Unit II.pptx failure mode and effects analysis

Unit II.pptx failure mode and effects analysis

1. Failure Mode and Effects Analysis (FMEA) Unit II Tools used In Product Development

2. Definition of FMEA Failure Mode and Effects Analysis (FMEA) is a method designed to: Identify and fully understand potential failure modes and their causes, and the effects of failure on the system or end users, for a given product or process. Assess the risk associated with the identified failure modes, effects and causes, and prioritize issues for corrective action. Identify and carry out corrective actions to address the most serious concerns.

3. What is FMEA? An FMEA is an engineering analysis D one by a cross-functional team of subject matter experts T hat thoroughly analyzes product designs or manufacturing processes E arly in the product development process. Finds and corrects weaknesses before the product gets into the hands of the customer.

4. What is FMEA? An FMEA should be the guide to the development of a complete set of actions that will reduce risk associated with the system, subsystem, and component or manufacturing/assembly process to an acceptable level.

5. What is FMEA? Performing an FMEA just to fill a checkbox in the Product Development Process and then filing it away, never to be seen again, is a waste of time and adds no value. If not for use as guidance through the development process, why waste the time and resources to do it in the first place? If effectively used throughout the product life cycle, it will result in significant improvements to reliability, safety, quality, delivery, and cost.

6. Types of FMEAs The three most common types of FMEAs are: System FMEA Design FMEA Process FMEA

7. Primary Objective of FMEA The primary objective of an FMEA is to improve the design. For System FMEAs, the objective is to improve the design of the system. For Design FMEAs, the objective is to improve the design of the subsystem or component. For Process FMEAs, the objective is to improve the design of the manufacturing process.

8. Worksheet of FMEA Part Name Function Failure Mode Failure Effect Cause of Failure Risk Priority Number Recommended Action Hand Brake Reducing speed of wheel by applying friction on wheel Insufficient friction between brake pads and wheels during heavy rain conditions . Bicycle does not slow down while applying brake leading to accident 1. Improper Friction, 2. Failure due to foreign particle, 3. Cable breaks 8 Redesign brake system, 2. Change brake friction material

9. Quality Function Deployment Quality Function Deployment Meeting Customer Requirements What must be done Who will do it, When

10. Definition of Quality Function Deployment Quality function deployment is a structured approach for defining customer needs or requirements and translating them into specific plan which will produce new product that satisfy customer needs . QFD was developed in Japan in the late 1960s by Professors Yoji Akao and Shigeru Mizuno .

11. Step 1: Identify Customer Wants A structured list of requirements derived from customer statements Step 2: Identify How The Good s /Service Will Satisfy The Customer’s w ants A structured set of relevant and measurable product characteristics Step 3: Planning Matrix Note down customer requirements observed in market surveys Includes relative importance of customer requirements, company and competitor performance in meeting these requirements Steps in QFD

12. Step 4: Interrelationship matrix Illustrates the QFD team's perceptions of interrelationships between technical need and customer requirements Step 5: Technical correlation (Roof) matrix used to identify where technical requirements support or impede each other in the product design Can highlight innovation opportunities Step 6: Technical priorities, benchmarks and targets Used to record the priorities assigned to Technical requirements by the matrix Measures of technical performance achieved by competitive products The degree of difficulty involved in developing each requirement The final output of the matrix is a set of target values for each technical requirement to be met by the new design, which are linked back to the demands of the customer Steps in QFD

13. Benefits of Adopting QFD Reduced time to market Reduction in design changes Decreased design and manufacturing costs Improved quality Increased customer satisfaction

14. House of Quality