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Rolls-Royce Proprietary
FMEA Origination The different types FMEA FMEAs Link with Continuous Improvement Our focus is on Process FMEA FMEA Worksheet Why we use FMEA When to use FMEA Potential Applications of FMEA Steps on completing FMEA
Rolls-Royce Proprietary
Developed by the Aerospace industry in the 1960s Spread to the Automotive industry Now used extensively across all industry sectors Reference SAE J-1739
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Process
An analytical technique used primarily by a Manufacturing Engineer/Team as a means to assure potential failure modes, causes and effects have been addressed for process related characteristics
Rolls-Royce Proprietary
Concept: To identify ways the product or process can fail and then plan
to prevent those failures, utilising mistake proofing tools and techniques.
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Problem:
T eam Members: Occurrence: Scores: High No. low No. High No. Low No. High No. Low No. (10) (1) (10) (1) (10) (1) Frequently/with certainty Rarely Dangerous/warranty statistic Not Significant Detection very unlikely Easily detected Recommende d C orre ctive Action
Issued By:
Revision: Date:
Assumptions:
Severity: Detection:
R e f. P a rt No . No . Na m e Is s ue
Function or Process
Failure Mode
Effect O f Failure
C ause O f Failure
Current C ontrols
C u rre n t S t a t u s
RPN
By
C o m p 'l D a te
C omme nts
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Why we use FMEA? rather than cure. Increase probability of DETECTION Identify biggest contributor to failures and eliminate them Reduce probability of failure occurring Build quality into the product & process
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Complex Part
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Observations
Quality data
Quality audit - material cert. Not stamped
20
Mill Profile
30
Heat Treatment
40 50
60
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Ref. P a rt No . No . Name Is s ue
Function or Process
Failure Mode
Effect O f Failure
Cause O f Failure
Current Controls
C urre nt S ta
OP 10 Issue Mat'l
OP 30 Heat treatment
OP 50 Final Inspection
Definition Effects of failure -Effects Effect - impact on customer requirements. Generally external customer focus, but can also include downstream processes.
Does not fit Can not load/fasten Poor performance Intermittent operation Erratic operation
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Step 3 - Identify potential effects of failures For each failure mode, identify the effect(s) on the current or next process or customer downstream in the manufacturing/assembly process. Describe the effects of the failure in terms of what the customer might notice or experience
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P a rt No . Na m e Is s ue OP 1 0
Function or Process
Failure Mode
Ultilizing wro ng m a te ria l
Effect O f Failure
Cause O f Failure
Current Controls
C u rre n t S t a t u s
RPN
0 0 0
OP 2 0
0 0 0 0
OP 3 0
He a t tre a tm e nt
0 0 0
OP 4 0
Drill a nd ta p Ho le
0 0 0 0
OP 5 0
Non-conforming part delivered to customer Safety issue Non-conforming part delivered to customer Traceability Failure to meet P/O requirement
0 0 0
Op 6 0
M a rk, P a c k & R e le a s e
3 1
0 0 0
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Definition - Causes Sources of process variation that causes the Failure Mode to occur.
Part not in fixture properly incorrect tool gage inaccurate
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P a rt No . Na m e Is s ue OP 1 0
Function or Proce ss
Failure Mode
Ultilizing wro ng m a te ria l
Effect O f Failure
fa ilure to m e e t Drg. R e quire m e nts
Cause O f Failure
C urrent Controls
C u rre n t S t a t u s
RPN
Safety issue
F a ilure to m e e t P ro file To le ra nc e S urfa c e finis h Va ria nt pa rt R e wo rk/S c ra p
Incorrect info. on router Material ID incorrectly Incorrect cutter Position of part on fixture Worn tooling
6 6
2 3 2 1 2
0 0 0
OP 2 0
3 3 3
0 0 0 0
OP 3 0
He a t tre a tm e nt
Incorrect Temp Incorrect Time Incorrect cutter Position of part on fixture Worn tooling
6 6
2 6 2 5 2
0 0 0
OP 4 0
P a rt do e s no t fit a t a s s e m bly
3 3 3
0 0 0 0
OP 5 0
No n-c o nfo rm ing pa rt de live re d to c us to m e r S a fe ty is s ue No n-c o nfo rm ing pa rt de live re d to c us to m e r Tra c ibility F a ilure to m e e t P /o re quire m e nt
6 6
2 1
0 0 0
Op 6 0
M a rk, P a c k & R e le a s e
3 3 1
6 2 4
0 0 0
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Rating 1 2 3 4 5 6 7 8 9 10
R e f. P a rt No . No . Na m e Is s ue
Function or Process
Failure Mode
Effect O f Failure
C ause O f Failure
C urrent C ontrols
C u rre n t S t a
OP 1 0
Is s ue M a t'l
Safety issue
F a ilure to m e e t P ro file To le ra nc e S urfa c e finis h
Training, audited procedure. Password protected router ID with marker. Operator training
2 4
OP 2 0
Va ria nt pa rt R e wo rk/S c ra p
Cutter identified Mistake proof fixture Process control -Change after a fixed # of parts
3 3
2 1
3 1 2
Wo rn to o ling
OP 3 0
F a ilure to m e e t da ta c a rd F a ilure to m e e t re quire m e nts re quire d m a t'l He a t tre a tm e nt (te m p/tim e ) pro pe rtie s
Inc o rre c t Te m p
1 6
OP 4 0
Drill a nd ta p Ho le
Cutter identified Operator skill Operator skill Inspection check list. Training and auditing of inspectors Calibration system. Audited procedure
3 3 3
2 5 2
3 4 4
OP 5 0
F a ilure to fully No n-c o nfo rm ing ins pe c t a ll pa rt de live re d to F ina l Ins pe c tio n fe a ture s c us to m e r
2 1
S a fe ty is s ue
De fe c tive ga ge
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Step 9 - Calculate the Risk Priority Numbers RPN = Risk Priority Number Multiply severity, occurrence and detection rankings together
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R e f. P a rt No . No . Na m e Is s ue OP 1 0
Function or Proce ss
Failure Mode
Effe ct O f Failure
Cause O f Failure
C urre nt C ontrols
ID with m a rke r. Ope ra to r tra ining Tra ining, a udite d pro c e dure . P a s s wo rd pro te c te d ro ute r
C u rre n t S t a t u s
RPN
72 24 18 12 3
Safety issue
F a ilure to m e e t P ro file To le ra nc e S urfa c e finis h
OP 2 0
3 3 3
2 2 1
3 2 1
OP 3 0
He a t tre a tm e nt
6 6
6 2
6 1
216 12 60 24 18
OP 4 0
Drill a nd ta p Ho le
P a rt do e s no t fit a t a s s e m bly
Ope ra to r s kill P ro c e s s c o ntro l -C ha nge a fte r a fixe d # o f pa rts C utte r ide ntifie d
3 3 3
5 2 2
4 4 3
OP 5 0
Ine xpe rie nc e o f Ins pe c tio n c he c k lis t. ins pe c to r/inc o m pre he ns ive Tra ining a nd a uditing o f c he c klis t ins pe c to rs C a libra tio n s ys te m . Audite d De fe c tive ga ge pro c e dure o pe ra to r e rro r/ unc le a r ins truc tio ns Inc o rre c t pa pe rwo rk o pe ra to r fa ile d to c o unt
6 6
2 1
2 1
24 6 162 12 8
Op 6 0
M a rk, P a c k & R e le a s e
3 3 1
6 2 4
9 2 2
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R e f. P a rt No . No . Na m e Is s ue
Function or Process
Failure Mode
Effe ct O f Failure
Cause O f Failure
C urrent C ontrols
C u rre n t S t a t u s
RPN
OP 1 0
Is s ue M a t'l
ID with m a rke r. Ope ra to r tra ining Tra ining, a udite d pro c e dure . P a s s wo rd pro te c te d ro ute r
72 24 18 12 3
Material stores to have 5's. All mat'l to be identified with labels. Re training. Regular audits
OP 2 0
3 3 3
2 2 1
3 2 1
OP 3 0
He a t tre a tm e nt
6 6
6 2
6 1
Calibrated clock that is part of the heattreat contol 216 system 12 Mistake proof fixture.Positive location
OP 4 0
Drill a nd ta p Ho le
Ope ra to r s kill P ro c e s s c o ntro l -C ha nge a fte r a fixe d # o f pa rts C utte r ide ntifie d Ins pe c tio n c he c k lis t. Tra ining a nd a uditing o f ins pe c to rs C a libra tio n s ys te m . Audite d pro c e dure
3 3 3
5 2 2
4 4 3
60 24 18
OP 5 0
6 6
2 1
2 1
24 6 Insert a mark part # operation prior to final view plus produce clear work instructions with 162 photos for operator 12 8
Op 6 0
M a rk, P a c k & R e le a s e
3 3 1
6 2 4
9 2 2
F a ilure to m e e t P /o re quire m e nt
o pe ra to r fa ile d to c o unt
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Reassess rankings when action completed FMEA must be a live document Review regularly Reassess rankings whenever changes made to product and/or process Add any new defects or potential problems when found
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QS9000 FMEA reference manual(SAE J 1739) Free Quality Tools Web Site
Www.freequality.org
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