FMEA training required as per knowledge gain and improve.pptx

FMEA

1. PROCESS FAILURE MODE & EFFECTS ANALYSIS (PFMEA) Sharing In Growth Teach Point Objectives and Principles

2. What is PFMEA? A structured technique for defining how things can go wrong with a process A method of clearly defining where the biggest risks are in a process Helps to evaluate the effect of failures on downstream stages of a process and customers Helps to prioritise problems for effective action

3. Why Use PFMEA? Discuss the benefits of using PFMEA Discuss the reasons for applying PFMEA in your own areas Safety: Exposes risks that could potentially impact product safety in service Quality: A method for identifying potential failure points that pose a risk to product quality Delivery: Helps to evaluate the effect of process failures and impact on customers Cost: Evaluate the potential cost impact of process failures People: Effectively utilises the skills and knowledge of operators

4. How? What can go wrong? What are the effects? Score severity of effects What are the causes & category Score the potential frequency of cause How can this be prevented & detected? Score the detection effectiveness Score the overall risk & rank What can be done? Design changes Process changes Changes to standards, procedures or guides Do it, review it & maintain it Failure Mode & Effects Analysis Process Step Process Details Potential Failure Mode Potential Effect(s) of Failure SEV Prevention of Failure Cause Detection of Failure Cause DET Potential Cause(s) of Failure OCC RPN Manage the risk

5. How – 6 Step Process 1.0 Map your process & agree scope 1. Map the Process 2 .1 Brainstorm all potential failure modes 2. Decide Failure Modes & Severity 2 .2 Identify potential effects of failures 2 .3 Assign Severity rankings 3 .1 Identify all potential causes of failure 3. Identify Potential Cause (Occurrence) 3 .2 Assign Occurrence rankings 4.1 Establish current controls 4. Controls and Detection 4.2 Assign Detection rankings 5.0 Calculate Risk Priority Number (RPN) 5. Calculate Risk 6 .1 Identify where actions need to be taken 6. Manage the Risk 6 .2 Re-assess RPN when actions complete & maintain 6 .3 Maintain PFMEA as a live document

6. Step 1 – Map the Process Use a team of people that understand the process. This should include people that actually operate each step of the process concerned. The team should physically walk the process with the process operators to ensure they map what “ actually happens ” The team should agree the scope of the PFMEA activity – How much of the process will it cover? 10 Hot Forge Value Stream Mill to Shape Drill Holes De-Burr 2 3 4 Process Step Process Details 10 Hot forge 20 Mill to shape 30 Drill oil drain holes

7. Step 2 – Decide Failure Modes & Severity 2 .1 Brainstorm all potential failure modes The way in which something goes wrong / is non-conforming:- Feature in wrong location Part too small Surface too rough Shaft not round Radius too large Identify the effect(s) of the failure on the next process or customer:- Does not fit/assemble Loss of engine performance Reduction in part life In-flight shut down Increase in process time Assign severity ranking 1 to 10 ranking of the seriousness of the effect of failure to the customer 1 = No effect 10 = Major problem with potential safety risks 2 .2 Identify potential effects of failures 2 .3 Assign Severity rankings Process Step Process Details Potential Failure Mode Potential Effect(s) of Failure SEV 10 Hot Forge Excess curvature High porosity Poor definition Final product dimensional non-conformance – does not fit Weakened structure leading to failure in service Longer machining cycle in step 20 5 8 4 2 .1 2 .2 2 .3

8. Step 3 - Identify Potential Cause (Occurrence) 3.1 Identify all potential causes of failure How the failure could occur, described in terms of something that can be corrected or controlled:- Fastener incorrectly tightened Part not held in jig properly Wrong tool used Gauge inaccurate Part installed wrong way round How frequently the failure cause is likely to happen or occur:- 1 = Never 10 = All the time 3.2 Assign Occurrence rankings Potential Failure Mode Potential Effect(s) of Failure SEV Excess curvature High porosity Poor definition Final product dimensional non-conformance – does not fit Weakened structure leading to failure in service Longer machining cycle in step 20 5 8 4 Potential Cause(s) of Failure OCC Temperature too high De-gassing due to reaction with iron oxide Temperature too low 6 4 6 3.2 3.1

9. Step 4 – Controls and Detection 4 .1 Establish current controls How do we detect the failure mode when it happens or prevent it from affecting the customer:- In process measurement Test panels Operator training Fixture design Detection ranking is an assessment of the probability that the current controls will be effective:- 1 = Certain to detect failure 10 = Failure cannot be detected 4 .2 Assign Detection rankings Potential Cause(s) of Failure OCC Temperature too high De-gassing due to reaction with iron oxide Temperature too low 6 4 6 Detection of Failure Mode DET Infra red camera on part None Infra red camera on part 5 2 5 Prevention of Failure Cause Process controller in furnace XRF analysis of oxide levels Process controller in furnace Current Process Controls 4.2 4.1

10. Step 5 – Calculate Risk RPN (Risk Priority Number) 4 .2 Assign Detection rankings 3.2 Assign Occurrence rankings 2 .3 Assign Severity rankings 5.0 Calculate Risk Priority Number (RPN) Multiply Severity, Occurrence and Detection ranking together, this will give a number between 1 and 1000. X X = Potential Cause(s) of Failure OCC Temperature too high De-gassing due to reaction with iron oxide Temperature too low 6 4 6 Detection of Failure Mode DET Infra red camera on part None Infra red camera on part 5 2 5 Prevention of Failure Cause Process controller in furnace XRF analysis of oxide levels Process controller in furnace Current Process Controls RPN 150 64 120 SEV 5 8 4 5.0

11. Step 6 – Manage the Risk 6.1 Identify where actions need to be taken 6.2 Re-assess RPN when actions complete 6.3 Maintain PFMEA as a live document Consider highest RPNs first, failures with the Highest Severity need to be given priority. Consider the following:- Severity cannot be affected without process/product re-design. How can the occurrence be reduced? How can we improve the detection? Actions Taken & Completion Date DET Thermocouples Installed 10/06/19 Thermocouples Installed 10/06/19 5 2 5 RPN 20 64 16 Recommended Corrective Actions Install thermocouples in cooling None Install thermocouples in cooling Responsibility & Target Completion Date M Latimer 23/06/19 M Latimer 23/06/19 SEV 5 8 4 OCC 2 4 2

12. Who? The team members involved will differ, dependent on manufacturing or transactional processes, and involve: Cross functional team – that understands each process step Independent person – promote discussion and question process Facilitator – to manage the activity

13. Summary Process Failure Mode and Effects Analysis is a logical stepped process that: Gives a deeper understanding of a given process and helps to define how things could go wrong within that process. Uses the skill and knowledge of the people who operate within said process Identifies the biggest risks that could cause potential problems to end users or customers Provides a structure for prioritising problems and addressing with effective actions Provides maintenance and continuous improvement process throughout the product / process life time, ensuring ongoing optimisation.