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STM Quality Limited
TOTAL QUALITY MANAGEMENT
What do we do when it"s #nished!
Introduction
Failure Mode and Efect Analysis?
F.M..A. is a sim$le way o% $redi&tin' what mi'ht 'o
wron'.
By usin' a stru&tured method( results
&an )e *uanti#ed and hen&e &om$ared.
+denti#es &riti&al and si'ni#&ant
&hara&teristi&s
,el$s en'ineers $rioritise and %o&us on
tilise indi-iduals" /nowled'e and s/ills within a team
en-ironment
Failure Mode and Efect Analysis
F.M..A.s &an )e done %or any desi'n( manu%a&turin' or
in1ser-i&e a&ti-ity
F.M..A.s are modular and &an )e
&arried out %or sin'le $arts or lar'e assem)lies
!ene"ts # Desi$n F.M.E. A.
Aids in e-aluatin' re*uirements and alternati-es Aids in
initial esi'n %or Manu%a&ture +n&reases $ro)a)ility o%
dete&tin' %ailure
modes and their e3e&ts Pro-ides additional in%ormation
%or
testin' re*uirements ,el$s identi%y &riti&al and
si'ni#&ant
&hara&teristi&s ,el$s -alidate test methods
!ene"ts # Process F.M.E. A.
+denti#es $otential $ro&ess related
%ailure modes whi&h will e3e&t internale4ternal
&ustomers 5edu&es &osts o% re$airs due to
%aulty
$ro&ess methodolo'y +n&reases e6&ien&y sta)lishes a
$riority system %or
&onsiderin' &orre&ti-e a&tions +denti#es
&on#rmed &riti&al and
si'ni#&ant &hara&teristi&s
F.M..A +denti#es 5is/s
$esi%n &esponsibility
To /ee$ u$ with &om$etition
To retain &urrent )usiness
,el$ o)tain new )usiness
FM..A.s are li-in' do&uments and are u$dated when9
Modi#&ation to a &om$onent( $ro&ess or system is
$lanned:
om$onent is to )e used in new en-ironment:
ustomer &on&ern arises.
Then identi%y )oundary %or analysis
<e4t( &reate a ;ow &hart %or one o$eration
Process Flow %hart
=$.>0 Pre$aration
=$.?0 Weld
=$.@0 assem)le
=$.C0 +ns$e&t D Pa&/StorePa&/
=$.20 Mould
!oundary For Analysis
Press EStart" )utton
=$.0 Trim
$esi%n &esponsibility
From Pro&ess ;ow9
nter a sim$le des&ri$tion o% the $ro&ess )ein' analysed
i.e. Pla&e $art on trim ma&hine #4ture:
+ndi&ate the $ur$ose o% the $ro&ess )ein' analysed i.e.
Fully seat $art in &orre&t orientation:
List se$arately other o$erations in-ol-ed with that
$ro&ess:
Pro&ess %un&tion &ontains )oth $rodu&t and
$ro&ess &hara&teristi&s.
Process)Function *e+uire,ents
What is the $ro&ess $ur$ose!
What is its %un&tion!
De"ne the Process Purpose
Process Purpose
=$.0 Trim
$esi%n &esponsibility
e#nition9
Potential %ailure mode is the manner in whi&h the $ro&ess
&ould $otentially %ail to meet the $ro&ess re*uirements
andor desi'n intent.
+t is a des&ri$tion o% the non1 &on%orman&e at
that s$e&i#& o$eration.
Failure Mode
<o %un&tion
Partial %un&tion
+ntermittent %un&tion
$esi%n &esponsibility
e#nition9
The e3e&ts o% the %ailure mode on the &ustomer. The
&ustomer &ould )e the ne4t o$eration( su)se*uent o$erations
or the #nal &ustomer user.
Efects o' Failure Mode
ne4t user
downstream user
ultimate &ustomer
ma&hines e*ui$ment
Efects o' Failure Mode
'ncorrect to
$esi%n &esponsibility
e#nition9
An assessment o% the seriousness o% the e3e&t o% the $otential
%ailure mode on the &ustomer.
eerity
o&&urren&e
ete&tion Add to or im$ro-e the &ontrol methods
han'e the desi'n ... or the $ro&ess i% o$erator sa%ety is
in-ol-ed
han'e the desi'n or $ro&ess
+m$ro-e a)ility to dete&t a %ailure mode
$esi%n &esponsibility
We ha-e seen that the F.M..A. as/s three *uestions9
What mi'ht 'o wron'!
What &aused the $ro)lem!
Failure Mode and Efect Analysis
From the answers to the three *uestions we &an wor/ out a ris/
$riority num)er9
*is/ Priority 0um)er
,ow do we &al&ulate the 5.P.<.!
We sim$ly use the s&orin' &riteria easily remem)ered
)y9
Se-erity o% the $ro)lem
a&h is 'i-en a -alue %rom > to >0
Let"s try this out %or S( = D
For 4am$le(
=&&urren&e > 2 ? @ C 7 N H >0
ete&tion > 2 ? @ C 7 N H >0
Failure Mode and Efect Analysis
,ow &an we use these -alues to 'i-e an o-erall ris/!
We multi$ly the three #'ures to'ether9
e.'. 7 4 @ 4 ? N@.
So the 5.P.<. is N@.
Failure Mode and Efect Analysis
From the 5.P.<. we &an now see the areas o% 'reatest
&on&ern
i.e. Those %ailures with the hi'hest ris/ $riority
num)ers
Failure Mode and Efect Analysis
We &an now %o&us our attention on the worst $ro)lems 8
those with the hi'hest 5.P.<.
With limited resour&es( this must )e a 'ood idea
We &an now eliminate or
redu&e the $otential %ailure
$esi%n &esponsibility
*eco,,ended Actions
The intent o% any 5e&ommended A&tion is to redu&e
ran/in's in the %ollowin' order9
Se-erity
$esi%n &esponsibility
*esponsi1ility
a&h a&tion must )e assi'ned to a s$e&i#& indi-idual
and not a de$t. or'anisation
$esi%n &esponsibility
Actions aken
Actions aken
Ad-anta'es o% F.M..A.s
+m$ro-ed $arti&i$ation a&ross traditional )oundaries
More ad-anta'es o% F.M..A.s
ses e4tensi-e D unta$$ed $ersonnel$ro&ess /nowled'e
to im$ro-e new D e4istin' wor/
Pro-ides a -ehi&le %or &ontinuous im$ro-ement
Su$$orts $rodu&t lia)ility
There are draw)a&/s %or F.M..A.s9
Must )e ade*uate time D resour&es %or F.M..A.s
Produ&t Lia)ility
Failure Mode and Efect Analysis
ee$ the meetin's short and the tem$o shar$
esi'n F.M..A. team 1 hairman( Produ&tion( Ser-i&e(
Quality Personnel
Pro&ess F.M..A. team 1 R= ,==S