Failure Mode & Effect AnalysisWhat is FMEA?ReliabilityReliability RequirementsFailure RateIntent of FMEAFMEA TeamFMEA DocumentationClass Assignment !!!!!!Stages of FMEASpecifying PossibilitiesQuantifying RiskCorrecting High Risk CausesRe-evaluation of RiskThe Design FMEA DocumentSlide 16The Design FMEA Document (Con. 1)The Process FMEA Document (Con. 2)Limitations:?Questions?Failure Mode & Effect AnalysisTom Hannan & Kevin KowalisEastern Illinois UniversitySchool of TechnologyTotal Quality SystemsINT 5133(FMEA)What is FMEA?“Is an analytical technique that combines the technology and experience of people in identifying foreseeable failure modes of a product or process and planning for its elimination.” () Before-The-Event action that makes it easier to find flaws in the systemORReliabilityIs the probability of the product to perform as expected for a certain period of time, under the given operating conditions, and at a given set of product performance characteristics.Reliability RequirementsBased on the definition of the part, assembly, or process under consideration, the reliability of each sub-system and the factors involved in the reliability must be found, and the appropriate relationships for each part, class, or module of the product must be computed.Failure RatePeriods of failure can conveniently be modeled by an exponential distribution, and the probability of survival of the product or process may be viewed as:Rt = e ^(-T *F) = e ^ -(T/o)Rt = the period of operation without failureT = time specified for operation w/o failureF = Failure rateO = the mean time to failureIntent of FMEA An Essential Part of Total Quality Management is FMEA! • Provides Training• Tracks the progress of a project• Helps communicating similar problems• Uncovers oversights, misjudgments, and errors• Calculate the probabilities of failures•Determine if product or process failure effects on other aspects.FMEA TeamFMEA methodology is a team effort where the responsible engineer involves who?• Assembly• Manufacturing• Materials• Quality• Service• Supplier• CustomerFMEA Documentation• Block Diagram• Design or Process Intent• The Customer Needs and Wants• The FMEA FormClass Assignment !!!!!!Divide up into four groups (N,S,E and W)• Change Tire• Flashlight• Unicycle• BicycleMake A Simple Block DiagramStages of FMEA • Quantifying Risk• Correcting High Risk Causes• Specifying Possibilities• Re-evaluation of RiskSpecifying PossibilitiesFunctionsPossible Failure ModesRoot CausesEffectsDetection/PreventionQuantifying RiskProbability of CauseSeverity of EffectEffectiveness of Control to Prevent CauseRisk Priority NumberCorrecting High Risk CausesPrioritizing WorkDetailing ActionAssigning Action ResponsibilityCheck Points on CompletionRe-evaluation of RiskRecalculation of Risk Priority NumberRPN = (S) * (O) * (D)S = SEVERITYO = OCCURRENCED = DETECTION RAKING19The Design FMEA Document• Item • Design Responsibility• Prepared By• Model Number/Year• Key Date• FMEA Date• Core Team• FMEA NumberThe Design FMEA Document• Item/Function• Potential Failure Mode• Potential Effect(s) of Failure• Severity (S)• Classification (CLASS)• Potential Cause(s)/Mechanism(s) of Failure• Occurrence (O)The Design FMEA Document (Con. 1)Current Design ControlsDetection (D)Risk Priority Number (RPN)Recommended ActionsResponsibility and Target Completion DatesActions TakenThe Process FMEA Document (Con. 2)Process Function/RequirementsPotential Failure ModePotential Effect(s) of FailureSeverity (S)Classification (CLASS)Potential Cause(s)/Mechanism(s) of FailureOccurrence (O)Current Process ControlsLimitations:FMEA document’s do not fix the identified problemDef. of the action to fix the problemWill not replace the basic problem-solving
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