Welcome -- Day 3

Failure Mode and Effects Analysis

 Warm-Up -- Day 3

Place Self Others Team

Purpose Agenda
FMEA Challenge

B
A C
A
 Team Warm-Up
Team Asks If Correct
A B 10 Points
If incorrect
Team Asks If Correct
A C 5 Points
If incorrect

Team Asks If Correct

A A 10 (-10)
 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
 Concept FMEA

Definitions
Day Functional Block
3
Diagrams
Concept FMEA Differences in ...
Path 1
Path 2
Path 3
 Concept FMEA
System
Design
Design
FMEA Sub-System
FMEA
Concept Component
Concept
FMEA
FMEA

Process
Process
Assembly
FMEA
FMEA
Manufacturing
 Concept FMEA
New forward illumination
system
Design
Design
FMEA Headlight without bulb
FMEA
Concept New aiming element
Concept
FMEA
FMEA

Electrostatic painting
Process
Process of lighting housing
FMEA
FMEA
New method of creating
holes
 Concept FMEA -- Team
Facilitator or Application Engineer
Technical Affairs
Representatives
Support from:
Advanced ... Team Service
Component
Engineer CORE Specialists
Team Suppliers
Manufacturing
Engineer System Testing
Quality Engineer Marketing Rep
 Functional Block Diagram
Electrical Power Body

User Input Light

Optic Light
Mechanism Source

Auto Aiming
Mechanism

Electrical Power
 Concept FMEA -- Path 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:
System Action Results
Description 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
System
Function
s Failure u e
s r c
 Concept 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:
System Action Results
Description 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
System
Function
s Failure u e
s r c
 Concept 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:
System Action Results
Description 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
System
Function
s Failure u e
s r c
 C-FMEA -- Design Controls
Typical Controls
Computer simulation
Mathematical modeling
Load calculations
Environmental
Laboratory

4-16
 Concept 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:
System Action Results
Description 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
System
Function
s Failure u e
s r c
 Section Summary
Definitions
Day Functional Block
3
Diagrams
Concept FMEA Differences in ...
Path 1
Path 2
Path 3
 Force Field Analysis
Systems Theory
Day Driving Forces
3
Restraining Forces
Force Field Practice Exercise 5
Analysis
 Systems Theory
A system is a set of elements each related
to each other
Related elements thrive on feedback
Causes and effects happening within the
system are circular versus linear
System has to have defined boundaries
 System Forces
Current ts of a
System
e men
E l
S y stem
Ne w

Driving Restraining
Forces Forces

VISION
 Practice Exercise 5

Driving Restraining
Forces Forces
 Section Summary
Systems Theory
Day Driving Forces
3
Restraining Forces
Force Field Practice Exercise 5
Analysis
Break
 FMEA Linkage

FMEA linkage
Day Inputs to FMEAs
3

Outputs from FMEAs
FMEA Linkage Practice Exercise 6
 Practice Exercise 6

DFMEA
DFMEA
IN
PUT CFMEA
CFMEA
S PFMEA
PFMEA
DFMEA
DFMEA
CFMEA
CFMEA
TS
PFMEA
PFMEA P U
T
OU
 Section Summary

FMEA linkage
Day Inputs to FMEAs
3

Outputs from FMEAs
FMEA Linkage Practice Exercise 6
 Evaluating FMEAs

Identify weaknesses
Day in an existing FMEA
3 Review sample of a
Evaluating well-done FMEA
FMEAs
 FMEA Header
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
 Function / Purpose
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
 Potential Failure Mode
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
 Potential Effect(s) of Failure
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
 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
 Classification
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
Potential Causes/Mechanism(s) Failure

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
 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
 Appropriate Controls Applied
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
 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
 Risk Priority Number
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
 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
 Responsibility & Target Completion Date

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
 Results
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
 Section Summary

Identify weaknesses
Day in an existing FMEA
3 Review sample of a
Evaluating well-done FMEA
FMEAs
FMEA Summary Exercise
Gather necessary
materials
Choose
team/roles
Monitor time
Complete all
tasks
Prepare Team
Process Review
Presentation -- Summary Exercise

Technical Team
Debrief Debrief
 Warm-Down -- Day 3
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
Pre-Post Comparisons