05 Fmea.ppt

Six Sigma Champion Training Failure Modes and Effects Analysis Champion Training What is a FMEA? Important to Understand the Cause Effect Relationship FMEA Model Fishbone Model 5M`s E Failure Mode Fishbone Model FMEA Form-Assessing Current Situation FMEA Form-Improvement Plan Steps in the FMEA Process 1. Select the Process FMEA team 2. Develop a Process Map and identify all process steps 3. List all the Key Process Outputs deliverables to satisfy internal and external customer requirements 4. For each Process Step, list Key Process Inputs 5. Develop CE matrix relating Product Outputs to Process Inputs 6. Rank the inputs according to importance Steps in the FMEA Process 7. Start the process FMEA by listing ways that each process step can fail Failure Modes 8. For each Failure Mode, identify the Effects and Causes 9. Assign Severity, Occurrence and Detection rating to each Cause 10. Calculate the risk priority number for each potential failure mode 11. Determine recommended actions to reduce all RPNs 12. Take appropriate actions 13. Re-calculate all RPNs Cause Effect Matrix This matrix provides the initial input to the FMEA. When each of the Key Output Variables Customer Requirements are not correct, that represents potential ”Effects. When each Process Step/ Key Input Variable is not correct, that represents a ”Failure Mode. 1. List the Key Process Output Variables 2. Rate each Key Process Output Variable on a 1-to-10 scale to importance to the customer 3. List Process Steps/ Key Input Variables 4. Rate each Process Step/ Key Input Variable relationship to each Output Variable on a 1-to-10 scale 5. Select the top Process Steps or Key Input Variables based upon CE Matrix Importance column to start the FMEA process * T R A I N I N G C O N S U L T I N G B u i l d i n g S u c c e s s W o r l d w i d e S O F T W A R E Cause Failure Mode Defect Effect A FMEA is a disciplined procedure that allows the engineer to anticipate failures and p