Warm-Up -- Day 2

Place Self Others Team

Purpose Agenda
 Team Definition
A team is a small number of people with
complementary skills who are committed to a
common purpose, performance goals and
approach for which they hold themselves
mutually responsible
 Warm-Up -- Teams
What can go wrong -- failure mode
What is the effect -- 1 failure mode
Why could it go wrong -- causes
What actions would you recommend
 Course Purpose
These three days are designed to ...
help you function effectively
as an FMEA team member,
but not to leave as an FMEA
team leader or an FMEA expert
 FMEA -- Review Day 1
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 FMEA -- Review Day 1
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Function
1

Function
2

Function
3 Sub- Sub-Sub-
Function Function
Function
n
Function Sub- Sub-Sub-
Function Function

Sub- Sub-Sub-
Function Function
 FMEA -- Review Day 1
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Function
1

Function
2

Function
3 Potential Failure Modes:
Function
n
No function
Partial function
Intermittent function
Unintended function
 FMEA -- Review Day 1
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Failure
Mode 1
Function
1
Failure
Mode n

Function
Potential Effects of Failure Modes:
2 Parts / Sub-components
Assembly
System
Function
n Vehicle
Government Regulations
Customer (Internal and End User)
 FMEA -- Review Day 1
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 Design FMEA Paths 2 and 3
Path 2:
Causes -- Occurrence
Day Actions
2 Special Characteristics
DFMEA Path 3:
Paths 2 & 3 Design Controls
Assessing Risk
Actions
Practice Exercise 3
 Design FMEA Path 2
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 Potential Cause of Failure
An indication of a design weakness, the
consequence of which is the failure mode

5-17
 What Might Cause Failure?
Two Assumptions for Cause ...
Item is manufactured and assembled within
engineering specifications
Design may include a deficiency that may
cause unacceptable variation (misbuilds,
errors, etc.)

5-18
Manufacturing Misbuilds
Due to Design Deficiencies

+ +
- -
Manufacturing Misbuilds
Due to Design Deficiencies

+ +
- -
 Causes of Failure
Use a Fishbone Diagram

Broken Bracket Loose Thread

Support Area
too Small
No
Adjustment
Thread Fusion
Material Propagation
Screw Thread Oversize
Engine Heat Thread Contamination

B-4
Thread Seizure
 Causes of Failure -- Why Ladder
Broken Bracket

Material
cracked
Bending
Level 1 WHY? overstress
Level 2 WHY? Support area
too small
Level 3
WHY?
 Sentencing Technique

Could result in Effect

Failure
Mode Due to
Cause
Sentencing Technique Example

Misaligned
Could result in
Beams
No
Adjustment
Due to
Thread
Seizure
 Causes of Failures
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Function Failure
1 Mode 1

Failure
Mode 2

Failure
Mode n
WHY?

M E P E M
 Design FMEA -- Occurrence
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

5-22
Suggested Occurrence Evaluation Criteria

Probability of Failure Possible Failure Rates Ranking

Very High: Failure is 1 in 2 10

almost inevitable 1 in 3 9

1 in 80 6
Moderate: Occasional
failures 1 in 400 5
1 in 2,000 4

Remote: Failure unlikely 1 in 1,500,000 1

 Recommended Actions
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 Select and Manage Actions
To Reduce: Consider This Action: To Accomplish This:

Severity Change the design ... Eliminate failure

mode(s)

Occurrence Change the design or Prevent cause(s), or

improve engineering reduce their rate of
specifications ... occurrence

3-37
 Identify Potential Special Characteristics

Design FMEA

S<8
S=9 S>5
S=10 O>4

YC YS

7-4
 Design FMEA Path 3
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c
 DFMEA -- Design Controls
1. Prevent the cause/mechanism or failure
mode/effect from occurring, or reduce
their rate of occurrence,
2. Detect the cause/mechanism and lead to
corrective action, and
3. Detect the failure mode.

5-25
 Design FMEA -- Detection
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

5-28
Suggested Detection Evaluation Criteria
Detection Criteria: Likelihood of Ranking
detection by design control
Absolute Design control will not and/or
Uncertainty cannot detect a potential cause 10
or there is no design control

Moderately Moderately high chance the

High design control will detect 4
potential cause and ...

Almost Design control will almost

Certain certainly detect a potential 1
cause ...
 Assessing Risk

Severity (S)

Severity X Occurrence (S X O)

Severity X Occurrence X Detection

(S X O X D) = RPN

5-31
 RPN -- Examples
S XO X

D
= RPN
2 10
10
 RPN -- Examples
S XO X

D
= RPN
10 2
2
 Select and Manage Actions
To Reduce: Consider This Action: To Accomplish This:

Severity Change the design ... Eliminate failure

mode(s) ...

Occurrence Change the design or Prevent cause(s), or

improve engineering reduce their rate of
specifications ... occurrence

Detection Add or improve the Improve ability to

design control detect a failure
methods mode ...

3-37
 Future Actions
Potential
___ System
Failure Mode and Effects Analysis
FMEA Number:
___ Subsystem Page 1 of 1
___ Component Design Responsibility:
Key Date: Prepared by:
Model Year / Vehicle(s): / FMEA Date (Orig): (Rev)
Core Team:

Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O DR
Failure Effect(s) e l Cause(s)/ c Process e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Action Results
Actions S O D R
Taken e c e P
v c t N
 Practice Exercise 3

Function
Potential Causes
Occurrence
Actions
Design Controls
Detection
RPN
Break
Presentation -- Practice 3

Technical Team
Debrief Debrief
 Section Summary
Path 2:
Causes -- Occurrence
Day Actions
2 Special Characteristics
DFMEA Path 3:
Paths 2 & 3 Design Controls
Assessing Risk
Actions
Practice Exercise 3
 Process FMEA
Path 1: Team -- Scope -- Purpose
Identify Failure Modes
Effects -- Severity
Day Select / Manage Actions
2 Path 2: Causes -- Occurrence
Select / Manage Actions
PFMEA Special Characteristics
Path 3: Process Controls
Paths 1-2-3 Assessing Risk
Select / Manage Actions
Practice Exercise 4
 Process FMEA
Potential
Failure Mode and Effects Analysis

Scope
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component

Team
Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c
 Process FMEA -- Team
Facilitator or Application Engineer
Technical Affairs
Representatives
Support from:
Team Specialists

Manufacturing / Suppliers
Process Engineer CORE Maintenance
Design Engineer Team
Production
Next Process
Engineer
 Process FMEA -- Scope
Create macro flow diagram
Identify boundary for analysis
Create micro flow diagram
Confirm support team composition

6-5
 Headlamp Assembly -- Macro
Assemble Bulb to 50
Assemble Bulb
10 Reflector
Holder

Bulb Test 60
Assemble Lens
20
to Reflector
Assemble Rear Cover 70
Assemble
Vertical Trimmer to 30
Reflector Photometric Test 80

Assemble Horizontal 40
Trimmer to Reflector Load onto Pallet

Inspection Operation Storage Transportation

 Headlamp Assembly -- Micro
Op 30 - Assemble Vertical Trimmer to Reflector
Locate and fix (2 screws)
30.1
base plate to reflector

Insert nose and positively

locate pre-assembled 30.2
screw and spring

Visually inspect trimmer 30.3

assembly
 Process Purpose Statements
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c
 Define Process Purpose
What does the process do at this operation?
Ensure that all process purposes are
considered

6-9
 Micro Flow -- Process Purpose
Purpose
Locate and fix (2 screws) Locate base plate --
base plate to reflector 30.1 correct orientation
Secure 2 screws to
specified torque
Insert nose and positively
Insert nose to correct
locate pre-assembled 30.2 position per visual aid
screw and spring Positively locate
screw/spring
sub-assembly
Visually inspect trimmer Visually inspect (to
30.3
assembly comply with part
drawing): screw,
spring, location, fixing
 Determine What Can Go Wrong
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-10
 Effects of Failure Modes
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-13
 Effects of Failure
Failure Mode: One or More Screws Not Fully Secured

Next Downstream Ultimate Vehicle Operator Government

Failure User Users Customer Operation Safety Regulations

Mode
None Repair / Visibility Headlamp None Non-
Rework impaired may not compliance
at night be able
and in fog to be
adjusted or
maintain
adjustment
 Process FMEA -- Severity
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-15
 Suggested Severity Evaluation Criteria

Effect Criteria: Severity of Effect Ranking

Hazardous May endanger machine or assembly
Without operator noncompliance with 10
Warning government regulation without warning

Hazardous May endanger machine or assembly

With Warning operator noncompliance with 9
government regulation with warning

Minor disruption to production line

Low 100% of product may have to be 5
reworked ...

No Effect
None 1
 PFMEA Path 1-- Actions
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-31
 Select and Manage Actions
To Reduce: Consider This Action: To Accomplish This:

Severity Change the design or Eliminate failure

the process if operator mode(s) ...
safety is involved ...

3-37
 Process FMEA Path 2
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c
 Assumptions for Cause
Two Assumptions for Cause ...
Assume in-coming parts are correct, what
would cause the operation to fail in this
manner?
What incoming sources of variation could
cause the operation to fail in this manner?

6-19
 Process FMEA -- Causes
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Action Results
Item Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
Function s Failure u e
s r c

Failure
Mode 1
Function
1
Failure
Mode n

WHY?
Function
2

M E P E M
Function
n
 Sentencing Technique

Could result in Effect

Failure
Mode Due to
Cause
 Process FMEA -- Occurrence
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-22
 Suggested Occurrence Evaluation Criteria

Probability of Possible Cpk Ranking

Failure Failure Rates

Very High: Failure is 1 in 2 0.33 10

almost inevitable 1 in 3 0.33 9

Low: Isolated failures 1 in 15,000 1.3

associated with similar 3 33
processes

Remote: Failure is 1 in 1,500,000 1.67 1

unlikely
 Recommended Actions
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-31
 Select and Manage Actions
To Reduce: Consider This Action: To Accomplish This:

Severity Change the design ... or Eliminate failure

the process if operator mode(s) ...
safety is involved ...

Occurrence Change the design or Prevent cause(s), or

process ... reduce their rate of
occurrence

3-37
 Process FMEA -- Path 3
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c
 Process Controls
1. Prevent cause / mechanism or failure mode
from occurring, or reduce rate of
occurrence,
2. Detect cause / mechanism and lead to
corrective actions, and
3. Detect failure mode

6-25
 Process FMEA -- Detection
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-27
 Suggested Detection Evaluation Criteria

Detection Criteria: Likelihood the existence of Ranking

a defect will be detected by process
controls before next or subsequent
process, or before part or
component leaves the
manufacturing or assembly location

Almost No known controls available

Impossible to detect failure modes 10

Moderately Moderately high likelihood

4
High current controls will detect ...

Almost Current control(s) almost 1

certain certain to detect ...
 Assessing Risk

Severity (S)

Severity X Occurrence (S X O)

Severity X Occurrence X Detection

(S X O X D) = RPN

6-30
 Recommended Actions
Potential
Failure Mode and Effects Analysis
___ System FMEA Number:
Design Responsibility:
___ Subsystem Page 1 of 1
Key Date:
___ Component Prepared by:
Model Year / Vehicle(s): FMEA Date ( Orig): (Rev)
Core Team:
Process Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O D R
Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

6-31
 Select and Manage Actions
To Reduce: Consider This Action: To Accomplish This:

Severity Change the design ... or Eliminate failure

the process if operator mode(s) ...
safety is involved ...

Occurrence Change the design or Prevent cause(s), or

process ... reduce their rate of
occurrence

Detection Add or improve the Improve ability to

control methods ... detect a failure
mode ...

3-37
 Future Actions
Potential
___ System
Failure Mode and Effects Analysis
FMEA Number:
___ Subsystem Page 1 of 1
___ Component Design Responsibility:
Key Date: Prepared by:
Model Year / Vehicle(s): / FMEA Date (Orig): (Rev)
Core Team:

Process
Action Results
Function Potential Potential S C Potential O Current D R Responsibility & S O DR
Failure Effect(s) e l Cause(s)/ c Process e P Recommended Target Actions e c e P
Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken v c t N
s Failure u e
Requirements s r c

Action Results
Actions S O D R
Taken e c e P
v c t N

3-32
 Special Characteristics
Special Characteristics involve those
products and/or process characteristics
which affect ...
Vehicle or process safety,
Compliance with government regulations, or
Customer satisfaction

7-4
 Special Characteristics
CRITICAL: Requirements that affect
compliance with government regulations
or safe vehicle / product function and
require special controls (S= 9 or 10)

SC SIGNIFICANT: Product and/or test requirements

important for customer satisfaction, summarized on
Control Plan and require special controls
(S = 5 to 8, O>3)

7-4
 Special Characteristics
OS OPERATOR SAFETY: Related to process parameter
that does not affect product but may have an impact
to safety, or government regulation applicable to
process operation
HI HIGH IMPACT: Product or process characteristics
when outside of specification tolerance severely
affect the operation of process itself or subsequent
operations (Does not require special controls)

7-5
 Special Controls
Above normal and customary which
drive process detection rating to 1 ...
Interim control directed by manufacturing,
Aimed at detecting and containing a
Special Characteristic-related defect prior
to shipment, and
Documented on Control Plans
7-6
 Identify Special Characteristics

7-11
 Managing FMEA Meetings
Circulate all relevant Information ahead of
meeting
Book meetings well in advance and
schedule adequate breaks
Clearly define objectives
Establish / adhere to effective roles
Communicate effectively
 Managing FMEAs
Consider likely changes to RPNs for
proposed actions before being implemented
Project manage agreed actions
Re-issue a revised FMEA
Process FMEA -- Exercise 4

Scope--Purpose
Failure Modes
Effects--Severity

Causes--Occurrence
Process Controls
Detection
Actions
Break
Presentation -- Practice 4

Technical Team
Debrief Debrief
 Section Summary
Path 1: Team -- Scope -- Purpose
Identify Failure Modes
Effects -- Severity
Day Select / Manage Actions
2

Path 2: Causes -- Occurrence

PFMEA Select / Manage Actions

Special Characteristics
Paths 1-2-3 Path 3: Process Controls
Assessing Risk
Select / Manage Actions
Practice Exercise 4
 Warm-Down -- Day 2
Place Self Others Team
Purpose Agenda
 Course Purpose
These three days are designed to ...
help you function effectively
as an FMEA team member,
but not to leave as an FMEA
team leader or an FMEA expert