risikomanagement mit fmea in zeiten agiler ... · pdf filefmea product: system analysis:...
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DIETZ Consultants, All rights reserved 11
Who we are
We speak:
� Boston | Wallenhorst | Berlin | Pune | Nanjing
ProjectsLocations
New Customers:
DIETZ Consultants, All rights reserved 22
Dietz Consultants ManagementDietz Consultants
GM Lassie LiCEO Winfried Dietz
Company Overview
Dietz ConsultantsDietz Business
Consultants Co. Ltd.
� Founded in 1990
� Headquartered in Berlin - Germany
� Founded in 2015
� Headquartered in Nanjing - China
Innovation & Risk Management
Quality & Production Systems
Supply Chain Management
“To provide leading edge consulting services and training that supports our clients to achieve excellence and continual improvement“
Our Mission
DIETZ Consultants, All rights reserved 44
FMEA und kognitive Verzerrung
Ein Baseballschläger und ein Ball kosten zusammen:1,10 €
Der Schläger kostet einen Euro mehr als der Ball!Was kostet der Ball?10 Cent? Wir akzeptieren die erste plausible Zahl, die uns in den Sinn kommt – und vermeiden die Anstrengung des NachdenkensDas trifft auch auf Risikobewertungen und FMEA zu!
Quelle:Irreführende Intuition (Daniel Kahneman); Israelisch-US-amerikanischer Psychologe, erhielt 2002 den „Wirtschafts-Nobelpreis“ (Urteilsheuristiken und kognitive Verzerrungen); Autor: Schnelles Denken, Langsames Denken
Unsere Gehirnarchtektur
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FMEA und kognitive Verzerrung
Der Ball kostet der Ball?0,05 €
Das war ein Beispiel für:„Schnelles Denken“Denken im „System 1“System 1 arbeitet:Automatisch, mühelos, ohne willentliche Steuerung.Optimal: Säbelzahntigerjagd, Rennwagen fahren, DiscobesucheSuboptimal: Kernreaktoren betreiben, Chef-/Kundengespräche, Risikoanalysen u. FMEA
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17 x 177 =?
• Exakte Lösung fällt nicht sofort ein
• Entscheiden: Berechnung durchführen?
• Zielgerichtete Anstrengung
• Strukturierung
• Körperbeteiligung (Muskulatur, Herzschlag, Pupillen,..)
1. „Langsames Denken“
2. Denken im „System 2“
FMEA und kognitive Verzerrung
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FMEA und kognitive Verzerrung
System 2 arbeitet:
• Mit Handlungsvollmacht, absorbiert Aufmerksamkeit, ist
anstrengend
• Optimal: Kernreaktoren betreiben, Chef-/Kundengespräche
führen, Risikoanalysen u. FMEA realisieren
• Suboptimal: Säbelzahntigerjagd, Rennwagen fahren,
Discobesuche
Achtung: Ihr System 2 denkt fälschlicherweise, dass es die
Kontrolle besitzt (gilt auch für die Experten bei FMEA)
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Anticipate : Build Quality into the product and process design
modification of data
costs are relatively low
Cost
of
ch
an
ges
hardware-modifications
costs are very high!
FMEA:document
FMEA:anticipate
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Erfolgsfaktoren für antizipierende Risikobewertungen
FMEA
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They are willing to fail
They enjoy their time alone
They are prepared to work and succeed on their own merits
They have staying power
They evaluate their core beliefs
They expand their mental energy wisely
They think productively
They tolerate discomfort
They reflect on their progress They move on
They keep control
They embrace change
They stay happy
They are kind
They are willing to take calculated risks
They invest their energy in the present
They accept full responsibility for their past behaviour
They celebrate other people’s success
18 THINGS MENTALLY STRONG PEOPLE DO
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Industry 4.0 will change the way we work
New business models: dirven by networking (instead of products )
Future!Past!
Scalelable
(more = better)Easy to anticipate
Hardware Quality
Failure modes and validation procedures will be late to identify !
Networks
Structures by
technologies
Iterative Design (Srum, Design
Thinking,..)Agil
Permanent
Beta
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� The Design-FMEA examines the demanded functions of products and systems up to dimensioning of features and characteristics
� The Process-FMEA examines processes for producing products and systems up to requirements regarding factors of influence.
Types of FMEA
Best Practice
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FMEA in the product development process
PlanningProductdevelopment
Processdevelopment
Product andprocessvalidation
Series production
FMEA (product and process)
MSA
PPAP / PPF
Conception, initiation, approval
Approval,Pre-development
PrototypePilot production,(prototype)
Series startup
APQP / Maturity validation of new parts (RGA)
SPC
8D Method
Feedback, evaluation and corrective action
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Memory jogger : key terms for FMEA risk mnagement
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
Failure-Mode- andEffects-Analysis
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FMEA Teams
S-FMEA D-FMEA P-FMEA
Core Team
� Moderator
� Developer
� Project leader
� Sale
� System experts
Optional
� Testing
� Customer service
� Technology experts
Core Team� Moderator
� Developer
� Designer
� Project leader
� Testing
� Quality assurance
� Production
Optional� Customer service
� Purchase / Logistic
� Technology experts
Core Team� Moderator
� Production planner
� Production
� Mounting
� Designer
� Project leader
� Testing
� Quality assurance production
Optional� Tool construction
� Logistic
� Process experts
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Typische Werkzeuge: Produktentstehung
� QFD: The customers “voice“ controls the product development process
� FMEA:
� FMEA Product: System analysis: Verification and optimization of the design concept (complete system, complexe sub systems, safety concepts, project risks)
� FMEA Product: Construction: Verification and optimization of the construction design (assemblies, components)
� FMEA Process: Verification and optimization of the production- / assembly process
� DoE: (Design of Experiments ): Robust Processes
� SPC: (Statistical Process Control): Steering of capable processes in control
� Process Control Plans: Active, passive & failsafe technologies
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FMEA-Procedure - an overview
Prepare the FMEA
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
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FMEA-Workflow
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
DIETZ Consultants, All rights reserved 2222
Performing a structural analysis means to illustrate the system elements hierarchically structured in order to describe system-relationships. The structural analysis’ level of detail results from goals set for the FMEA.
Tree structure:
� System elements
� Hierarchically description of structural relationships
Strukturanalyse
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1. level 2. level 3. level 4. level 5. level
ASSDriver door
CGEngine
PT Guide railASS
Window
ASSCar body
PT Glass
ASSWindow operator
ASSPassenger
door
Interface: Driver door/
car bodyCG Trans-missionASS – Assembly
CG – Component GroupPT – Part
Structure tree of a product FMEA
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Structure tree of a process-FMEA
Degreasingagent
Washing 1
Carburization
Chilling
Operator
Washingmachine
Components
Gas carburising
Level 1
Overall process
Level 2
Sub-process
Level 3
4 M‘s
Washing 2
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FMEA-Workflow
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
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Functional analysis
After describing the system element’s function precisely, we illustrate the interaction of functions from different system elements via linked functions nets.
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� A Parameter Diagram (P diagram) presents the correlation between systemparameters in the form of a block diagramm
� A P-diagram is the ideal introuction to an FMEA:� System elements of the FMEA and its functions are determined and� easily visualised
� A P-diagram consists of the following elements and relationships:
Parameter Diagram (P-diagram)
System function
Control Parameters
Noise Parameters
Input variables
Output variablesdesired
Output variablesundesired
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FMEA-Workflow
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
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Failure analysis
We derive the possible malfunctions (red) from the functions (green) every system element has and link them to create a failure net.
The malfunctions position within the failure net determines if it is a effect, failure mode or cause.
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Failure analysis
Multiple malfunctions can be assigned to a function:
Function: provide voltage of 42V
� MF 1: Voltage too low
� MF 2: Voltage too high
� MF 3: Voltage pulsates incorrect
� MF 4: No voltage
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Failure net
Why?Why?
Effect? Effect?
CG Window
Raising / lowering not possible
PT Guide rail
Groove geometry too small
ASS Window operator
Too little adjustment force initiated on PT
window
ASS Driver door
Interior not tight
ASS Driver door
Defined opening not possible
Failure effects
Failure type(Focus element)
Failure causes
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Failure net
Why?Why?
Effect? Effect?
Washing
Malfunction: Grease content on the
surface too high
OperatorMalfunction: wrong
washing program set
Washing machine
Malfunction:temperature too low
Gas carburising
Tech. requierements not met – testing rejected
goods
Gas carburising
Economic goals not met – costs of post-
processing
Failure effects
Failure type(Focus element)
Failure causes
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FMEA-Workflow
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
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Measures analysis
We describe existing measures which are aimed to prevent or detect causes of failure.
We perform a risk assessment for each combination of failure effect, failure, causes of failure and measures to prevent and detect causes of failure.
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Challenge: detection rate
visual inspection „wrong varnished /fender /metal sheet“
35
� Random failure (few vehicles)
� Easily recognizable failure
� 100%- visual inspection
� Random failure (few vehicles)
� Heavy recognizable failure
� 100%- visual inspection
D=3 D=9
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FMEA-Workflow
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
DIETZ Consultants, All rights reserved 3737
FMEA-Workflow
The 5 steps (according to VDA)
1. Structural analysis
2. Functional analysis
3. Failure analysis
4. Measures analysis
5. Optimiziation
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