify the process 2. Process FMEA (PFMEA)-an and updated as changes are made to the design or the process. step and input under investigation. Each analysis process used to identify and study malfunctions of military systems. As PFMEA is fed from a cause and effect ma- with a particular process design. by reliability engineers in the 1950s to step is identified sequentially. If the evaluate the relative risks associated FMEA was first developed and used trix, only high-value steps might be listed. 2. Potential failure mode-Identify Both are similar-with the exception of such, it has been a worthy and valuable the first column of the FMEA document. all the ways a failure can occur at this technique. Subsequently, it has become Table 1 provides an example of an FMEA process step. commonplace in just about every lean Six document's format. Sigma practitioner's tool kit. As common 3. Potential failure effects-Iden- The DFMEA's first column uses a FMEA document general format / TABLE 1 May be a product, assembly, subassembly or part Improvement activities Initial development of the FMEA Process Potential Potential Potential Current step/ failure failure SEV OCC causes controls input mode effects 1 2 3 4 DET = detection FMEA = failure mode and effects analysis OCC = occurence 42 QP * www.qualityprogress.com 5 6 tify all the effects each failure mode has, 7 DET RPN 8 9 Post-improvement activities Actions recommended Resp. Actions taken 10 11 12 Resp = responsible RPN = risk priority number SEV = severity SEV OCC DET 13 RPN http://www.qualityprogress.com

Table of Contents for the Digital Edition of Quality Progress - June 2014

Up Front
LogOn
Expert Answers
Keeping Current
Mr. Pareto Head
No Weak Links
Need for Speed
Solid Base
Insurance Policy
3.4 per Million
Quality in the First Person
Career Corner
Statistics Roundtable
2014 Software Showcase and Directory
QP Toolbox
QP Reviews
Back to Basics

Quality Progress - June 2014

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