9781563273773

The Basics of FMEA, 2nd Edition

by ;
  • ISBN13:

    9781563273773

  • ISBN10:

    1563273772

  • Edition: 2nd
  • Format: Paperback
  • Copyright: 2008-12-10
  • Publisher: Productivity Pr

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Supplemental Materials

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Summary

Originally designed to address safety concerns, Failure Mode and Effect Analysis (FMEA) is now used throughout the industry to prevent a wide range of process and product problems. Useful in both product design and manufacturing, FMEA can identify improvements early when product and process changes are relatively easy and inexpensive to make.

Table of Contents

Introductionp. ix
What Is an FMEA?p. 1
The History of FMEAsp. 1
What Is the Purpose of an FMEA?p. 3
Part of a Comprehensive Quality Systemp. 3
FMEAs and Bottom-Line Resultsp. 4
Example 1p. 4
Example 2p. 4
Example 3p. 5
ISO 9000, ISO/TS 16949, and FMEAsp. 7
The FMEA Processp. 9
Evaluating the Risk of Failurep. 10
Assessing the Risk Priority Numberp. 10
The FMEA Teamp. 11
FMEA Team Sizep. 11
FMEA Team Membershipp. 12
FMEA Team Leaderp. 12
The Role of the Process Expertp. 12
Training the FMEA Teamp. 13
FMEA Boundaries of Freedomp. 15
FMEA Scopep. 16
FMEA Start-Up Worksheetp. 17
Product/Design versus Process FMEAsp. 19
Product/Designp. 19
Processp. 20
Ten Steps for an FMEAp. 23
The FMEA Worksheetp. 23
Review the Process or Productp. 25
Brainstorm Potential Failure Modesp. 25
List Potential Effects for Each Failure Modep. 26
Assigning Severity, Occurrence, and Detection Rankingsp. 26
Assign a Severity Ranking for Each Effectp. 31
Assign an Occurrence Ranking for Each Failure Modep. 36
Assign a Detection Ranking for Each Failure Mode and/or Effectp. 36
Calculate the Risk Priority Number for Each Failure Modep. 36
Prioritize the Failure Modes for Actionp. 37
Take Action to Eliminate or Reduce the High-Risk Failure Modesp. 38
Calculate the Resulting RPN as the Failure Modes Are Reducedp. 38
FMEA Case Studyp. 41
Review the Processp. 41
Brainstorm Potential Failure Modesp. 42
List Potential Effects of Each Failure Modep. 42
Assign a Severity Ranking for Each Effectp. 46
Assign an Occurrence Ranking for Each Failure Modep. 46
Assign a Detection Ranking for Each Failure Mode and/or Effectp. 46
Calculate the Risk Priority Number for Each Failure Modep. 46
Prioritize the Failure Modes for Actionp. 47
Take Action to Eliminate or Reduce the High-Risk Failure Modesp. 47
Calculate the Resulting RPN as the Failure Modes Are Reduced or Eliminatedp. 47
When and Where to Use FMEAsp. 49
Safetyp. 49
Accounting/Financep. 50
Software Designp. 50
Information Systems/Technologyp. 50
Marketingp. 51
Human Resourcesp. 51
Purchasingp. 51
Creating a Process Flowchartp. 53
Brainstormingp. 57
Brainstorming Rulesp. 57
Reaching Consensus on Severity, Occurrence, and Detection Rankingsp. 59
Team Votingp. 59
Get the Process Expert Involvedp. 60
Defer to One of the Team Membersp. 60
Rank Failures and Effects within a Ranking Categoryp. 60
Talking It Outp. 61
Use the Higher Rankingp. 61
Examples of Custom Ranking Scalesp. 63
Process Improvement Techniquesp. 73
Mistake Proofingp. 73
Design of Experimentsp. 74
Statistical Process Controlp. 74
Team Problem Solving Using CI Toolsp. 75
ISO/TS 16949 Requirements Referencing FMEAsp. 77
Alternative FMEA Worksheetsp. 81
FMEA Glossary of Termsp. 85
Indexp. 87
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