FMEA - Failure Mode and Effects Analysis

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 FMEA - Failure Mode and Effects Analysis

1. 1. PREMIUM POWERPOINT SLIDES Effects Analysis Failure Mode and
2. 2. FAILURE MODE AND EFFECTS ANALYSIS (FMEA)POWERPOINT TEMPLATE
3. 3. AGENDA BASIC CONCEPT Definition– what is FMEA? WHY FMEA? BENEFITS And TARGETS OF FMEA TYPES OF FMEA PROCEDURE Key FIGURES LAUNCH And TRAINING OF FMEA Phase model DAMUK FMEA Form SHEET
4. 4. BASIC CONCEPT  The later an error is detected, the more difficult and expensive is to correct  Instead of using error detection and correction, avoid errors all together by identifying and evaluating the causes of potential errors in the concept phase  Thus, inspection or error-tracking costs that would otherwise occur in the production phase or even after delivery can be avoided and overall costs reduced  Through past findings, the repetition of defects in new products and processes is avoided  The principle of error prevention plays the key role  The quality awareness of every employee is the focus  Quality control is no longer an area of expertise, but should be of common knowledge for each and everyone
5. 5. DEFINITION – WHAT IS FMEA? The important methodic instrument of reliability technology is used to detect possible product and process errors and their causes and consequences at an early stage ANALYSISMETHOD Possible errors are evaluated with a key figure regarding their relevance for the customer, their probability of occurrence and detection KEY FIGURES Within quality and safety management, FMEA is applied to increase technical reliability especially in the development and planning phase of new products and processes TECHNICAL RELIABILITY FMEA is used to monitor the maturity level of products and processes and is therefore an important managing instrument to support interdisciplinary teamwork MATURITY MONITOR
6. 6. WHY FMEA? Extending the term “quality” to services and intra-company cooperation requires modern quality management within the whole company Being aware that lacking quality means less profit has led to the fact that quality has top priority within corporate goals Orientation towards requirements of internal and external customers increases competitiveness Aim to create an awareness for the fact that flawless products and services can only be reached by continuous improvement
7. 7. UNPLEASANT DRIVING EXPERIENCE THE STEERING WHEEL IS VIBRATING THE CAR IS VIBRATING THE AXIS IS VIBRATING THE WHEEL IS BEATING THE TIRE IS IMBALANCED THE MECHANIC DID NOT BALANCE THE TIRES SE 0 CAR SE 1 VEHICLE SE 2 AXIS SE 3 WHEEL SE 4 TIRE SE 5 DEALER Effect Error Effect Cause Error Effect Cause Error Effect Cause Error Effect Cause Error Effect Cause Error SYSTEM level ERror EXAMPLE
8. 8. BENEFITS AND GOALS OF FMEA Recognizing risks that are connected with products or processes in the company Avoiding or decreasing costs for quality control, reworking and error correction Designing processes in such a way that they run smoothly Assuring functionality, safety and reliability to minimize liability claims Developing products from the start, so that no errors, quality defects or damages arise
9. 9. TYPES OF FMEA  Makes early assessment of the manufacturing suitability of a product  Considers systematic failures during the construction phase  Possible breakdowns and errors that can occur on separate parts of the system are regarded and proactively avoided  Detects error causes usually arising in the construction and manufacturing phase  Is directed by a responsible engineer  Construction plans are the basis  Explores the interaction of subsystems or components of an entire system  Aims to identify potential weaknesses, that could arise at the interaction of single components  Considers random and systematic failures during operation  Analyzes procedures of the considered system  Is based on results from the Construction FMEA and determines possible weaknesses in the production process  Examines the process related to error causes  Thus, process suitability, reliability and quality are ensured at an early stage  Is guided by a responsible employee of the production  Design drawings are the basis HardwareFMEASYSTEM FMEAprocess FMEA  Same purpose as Hardware FMEA, but for generated program codes  Aims to analyze, evaluate and eliminate risks from the hardware and electronic fields CONSTRUCTION FMEA SoftwareFMEA System FMEA, Construction, Hardware and Software FMEA have been combined to PRODUCT FMEA, which investigates functional correlations in the considered system.
10. 10. TYPES OF FMEA Application areas of product and process FMEA concept development Process Planning PRODUcTION SERIEs  Systematic analysis of product and process  Elimination of error causes and risks in development and planning taking all departments into account  Principle of error prevention Product FMEA System analysis Product FMEA Consideration of functions Product FMEA Consideration of construction Process FMEA Manufacturing process Process FMEA Assembly process
11. 11. problem CAUSE-AND-EFFECT-DIAGRAM Cause EFFECT MACHINE This is placeholder text All phrases can be replaced with your own text Insert your own text here This is placeholder text MEASUREMENT Insert your own text here All phrases can be replaced with your own text This is placeholder text Insert your own text here MATERIALS This is placeholder text Insert your own text here This is placeholder text All phrases can be replaced with your own text MOTHER NATURE Insert your own text here All phrases can be replaced with your own text This is placeholder text Insert your own text here METHOD This is placeholder text Insert your own text here This is placeholder text All phrases can be replaced with your own text MAN Insert your own text here All phrases can be replaced with your own text This is placeholder text Insert your own text here
12. 12. PROCEEDING IN 5 STEPS StructureAnalysis Function Analysis error Analysis RISKevaluation Optimization RPI* This is placeholder text This is placeholder text This is placeholder text S SIGNIFICANCE D DETECTION P PROBABILITY *Risk Priority Index
13. 13. KEY FIGURES  P: occurrence probability of error causes  S: significance for the customer  D: detection probability of the error or its cause  Key figures P, S and D are basis for evaluating the risk  Can take integer values between 1 and 10  RPI: with the Risk Priority Index a risk ranking can be generated  It results from the multiplication of P, S and D and can therefore take values between 1 and 1,000  The benefit is still questioned, as the same results could have been emerged in different ways RPI* = p × s × d *Risk Priority Index
14. 14. IMPLEMENTATION AND TRAINING OF FMEA 1. Decision of the Management  Turning away from the commonly practiced crisis management and shift to a preventive quality management in the whole company  Due to the long-term and comprehensive importance of a reorientation, only the management can make the decision to introduce FMEA and implement it  Active support during the introduction phase and common interest in future results are essential aspects of the management’s fundamental decision
15. 15. FMEA – PHASE MODEL DAMIC Guideline for an efficient implementation of FMEA Methods in the Company Definition: preparation and system definition Analysis: systematic determination of demands and risks; conduct FMEA in the team Measurement decision: define measures and procedures Implementation: realizing and evaluating through verification, validation and monitoring Communication: present, inform and communicate Ico ns Analysisimplementation Measures decision Definition communication
16. 16. VARIANTS OF FMEA Bow Tie  Method developed by Shell to solve problems in the off-shore sector  Graphic method that depicts causes on one side, effects on the other side, and the error itself in between  Between causes and effects, barriers are planned in order to avoid errors and reduce error consequences  For each error, this results in an image that resembles a bow tie  Barriers that have not been implemented can be introduced with the help of a measure plan
17. 17. VARIANTS OF FMEA HAZOP – Hazard-Operability H POZAIn the chemical industry, Process FMEA is often replaced or added by the Hazard Operability Method Whole process facilities are divided into subsystems based on installation plans, work instructions, and formulations (e.g.) For each plant unit, target functions are listed; for every target function, possible disturbances are searched for and appropriate counter measures are planned A HAZOP Analysis is performed by a group of project and process engineers, as well as experts of work safety, environment protection and fire protection An experienced moderator motivates the group for creative work and is responsible for the preparation and follow- up of discussions
18. 18. VARIANTS OF FMEA Kepner-Tregoe Method (KT-Method)  This method doesn’t stop at the collection of random results, but sets a specific structure of analyzing problems  Thereby, comparable problems from the past are considered as former findings might help solve current problems  In 1970, the method was applied by NASA to save flight Apollo 13  The saying: “Houston, we have a problem.” is the first step to solve a problem with the KT-Method Simplified description of the method:  Naming the problem (with the help of the 5W-Technique or Fish Bones Technique)  Describing the problem and analyzing the cause  Examining the cause analysis  Finding the solution
19. 19. 1. Master data  Information on the FMEA type, the considered unit or system and people involved  The considered system and the associated FMEA number have to be clearly recognizable 2. System element / function / task  Description of the considered object (system, module, product, component)  List of all features and functions which the object has to fulfill  During a Process FMEA, the planned work sequence is described in detail 3. Possible error consequences  Successively, each possible error is regarded and treated as if it had occurred  The particular impact on the entire system is described in such a way as the customer would recognize it FMEA FORM SHEET Explanations
20. 20. FMEA FORM SHEET – VARIANTS Function: Text: Function: Text: Possible error consequences: Significance: Systemelement /Function: Possible error/malfuncti on: Possible error causes: Current state: Proposed correction measures: Responsible person / Deadline: FAILURE-MODE-AND-EFFECT-ANALYSIS FMEA Product name: Product no.: Model/System/Production: Techn. Revision state: Created by (Name/Dep.): Created: Occurrence: RPI: RPI: Avoidance measures: Detection measures: Taken measures: Significance: Occurrence: RPI: Improved state: Revised: Effort (in hrs): Detection: Function: Text: Design FMEA Process FMEA
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