Quality Progress - October 2017 - 23

at 36, which, according to Table
3, is undesirable. The engineering team brainstormed several
options. The team decided the
best method to reduce the RPN
was to increase the probability
of detection. By using an X-ray
inspection of the welds, the
detection value was reduced
to two, bringing the RPN to 24,
which, according to Table 3, is
tolerable.
Has the engineering team fully
reduced the risk? No, because
the criticality/severity is four and
the probability of occurrence is
three. Table 4 indicates the risk as
unacceptable. Because the criticality/severity cannot be reduced,
the engineering team must find a
way to reduce the probability of
occurrence.
To reduce the probability of
occurrence, the team decided
to replace the manual welding
process with a robotic welding
process. The results of this have
reduced the RPN to 16, which
Table 3 indicates is tolerable. The

make a 33% reduction in the RPN,
which takes us from an unacceptable risk level to a tolerable risk
level.
Another consideration is evaluating the criticality and probability
of occurrence. Table 4 provides an
example of criticality and occurrence action requirements.

Applying FMEA

Many organizations design products that have a direct impact
on safety. Engineering departments are especially focused on
identifying and eliminating safety
concerns to reduce or prevent
user injury. Table 6 is a portion of
an example FMEA pertaining to
safety as part of a design project.
Table 6 also shows the three
potential causes of failure-
improper welds, improper
materials and design error-all
have RPNs that are undesirable.
As an example, let's focus on the
first potential cause of failure:
improper welds.
The initial RPN was calculated

FMEA Included as
Webinar Topic
Failure mode and effects analysis and how to
effectively use it to address the risk management requirements of ISO 9001:2015 is just one
of the webinars offered by ASQ's Reliability
Division.
The webinars are a way for division members
to earn recertification units (RU). The webinars,
free to division members, have been offered by
the division since 2010. Since then, more than
160 free webinars have been offered to more
than 7,000 individuals, totaling more than
14,000 hours of instruction.
Each webinar averages about 90 participants. Many webinars are available not only in
English, but also Mandarin and Spanish. Webinar presentations have been made by several
highly regarded practitioners and educators.
Each webinar is recorded and published to the
division's website at www.asqrd.org.
At the end of each one-hour webinar, an
email is sent to each attendee, confirming participation and indicating that 0.1 RUs have been
earned for participating.
For more information, visit www.asqrd.org.
-J.B., D.B. and M.D.

TA B L E 6

Potential
cause of
failure

Fails to
support the
operator cage
in a roll over

User
injury

4 Improve
welds

Fails to
support the
operator cage
in a roll over

User
injury

Specify
4 Improper
materials 2 steel
tubing

Fails to
support the
operator cage
in a roll over

User
injury

4 Design
error

Current
controls

Recommended
actions

Actions taken
Add X-ray
inspections
as part of the
measurement

4 3 2 24

Specify 4130
4 32 chomoly steel
tubing

Specify 4130
chromoly steel
tubing in the
material

3

Perform virtual
physical
3 36 and
performance
testing

Analyze testing
results to ensure
the design criteria are achieved

3 2 2 12

X-ray
weld
3 Visual
of
inspections 3 36 inspection
welds

3 Prototype
testing

1

RPN

Potential
effects
of failure

SEV
OCC
DET

Supports
Safety operator
bar
cage in
roll over

Potential
failure mode

DET
RPN

Function

OCC

Item

SEV

Example of FMEA

2 6

SEV = severity
OCC = occurrence
DET = detection
RPN = risk priority number
FMEA = failure mode and effects analysis

qualityprogress.com ❘ October 2017

QP 23


http://www.asqrd.org http://www.asqrd.org http://www.qualityprogress.com

Table of Contents for the Digital Edition of Quality Progress - October 2017

Seen and Heard
Progress Report
Mr. Pareto Head
Expert Answers
Career Coach
In Focus
The Results Are In
Visual Aid
Experimental Learning
Statistics Spotlight
Standard Issues
Marketplace
Footnotes
Try This Today
STANDARDS AND AUDITING GUIDE
Quality Progress - October 2017 - intro
Quality Progress - October 2017 - cover1
Quality Progress - October 2017 - cover2
Quality Progress - October 2017 - 1
Quality Progress - October 2017 - 2
Quality Progress - October 2017 - 3
Quality Progress - October 2017 - 4
Quality Progress - October 2017 - 5
Quality Progress - October 2017 - Seen and Heard
Quality Progress - October 2017 - 7
Quality Progress - October 2017 - Progress Report
Quality Progress - October 2017 - Mr. Pareto Head
Quality Progress - October 2017 - 10
Quality Progress - October 2017 - 11
Quality Progress - October 2017 - Expert Answers
Quality Progress - October 2017 - 13
Quality Progress - October 2017 - Career Coach
Quality Progress - October 2017 - 15
Quality Progress - October 2017 - 16
Quality Progress - October 2017 - 17
Quality Progress - October 2017 - In Focus
Quality Progress - October 2017 - 19
Quality Progress - October 2017 - 20
Quality Progress - October 2017 - 21
Quality Progress - October 2017 - 22
Quality Progress - October 2017 - 23
Quality Progress - October 2017 - 24
Quality Progress - October 2017 - 25
Quality Progress - October 2017 - The Results Are In
Quality Progress - October 2017 - 27
Quality Progress - October 2017 - 28
Quality Progress - October 2017 - 29
Quality Progress - October 2017 - 30
Quality Progress - October 2017 - 31
Quality Progress - October 2017 - 32
Quality Progress - October 2017 - 33
Quality Progress - October 2017 - Visual Aid
Quality Progress - October 2017 - 35
Quality Progress - October 2017 - 36
Quality Progress - October 2017 - 37
Quality Progress - October 2017 - 38
Quality Progress - October 2017 - 39
Quality Progress - October 2017 - Experimental Learning
Quality Progress - October 2017 - 41
Quality Progress - October 2017 - 42
Quality Progress - October 2017 - 43
Quality Progress - October 2017 - 44
Quality Progress - October 2017 - 45
Quality Progress - October 2017 - 46
Quality Progress - October 2017 - 47
Quality Progress - October 2017 - Statistics Spotlight
Quality Progress - October 2017 - 49
Quality Progress - October 2017 - Standard Issues
Quality Progress - October 2017 - 51
Quality Progress - October 2017 - 52
Quality Progress - October 2017 - 53
Quality Progress - October 2017 - 54
Quality Progress - October 2017 - 55
Quality Progress - October 2017 - STANDARDS AND AUDITING GUIDE
Quality Progress - October 2017 - 57
Quality Progress - October 2017 - Marketplace
Quality Progress - October 2017 - 59
Quality Progress - October 2017 - Footnotes
Quality Progress - October 2017 - 61
Quality Progress - October 2017 - 62
Quality Progress - October 2017 - 63
Quality Progress - October 2017 - Try This Today
Quality Progress - October 2017 - cover3
Quality Progress - October 2017 - cover4
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