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Lecture 2-3
Design FMEA
Customer Defined
FMEA
Living Document
FMEA
Drawings
What is DFMEA?
FMEA
Design FMEA
FMEA
DFMEA Assumptions
FMEA
DFMEA Phases
FMEA
Planning Phase
Timing: early in the design process
Purpose: quick visibility of most obvious weak points
Development Phase
Timing: design and preliminary component specs are
available
Purpose: expansion of planning phase
Time Phase
FMEA
CONCEPT
The FMEA
ENG PROTOTYPE
develops in
complexity and
detail as the
DEVELOPMENT
product
progresses
through the
design phases
8
FMEA
HARDWARE
BOTTOM-UP
TOP-DOWN
FUNCTIONAL BLOCK
RELIABILITY BLOCK
9
FMEA
a composite of subsystems
Interface
FMEA
Functional
Cooling system
Propulsion system
Braking system
Steering system
Geographic
Engine compartment
Passenger compartment
Dashboard / Control Panel
Rear end
etc.
Interface components
If an engine-driven
belt powers both a
water pump and a
power steering
system, be sure to
include it as part of
one, or as a separate
interface element.
11
AUTOMOBILE
SUBSYSTEM
ASSEMBLY
FMEA
SUBASSEMBLY
COOLING
RADIATOR
WATER PUMP
COOLANT
HOSES, CLAMPS
THERMOSTAT
PROPULSION
FUEL
STORAGE
DELIVERY
AIR
CARBURATOR
SPARK / IGNITION
BATTERY
GENERATOR
PLUGS
COIL
DISTRIBUTOR
ENGINE
ETC . . . .
TRANSMISSION
ETC . . . .
12
Functional FMEAs
FMEA
13
Functional Block
FMEA
FUNCTIONAL BLOCK
MOUNTING DECK,
COVER
BASE DECK
STAMPED
COVER
COVER SEAL
TAPE SEAL
Reliability Block
FMEA
R EL IAB IL IT Y B L O C K
HEA D
P RE AM P
F IL T ER
A M P (A G C )
S L IM M IN G
A to D
D EC O D E
CO NTRO L
B UF F ER
HO S T
15
Detailed FMEAs
FMEA
16
Technique - Hardware
FMEA
HARDWARE
FMEA follows
the hardware
BOM from the
bottom-up, or
the top-down
UNIT ASSY
BASE FINAL
ASSY
MOTOR ASSY
MOTOR POLE
ASSY
MOTOR POLE
SPACER
MACHINE
SCREW
MOUNTING
BRACKET
MAGNET
MOTOR POLE
Handbook pg. 14
17
Interface FMEAs
FMEA
18
DFMEA Form
FMEA
19
Worksheet
FMEA
FMEA WORKSHEET
PRODUCT:
ITEM:
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
ENGR
POTENTIAL
CAUSES
PG
VERIFICATION OR
CURRENT CONTROL
RPN
20
10
FMEA
PRODUCT:
FMEA NO.
PROCESS/OPERATION:
Oklahoma City
FUNCTION
SEVERITY
POTENTIAL
FAILURE MODE
POTENTIAL
EFFECTS OF
OCCURRENCE
FAILURE
1.
PAGE
PLANNING REFERENCE:
POTENTIAL
CAUSE(S) OF
DATE:
DETECTION
CURRENT
CONTROLS
RPN = S x O x D
RPN
ACTION
PRIORITY
CORRECTIVE
ACTION
RESPONSIBILITY
& DATE DUE
ACTION
TAKEN
RESULTING
S
FAILURE
DESIGN ENGINEER
OF
BY:
3.
RPN
ENGINEER WITH
PROGRAM TEAM
(MANUF ENGINEER)
2.
Ground Rules
FMEA
22
11
Function
FMEA
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
PG
VERIFICATION OR
CURRENT CONTROL
RPN
Common problems
Not all functions are identified
The description is not exact or concise
The description is not in direct language
23
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
VERIFICATION OR
CURRENT CONTROL
PG
RPN
12
Effects of Failure
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
PG
VERIFICATION OR
CURRENT CONTROL
RPN
25
Severity of Effect
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
VERIFICATION OR
CURRENT CONTROL
PG
RPN
26
13
Severity of Effect
Design
FMEA
Ranking
Unreasonable to expect that the minor nature of this failure would cause any
real effect on the overall performance
Improbable, minor
Low
The failure is insignificant and the user is only minimally affected
The product is fully functioanl and the failure is viewed as a nuisance item
2
3
Moderate
Failure causes customer dissatisfaction in the form of annoyance
Failure notices by customer requires correction
Customer notices slight performance degradation
4
5
6
High
Loss of some product function but not of system performance
Extreme
Potentailly hazardous affect. possibly safety-related
Product safety of liability hazard
9
10
27
FMEA
28
14
Potential Causes
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
PG
VERIFICATION OR
CURRENT CONTROL
RPN
FMEA
30
15
Cause-Effect Model
FMEA
FAILURE
MODE
LIKELY EFFECTS
LIKELY CAUSES
TRIGGER
PREVENTIVE
ACTIONS
CONTINGENT
- ADAPTIVE
- CORRECTIVE
31
Occurrence
FMEA
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
VERIFICATION OR
CURRENT CONTROL
PG
RPN
32
16
Occurrence of Cause
FMEA
Design
Possible
Failure Rate
(DPPM)
Ranking
Remote
Failure is unlikely. No known failures associated with almost identical designs
<1 in 10
(<1)
Very Low
Only isolated failures associated with similar designs
< 1 in 20,000
(<50)
<1 in 4,000
(<250)
1 in 1,000
1 in 400
1 in 80
4
5
6
1 in 40
1 in 20
7
8
1 in 8
1 in 2
9
10
Low
Occassional failures associated with similar designs
Moderate
Previous designs have experienced problemsor occassiona lfactory out-of control
conditions
High
Similar designs have experience problems which have led to stop-ship conditions
Extreme
Failure almost inevitable
33
FMEA
34
17
Engineering Verification
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
PG
VERIFICATION OR
CURRENT CONTROL
RPN
35
Effectiveness
FMEA WORKSHEET
TYPE: DESIGN PROCESS OTHER___________________
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
VERIFICATION OR
CURRENT CONTROL
PG
RPN
36
18
FMEA
Ranking
Very Effective
Design evaluation controls will detect a design weakness prior to production release
1
2
High
Controls will have a good chance of detecting design weakness
Will be detectable after release but before build
3
4
M oderate
Controls may detect design weakness before initial shipment
Will be detected prior to shipment to customer
5
6
Low
Controls not likely to detect design weakness and must wait for larger volume
7
8
Very Low
Controls will probably not detect falure
Controls cannot ir will not detect failure
9
10
37
Effectiveness (Detection)
FMEA
38
19
FUNCTION
POTENTIAL
FAILURE MODE
EFFECTS OF
FAILURE
FMEA
PRODUCT:
ITEM:
ENGR
POTENTIAL
CAUSES
PG
VERIFICATION OR
CURRENT CONTROL
RPN
Occurrence
x Severity
x Effectiveness
RPN = O x S x E
39
Action Priority
FMEA
RPN range
OVER 200
100-199
26-99
1-25
40
20
FMEA
Ef
fec
tiv
en
es
s
RP
N
Oc
cu
rre
nc
Fa
ilu
Se
ve
rit
re
M
od
96
96
SAME RESULT
Handbook pg. 29
41
FMEA
Ef
fec
tiv
en
es
s
RP
N
Oc
cu
re
nc
y
Se
ve
rit
Fa
ilu
re
M
od
96
96
FOCUS ON SEVERITY
42
21
FMEA
SEVERITY
HIGH PRIORITY
MEDIUM
PRIORITY
LOW PRIORITY
1 2 3 4 5 6 7 8 9 10
OCCURRENCE
* Failure Modes and Effects Analysis, Paul Paladay, PT Publications, 1995
Actions
43
FMEA
22
Specifications
FMEA
What problems do we
encounter with specifications?
Component misspecification due to
communication problems
Unenforceable specs - cant be verified with
present technology
Improper specs - standard conditions can
be a trap! OR specs for past products no
longer sufficient for new ones
45
FMEA Homework 2
FMEA
23
FMEA Homework 2
FMEA
ADHESIVE
RECESSED AREA
FMEA
PRODUCT:
FMEA NO.
PART / SYSTEM:
P AR T OR
S YS TEM
FUNCTION(S)
POTENTIAL
FAILURE MODE
PAGE
DRAWING REFERENCE:
EFFECTS OF
FAILURE -LOCAL,
NEXT LEVEL, END
USER
EFFECTIVENES
OCCURRENCE
S
POTENTIAL
CAUSES OF
FAILURE
DATE:
DESIGN
VERIFICATION
ACTIVITES
OF
BY:
RPN = S x O x E
E R PN
ACTIO
N
RECOMMEN.
CORRECTIVE
ACTIONS
RESPONSIB
& DUE
DATE
R ES U LTIN G
ACTIONS
TAKEN
E RP N
48
24