MFMEA MANAGEMENT PROCESS

May 2004

MFMEA MANAGEMENT PROCESS WORKSHOP

Introduction - 5 min. Overview - 20 min. Process - 35 min. Break - 10 min. Expectations - 10 min. Workshop Example - 30 min. Q&A - 10 min.

MFMEA MANAGEMENT PROCESS WORKSHOP

OVERVIEW

MFMEA MANAGEMENT PROCESS OVERVIEW

Workshop objective
To communicate DaimlerChryslers recommendation on how Tooling & Equipment Suppliers should incorporate MFMEA (Machinery Failure Mode and Effect Analysis) activities during a program. To differentiate between the various types of FMEAs To clarify DaimlerChryslers expectations regarding the MFMEA management process

MFMEA MANAGEMENT PROCESS OVERVIEW

Why do you need to utilize MFMEAs?

MFMEA MANAGEMENT PROCESS OVERVIEW

Why do you need to utilize MFMEAs?
To increase the probability that machine failures and their effects on the customer will be reduced by eliminating or controlling potential (and historical) failure modes before the machinery is built To provide information for the planning of an effective preventive maintenance program resulting in reduced mean time to repair To prioritize potential failure modes so that the highest risk issues are addressed first To provide future reference in analyzing field concerns, evaluating design changes and developing new machinery designs

MFMEA MANAGEMENT PROCESS OVERVIEW

Which standards mandate the use of MFMEA?

DaimlerChryslers Advanced Quality Planning Requirement, Sec. 6 The Design Supplier shall utilize Machinery Design FMEAs that address issues regarding safety, cycle time, downtime, maintenance and product quality.

MFMEA MANAGEMENT PROCESS OVERVIEW

What is an MFMEA?
The Machinery FMEA is an analytical technique used to ensure that potential causes of failure modes, related to the operation of machinery, are identified and controlled to the greatest possible extent. It focuses at the machinery subsystem/component level to identify, and eliminate or control failure modes and their impact on machine performance by implementing corrective actions such as design changes, machine controls and preventive/predictive maintenance.

MFMEA MANAGEMENT PROCESS OVERVIEW

Is there a recommended MFMEA format?

Format is not as important as utilization of the Severity, Occurrence and Detection criteria/scale included in the manuals below. AIAG (Automotive Industry Action Group) format and manual, First Edition issued November 2001.

MFMEA MANAGEMENT PROCESS WORKSHOP

VARIOUS TYPES OF FMEAs

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MFMEA MANAGEMENT PROCESS OVERVIEW

Various types of FMEAs Customer Product DFMEA

Design evaluation of customer product along with every related system, subassembly, and component (Wiper motor, door assembly, I.P. assembly etc.)

Customer Process FMEA

Evaluation of customer manufacturing process to ensure that it meets operational requirement (Process to machine a head, process to assemble an underbody, process to assemble a seat, etc.)
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MFMEA MANAGEMENT PROCESS OVERVIEW

Various types of FMEAs continued

Machinery Design FMEA (MFMEA)
Evaluation of the overall operating performance of the machinery in a production environment (safety, reliability, maintainability, durability, PM, installation, specific machine quality issues, etc) (BIW/TCF assembly equipment, conveyors, machining lines, etc.)

Machinery Suppliers Internal Process FMEA

Evaluation of machinery suppliers internal processes (Estimating, processing, design, purchasing, build, etc.)
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CUSTOMER RESPONSIBLE FMEAs Product DFMEA

RESPONSIBLE Customer Design evaluation of customer product along with every related system, subassembly and component.

MACHINERY SUPPLIER RESPONSIBLE FMEAs Machinery Design FMEA (MFMEA)

Machinery Supplier

Customer Process FMEA

Customer

Machinery Supplier's Internal Process FMEA

Machinery Supplier

FOCUS

Evaluation of the overall operating performance of the machinery in Evaluation of (customer) process Evaluation of machinery supplier's a production environment (safety, design to ensure that it meets internal manufacturing and reliability, maintainability, operational requirements assembly process durability, cycle time, other specific machine quality issues) The machinery will meet the design intent and will be manufactured and assembled to the designed intent. The process will meet its design intent. New machinery designs, new technology, new process, modification to existing process or design, use of existing machinery in new environment End User (Customer: Plant Engineering + Maintenance + Production + Support Personnel)

ASSUMPTION

The machinery will meet the design intent and the product will The machinery capability be manufactured and assembled performance is defined. to the designed intent.

The machinery, as designed, will meet the designed intent.

New process, new machinery New product design, modification design, modification to existing to existing product design, use of NEEDED FOR design or process, use of existing existing design in new design or process in new environment environment End User + Design Responsible End User (Customer: Subsequent Engineers + Material Engineers + Manufacturing + Downstream WHO COULD Manufacturing + Assembly BE AFFECTED Manufacturing + Assembly Operation + Service + Quality + Operation + Service Operation) Suppliers FMEA START Beginning of product design process

New supplier's internal process, modification to existing process; new machinery when a generic FMEA cannot be applied Supplier Internal: Subsequent Manufacturing + Downstream Manufacturing + Assembly Operation + Service Operation

FMEA UTILIZATION

Prior to manufacturing of any machinery that will be used for production Beginning of supplier's internal Before the production drawings Prior to the start of machinery Prior to the start of machinery manufacturing and assembly are released for tooling design phase build process Note : FMEAs never finish; they are living documents that should be continually updated as changes to the original machinery design/process occur and/or new information is obtained After (customer) manufacturing During process verification phase process is defined

MFMEA MANAGEMENT PROCESS WORKSHOP

MFMEA MANAGEMENT PROCESS

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MFMEA MANAGEMENT PROCESS

Who has the lead responsibility for the MFMEA Management Process?
A. B. C. D. The machinery design responsible Supplier (Tier 1/OEM) The component design responsible Supplier (Tier 2) The AME Engineer The Supplier Quality Specialist

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MFMEA MANAGEMENT PROCESS

Who has the lead responsibility for the MFMEA Management Process?
A. B. C. D. The machinery design responsible Supplier (Tier 1/OEM) The component design responsible Supplier (Tier 2) The AME Engineer The Supplier Quality Specialist

Note: MFMEAs should be initiated and managed by the Suppliers Project Manager and supported by the Quality Department.
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MFMEA MANAGEMENT PROCESS

The MFMEA management process includes three steps:

Step I: Managing an MFMEA Kick-Off Meeting at the beginning of design phase Step II: Step III: Managing / Performing MFMEA activities Managing MFMEA Follow Up

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MFMEA MANAGEMENT PROCESS

Managing an MFMEA Kick-Off Meeting at the beginning of the design phase

1.

Identifying team members Defining OEM/Suppliers responsibilities Defining required supporting documentation Defining critical sub-system/component list

2. 3. 4.

Note: It is the OEMs responsibility to explain the purpose and objective of MFMEAs during this meeting.
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MFMEA MANAGEMENT PROCESS

MFMEA TEAM
OEM Project Management Design* Field Service * Quality DCX Engineering Process Engineering * Technicians DCX User Plant* Maintenance DCX Purchasing Quality Etc. As Required

Production Manufacturing Engineering

Buyer

Tool Follow Up

Tool Design

Tier 2 *

Design

* Minimum requirement

Field Service

Quality
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MFMEA MANAGEMENT PROCESS

OEM/Suppliers responsibilities:
Assigning an MFMEA manager/team leader Managing and scheduling all MFMEA design reviews Facilitating Tier-2, Tier-3 MFMEAs, if necessary Reviewing Tier-2, Tier-3 MFMEAs before presentation to DCX Issuing MFMEA Meeting Minutes Tracking status of all required MFMEAs via internal project MFMEA tracking matrix Tracking issues to closure Maintaining an Evidence Book (a part of the Project Book that contains all MFMEAs and supporting documentation) FAQ: What if a Tier-2 does not have their own MFMEA? The Tier-2 may not have pre-existing MFMEAs. If they do not have them, the OEM will make sure they come prepared with data to the MFMEA review meeting, and the Tier-1 will facilitate the MFMEA.
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MFMEA MANAGEMENT PROCESS

Required supporting documentation:

Step-by-step sequence of equipment operations (also for sub-system / components)* Process flow charts Layout drawings Sub-system/Component drawings* Sub-system/Component MFMEAs - Tier-2, Tier-3 Actual components, if possible Warranty/Service data, Field Performance data, Component Reliability studies Severity, Occurrence, Detection sheet* Corrective Action Requests, if any (external and internal) PM Task list (Recommended scheduled maintenance)* Revision history of the component

* Must Have
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MFMEA MANAGEMENT WORKSHOP

Critical sub-system / component list

(OEM) MFMEA team leader presents a list of all component suppliers and all components required for machinery design and build MFMEA team decides which sub-systems/components require an MFMEA, based on teams past experience and criticality of the component or subsystem. All required MFMEAs are listed in a standard project MFMEA tracking matrix used for MFMEA scheduling and status update

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MFMEA MANAGEMENT WORKSHOP

Critical sub-system / component list FAQ:

When is an MFMEA required? MFMEA is recommended for: New machinery designs, new technology, new process, modification to existing process or design, use of existing machinery in new environment. What kind of components/sub-systems do you perform MFMEAs for? MFMEAs are performed for replaceable components such as cylinders, cutting tools, slides, drive motors; or subsystems such as sealing systems, weld guns, an elevator etc. What if a supplier has an existing generic MFMEA? It still needs to be reviewed and updated with new information (flow chart, CARs - internal, DCX and other customers)
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MFMEA MANAGEMENT WORKSHOP

Critical sub-system / component list FAQ continued:

What if a same component/subsystem (Tier-2) MFMEA was done on a previous program under a different management? Although previously done, it still has to be reviewed and updated. What if there is a same Tier-2 supplier/component for different OEMs on the same program that requires an MFMEA? A SQA Specialist coordinates / schedules an MFMEA review or one of the OEMs takes a lead. Are all MFMEAs Tier-2 responsibilities? No, if a component/subsystem is an OEMs internal design, the MFMEA is done by the OEM.
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MFMEA MANAGEMENT WORKSHOP

Critical sub-system / component list FAQ continued:

Whose responsibilities are MFMEAs for component specified by DCX? Although DCX specifies component suppliers, it is still the OEMs responsibility to manage MFMEAs. What is SQA role in the MFMEA Management Process? If involved in a program, DCX Quality Specialists role is to: - Participate in MFMEA Kick-Off meetings - Coach MFMEAs, if necessary - Coordinate Tier-2 MFMEAs that are the same for different OEMs, if necessary - Help leverage Tier-2

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MFMEA MANAGEMENT PROCESS

The MFMEA management process includes three steps:

Step I: Managing an MFMEA Kick-Off Meeting at the beginning of design phase Step II: Step III: Managing / Performing MFMEA activities Managing MFMEA Follow Up

Note: It is the OEMs responsibility to assess if a Tier-2 MFMEA needs to be facilitated or reviewed only.

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MFMEA MANAGEMENT PROCESS

Managing / Performing MFMEA activities 1. Presenting a detailed step-by-step of the sequence of operations of the suppliers equipment 2. Reviewing field data, corrective actions & PM requirements 3. Utilizing the MFMEA process

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MFMEA MANAGEMENT PROCESS

Who Facilitates the MFMEA

A. B. C. D. The Plant Maintenance Manager The Supplier Quality Specialist The OEM Project Manager The OEM Project or Quality Engineer

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MFMEA MANAGEMENT PROCESS

Who Facilitates the MFMEA

A. B. C. D. The Plant Maintenance Manager The Supplier Quality Specialist The OEM Project Manager The OEM Project or Quality Engineer

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MFMEA MANAGEMENT PROCESS

The MFMEA management process includes three steps:

Step I: Managing an MFMEA Kick-Off Meeting at the beginning of design phase Step II: Step III: Managing / Performing MFMEA activities Managing MFMEA Follow Up

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MFMEA MANAGEMENT PROCESS

Managing MFMEA Follow Up

Follow Up is based on criticality or number of recommended actions Issues should be transferred to project issues tracking document with the assigned responsibility and timing Once issues are resolved, an updated MFMEA should be distributed Note: The MFMEA process for the specific project is not considered closed until all recommended actions are satisfied

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MFMEA MANAGEMENT PROCESS

Managing MFMEA Follow-Up FAQ:

Do we need to define an RPN threshold prior to the start of the MFMEA? YES No

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MFMEA MANAGEMENT PROCESS

Managing MFMEA Follow-Up FAQ:

Do we need to define an RPN threshold prior to the start of the MFMEA? NO The RPN should be used to prioritize actions. In many cases a predefined threshold drives the wrong behavior of trying to keep values under the defined threshold. Focus on the issues not the numbers!

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MFMEA MANAGEMENT PROCESS WORKSHOP

DAIMLERCHRYSLER EXPECTATIONS

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MFMEA MANAGEMENT PROCESS EXPECTATIONS

It is the expectation of DaimlerChrysler that all Tooling & Equipment Suppliers: Follow the MFMEA management process intent that was presented at this workshop Update MFMEAs continually as changes to the original machinery design/process occur and/or new information is obtained Utilize the MFMEA process for each project Issue meeting minutes after each MFMEA review / follow up Use MFMEA as a design review tool, not as a separate activity

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MFMEA MANAGEMENT PROCESS EXPECTATIONS continued

Have at least one person that is adequately trained in FMEA facilitation and is available for current projects Utilize MFMEAs with a team that consists of individuals who collectively possess a complete knowledge of the machinery and its process Utilize MFMEAs during the design phase, not after machinery is built Evaluate reliability and maintainability of existing similar equipment as a part of the MFMEA process

USE MFMEAs, DONT JUST DO THEM!

ASK QUESTIONS!

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MFMEA MANAGEMENT PROCESS WORKSHOP

EXAMPLE of MFMEA PROCESS at ABC COMPANY

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MFMEA KICK-OFF MTG AT ABC COMPANY

2002 CS UNDERBODY LINE EQUIPMENT Date: 02/03/01 Present: See attached attendees list w/phone numbers and e-mail addresses Meeting Agenda: Review DCX MFMEA Management Process Identify MFMEA team members (see attached list). Tim Moc, ABC company, identified as the MFMEA team leader Identify required MFMEA supporting documentation; including AIAG S, O, D criteria/scale Identify sub-system/components (critical list) that require an MFMEA, see the attached MFMEA Status Tracking Matrix- ABC company

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MFMEA STATUS TRACKING MATRIX ABC COMPANY (after initial MFMEA Kick-Off Mtg.)

Major System Underbody

System/Comp. Transfer System: Cross-Transfer Lift-Table Roller-Table Sealing Systems Clinch Nut Robot Weld Guns (Trans-guns)

Supplier (OEM/2nd)

Preparation Date

MFMEA Reviewed (DC)

Notes/Comments

% Complete 0% 0% 0% 0% 0% 0% 0%

XYZ XYZ XYZ DFG Co. Fastener Group Welding Corp.

Overall % Complete

0.00%

Updated by Tim Moc on Feb. 4, 01

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POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS MACHINERY FMEA

System: Sealing Systems Subsystem: Controlled Pressure Sealer Gun Component: Regulator Program/Plant: CS / Windsor Core Team: T. Smith, J. Jones, P. Borick
C l a s s Potential Cause(s)/ Mechanism(s) of Failure O c c u r D e t e c Action Results S O Actions e c Taken v c

FMEA #: Page: 1 of 3 Design Responsibility: Key Date: DFG Company 15-Oct-01 Prepared by:

001-CS T. Smith

FMEA Date (Orig.): 15-Oct-01 (Rev.): 5-Jan-02

Item / Function

Potential Failure Mode

Potential Effect(s) of Failure

S e v

Current Controls -Prevention -Detection

R P N

Recomm. Actions

Resp. & Target Compl. Date

D e t

R P N

Constant Pressure Fluid Regulator

Fluid (sealer) leakage

Incorrect amount of sealer to product (part quality issue)

Worn packing seal caused by sealer incompatibility

None

10

250

Perform reliability testing to determine compatibility performance between packing seal and sealer type (sealer packing seal interaction)

J. Jones / 30-Nov-01

Fluid flow rate is proportional to voltage input

Added 5 verification / reliability testing for assessing compatibility (interaction) between packing seal and sealer type to design process. Re: Test Doc. 10-01

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Worn shaft

1 Design reliability 2 testing validates shaft performance (1 mil. Cycles)

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None required.

Regulates sealer flow to specifications (width 4mm x height 2mm)

Proportional air valve regulator fails to control air source for proper sealer flow

Sealer flow not 5 to specification (part quality issue). Regulator requires replacement

Lost of external air source to regulator causes overheat condition

3 None

10

150

Add pressure sensing switch to monitor air flow from external source (Switch signals system shut down under no-air flow condition)

J. Jones / 20-Jan-02

Pressure switch (Model No. FTC-125) added to system. Design validation testing completed on 5-Jan-02.

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MFMEA STATUS TRACKING MATRIX ABC COMPANY (after DFG Co MFMEA Review)

Major System Underbody

System/Comp. Transfer System: Cross-Transfer Lift-Table Roller-Table

Supplier (OEM/2nd)

Preparation Date

MFMEA Reviewed (DC)

Notes/Comments

% Complete 0% 0% 0% 0%

XYZ XYZ XYZ

Pending Pending Pending

Sealing Systems

DFG Co.

15-Oct-01

5-Nov-01

Pressure switch addition under review. Ref. Open Action Item No. 77. Reliability testing for compatibility of packing seal and sealer type in process. Ref. Open Action Item No. 78 No action items identified

30%

Clinch Nut Robot Weld Guns (Trans-guns)

Fastener Group Welding Corp.

1-Oct-01 Pending

10-Oct-01

100% 0%

Overall % Complete

16.25%

Updated by Tim Moc on Nov. 16, 01

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EXAMPLE: PROJECT OPEN ISSUES ABC COMPANY - 2002 CS UNDERBODY LINE EQUIPMENT
ABC Company
T roy, Michigan T elephone: (810) XXX XXXX, T elefax: (810) XXX XXXX

OPEN ACTION ITEMS

Last Meeting: 1/22/2002 Last Update: 1/22/2002 Project Description: UNDERBO DY LINE Project Manager: Tim Moc

Item No Priority

Issue / Concern Pneumatic regulator fails due to overheating caused by insufficient air supplied to device

O riginator

Date Entered

Resolution

Person Responsible

Due Date

Date Resolved

Status

77

Green

MFMEA

78

Green

Packing seals worn due to sealer incompatibility

MFMEA

11-15-01 : Under investigation 12-12-01 : Design validation test in progress (adding 15-Nov-01 pressure switch to monitor air source). 11-15-01: Verification / reliability testing for assessing compatibility (interaction) between packing seal and sealer type in process (Ref. DFG Co. Test Document 1015-Nov-02 01). Target completion date 11-30-01.

T . Glass

1/20/2002

1/20/2002

Closed

T . Glass

11/30/2001

11/30/2001

Closed

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MFMEA MANAGEMENT PROCESS WORKSHOP

QUESTIONS?

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