Quality Improvement Using FMEA : A Short Review · 2017-06-07 · Handbook in 1984 to promote FMEA. FMEA methodology is now effectively used in a variety of industries including semiconductor,
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 06 | June -2017 www.irjet.net p-ISSN: 2395-0072
1Production Engineering Department PEC University of Technology, Chandigarh 2Production Engineering Department PEC University of Technology. Chandigarh
2.1 Design FMEA (DFMEA) DFMEA is kind of tool to identify and prevent failure modes of products, that are related to their design, in order to validate the established design parameters for a specific functional performance level, at system, subsystem or component level. It aids in the objective evaluation of design requirements and design alternatives. It provides additional information to aid in the planning of efficient design testing. In order to eliminate or mitigate the effects, DFMEA plays an important role by selecting the optimal design variant and develop a documentary base to support future designs in order to reduce the risks which is associated with the faulty products that reach to the customers.
2.2 Process FMEA (PFMEA)
The purpose of this variant of FMEA is to determine the
potential failure modes of manufacturing/assembly
processes at operation, subsystem or system level and
to eliminate as early as possible the process faults that
could lead to the separation of defective products and
avoid using improper methods as part of the processes.
PFMEA also provides solutions for the development of
future processes and validation programs.
3. Research Methodology
Step 1: First of all collect the functions of
system and make a hierarchical structure. Then
divide the system into several subsystems,
having number of components.
Step 2: Now determine the failure modes of
each component and its effects. Assign the
severity ranking (S) of each failure mode
according to the respective effects on the
system.
Step 3: Determine the causes of failure modes
and estimate the likelihood of each failure that
can occur. Give the rating of ocurrance (O) to
each failure mode according to the likelihood of
its occurrence.
Step 4: Make a list of approaches to detect the
failures and determine the ability of system to
detect the failures prior to the failures
occurring. Hence assign the detection rating
(D) of each failure mode.
Step 5: Calculate the risk priority number
(RPN) and prepare the priorities for attention.
Step 6: Take suitable actions to enrich the
performance of system.
Step 7: Prepare FMEA report in a tabular form.
4. RISK ASSESSMENT FACTORS
Probability of Severity (S): A number from 1 to 10 is
selected, depending on the severity of the potential
failure mode’s effect
• 1 = no effect • 10 = maximum severity
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 06 | June -2017 www.irjet.net p-ISSN: 2395-0072
Used in the design of products and processes (manufacturing line, service procedures, etc.) to anticipate and address potential failure modes early in the process when they are least expensive for correction.
It contributes to the development of effective maintenance procedures. For instance, MSG-3 analysis for aircraft industry.
Identifies the failure modes discovered during testing and update the probabilities of occurrence based on the Reliability Growth testing data.
It is used to evaluate critical plans to modify an existing process.
Used to investigate the credibility of existing systems/processes.
Helps in providing a central location for reliability-related information for the process.
Provides a basic knowledge that helps for the future troubleshooting efforts.
Acts as a learning tool for new engineers. It provides input to other system analyses, for
example Reliability Block Diagram (RBD), Fault Tree, etc.
It can be used to Contribute in the identification of requirements for built-in test equipment (BITE).
It is also included among Probabilistic Risk Assessment (PRA) techniques (such as in nuclear power and other industries).
It is performed to satisfy a customer requirement and/or to comply with Safety and Quality requirements, such as:
o Six Sigma o FDA Good Manufacturing Practices o Process Safety Management Act (PSM
act)
6. Conclusion
In 1950s the attention was paid to the safety to prevent accidents that can be predicted in aerospace industry in advance led to the development of the FMEA methodology. Later, it was introduced as key tool for increasing efficiency and quality in manufacturing processes. In 1970’s automobile company came with FMEA to address the potential problems in the Research and Development (R&D) in the early stage of production and published the
Potential Failure Mode and Effects Analysis Handbook in 1984 to promote FMEA. FMEA methodology is now effectively used in a variety of industries including semiconductor, processing, food service, plastics, software, and healthcare. Several approaches and applications of FMEA have been developed so far. FMEA can be used to optimize the decision making process in new product development in automobile industry .FMEA can be implemented at the design stage once actual failures are observed during test, production and operation. On the basis of results and analysis stated above we are going to implement FMEA on the sub processes involved in welding processes starting from the sheet handling to welding process.
7. Reference
[1] A. A. Nannikar, D. N. Raut, M. Chanmanwar, S. B.
Kamble and D. B. Patil, “FMEA for Manufacturing and
Assembly Process”, International Conference on
Technology and Business Management, pp. 26-28,
March 2012.
[2] Segismundo, Paulo Cauchick Miguel, "Failure mode
and effects analysis (FMEA) in the context of risk
management in new product development: A case
study in an automotive company", International
Journal of Quality & Reliability Management, Volume
25 Issue 9, pp.89 – 912, 2008.
[3] Arabian-Hoseynabadi, H. and Oraee, H. and Tavner,
P. J. “Failure Modes and Effects Analysis (FMEA) ”,
International journal of electrical power and energy
systems, Issue 7, pp. 817-824, 2010.
[4] ArunChauhan, Raj Kamal Malik, Gaurav Sharma,
MukeshVerma, “Performance Evaluation of Casting
Industry by FMEA - A Case Study”, International
Journal of Mechanical Engineering Applications
Research, Volume 2, Issue 2, pp. 113-121, 2011.
[5] Carl S. Carlson, “Understanding and applying the
fundamental of FMEAs”, IEEE, January 2014.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 06 | June -2017 www.irjet.net p-ISSN: 2395-0072