making the fmea training effective
TRANSCRIPT
Making the FMEA Training Effective
By
Norma Simons
Performance Innovation LLC
What is an FMEA
A process that:O Recognizes and evaluates
potential failure modesO Identif ies causes of failureO Identif ies actions which could
prevent failuresO Documents ideas of the team
System FMEA
Machinery FMEA
Process FMEA
Design FMEA
Subsystems
Components
Manufacturing Process
Assembly
Equipment
Tooling
The FMEA addresses:
O The function the system/process/product per forms
O The way in which failure can occur
O The ef fect of failure on the customer
O The severity of the failure
O
The Voice of the Customer
The FMEA Addresses: (Con’t.)
O The possible causes of the failure O The l ikelihood that the cause wil l
result in the failureO Mechanisms to prevent or detect the
failure modeO Reliabil ity of the detection
mechanismsO The risks associated with the failure
The Voice of the Company/Engineer
Five Major Elements for Effective Application of the FMEA
O Cross-functional training for key personnel
O Involvement required by each team member
O Train around a company projectO Establish guidelines for continuing the
FMEAO Have a coach or facilitator provide
additional support
Cross-Functional Training for Key Personnel
•• A Training program on FMEA offered for
one or two days
• Training should include• Benefits of FMEA• Use of FMEA forms• Steps for Developing the FMEA• Discussion on systemic issues
for implementing FMEA
• Cross- functional training especially from the same organization helps to view the information from different perspective•
Train around Company Project
• Select a company project prior to training
• Select teams who will work on the project
• Begin applying FMEA concepts to the projects selected towards the end of the training session
FunctionalApproach
O Used early in design
O Easy to change
O Considers the function of each part.
O Used when design is complete
O Difficult to change
O Involves listing each part and its failure modes.
HardwareApproach
DFMEA
Involvement of each Team Member
Sample of documents required for a typical PFMEA
Other inputs:• Scrap, rework and customer complaints from similar products• Measurement systems• Machine performance• Process Capability• Process Controls etc.•••
Guidelines for Continuing the FMEA
O Use a consistent manualO Agree on definition of termsO Agree on scoring guidelines for the severity, occurrence
and detectionO Determine how to establish priorities for corrective
actionsO Establish team management guidelines
O How often to meetO Length of meetingO Documentation of FMEA
Coach/Facilitator for Additional Support
O Use a coach – internal or external for additional support
O Support provided on-site or on-lineO Use of checklist at the end of the FMEAO Conduct audits on the production floor to
evaluate the effectiveness of the FMEAO Identify performance measures such as
customer complaints, on time delivery performance
Contact InformationNorma Simons
39555 Orchard Hills Place, Suite 600
Novi, Michigan 48375
248 529 6701 (office)
248 417 0762 (cell)
www.performance-innovation.com