Welcome -- Day 1

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Welcome -- Day 1

• Failure Mode and Effects Analysis

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FTEP Modules
Quick QFD
Systems Engineering Fundamentals
Global 8D
Ford Technical Education Program
FMEA
Process Control Methods
ExperimentalDesign
Reliability
Parameter Design
ToleranceDesign
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Warm-Up -- Day 1
Place Self Others Team Purpose
Agenda
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(No Transcript)
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Course Purpose
These three days are designed to ... help you
function effectively as an FMEA team member,
but not to leave as an FMEA team leader or an
FMEA expert
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Participant Materials

• Questionnaire
• Only one correct answer is possible
• Do NOT guess if unsure of answer

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FMEA -- An Introduction

• Why Do FMEAs?
• Definition, Purpose, Types, Benefits
• FMEA Working Model
• Generating / Managing
• Team Approach

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Ford 2000 Strategies
EmpoweredPeople
Achieve Worldwide Growth
Ford
The Worlds Leading Automotive Company
Achieve Worldwide Product Excellence
The Low CostProducer
Lead in Corporate Citizenship
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(No Transcript)
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Why Do FMEAs?

• Appropriate recommended actions may not have been
  taken
• Significant savings in engineering time --
  reduction in changes immediately before and after
  Job 1

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FMEA -- Definition
Structured group of activities which ...

• Recognize and evaluate the potential failure of a
  product or process and its effects
• Identify actions which could eliminate or reduce
  the chance of the potential failure occurring
• Document the process

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FMEA Purposes
Failures
Time
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FMEA Purposes
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FMEA -- Purposes
FMEAs are intended to ...

• Identify potential failure modes and rate
  severity of effects
• Identify critical and significant characteristics
  
• Help engineers prioritize and focus on
  eliminating product and process concerns and
  helps prevent problems from occurring
• Test adequacy of controls from DCP process

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FMEA -- Types
Concept FMEA
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Benefits -- Concept FMEAs
Design

• Helps select optimum concept
• Identifies potential failure modes
• Considers potential effects
• Helps generate occurrence ratings
• Identifies testing requirements
• Helps determine if hardware system redundancy is
  required

Concept
Process
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Benefits -- Design FMEAs
Design

• Aids in evaluating requirements and alternatives
• Aids in initial design for DFM
• Increases probability of detecting failure modes
  and their effects
• Provides additional information for testing
  requirements
• Helps identify critical and significant
  characteristics
• Helps validate DVPs and SDSs

Concept
Process
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Benefits -- Process FMEAs
Design

• Identifies potential product related failure
  modes
• Assesses effects on all customers
• Identifies potential Manufacturing and Assembly
  causes to focus controls on reducing occurrence
  and/or increasing detection
• Establishes a priority system for considering
  corrective actions
• Identifies confirmed critical and significant
  characteristics

Concept
Process
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FMEA Working Model
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Generating FMEAs
Who initiates?
Who prepares?
Who updates?
Who is FMEA customer?
When to discard?
Failure Mode and Effects Analysis
FMEAs
When started and updated?
How is FMEA documented?
Relationshipto FPDS?
When is FMEA complete?
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Managing FMEAs
FMEAs are living documents, and are updated when
...

• Modification to a component, process or system is
  planned
• Component is to be used in new environment
• Customer concern arises Global 8D

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FMEAs and Systems Engineering
Customer
Customer
Customer Focus
Musts / Wants
Satisfaction
Customer Experience Feedback
CFMEA
Vehicle Level Inputs
Customer
Purchase, Operate

Purchaser / owner / operator
Disposal
Maintain
Requirements

Regulatory (FMVSS, EPA, ...)

Corporate (WCR, ABS, Manuf, ...)
Requirements
Feasibility
Feedback
Cascade
Vehicle Level Requirements
Vehicle

Vehicle Attributes
DVM / DVP
Production
Verification

Vehicle System Specification - VDS
Feasibility
Requirements
Feedback
Cascade
DFMEA
System / Subsystem Level
PFMEA
DVM / DVP
System

System
Verification

Subsystem Design Specifications -
SDS
Requirements
Feasibility
Feedback
Cascade
Part /
Part/
Component Fabrication /
Verification
Component Design
Component Design Specification - CDS

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Team Approach -- FMEA
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Section Summary

• Why Do FMEAs?
• Definition, Purpose, Types, Benefits
• FMEA Working Model
• Generating / Managing
• Team Approach

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Break
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Design FMEA -- An Introduction

• Identify FMEA Team
• Establish Scope
• Describe Function
• Brainstorming
• Function Trees
• Practice Exercise 1

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Design FMEA
Scope
Team
Team
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Design FMEA -- Team
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Design FMEA -- Scope
Once core team is established...

• Create a block diagram
• Identify the boundary for analysis
• Confirm composition of the support team

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Constructing Block Diagrams
Component/Assembly
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Block Diagram -- Example
Headlamp Assembly
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Block Diagram -- Example
Vertical Trimmer Assembly
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Block Diagram -- Example
Lateral Location Screw
Clips 2
Reflector
Vehicle BodyUpper CrossMember
VerticalTrimmerAssembly
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Determine Function
Scope
Team
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What is Function ?

• Design intent or engineering requirement
• Must be measurable or set at an actionable level
• Representation of all wants, needs and
  requirements, both spoken and unspoken

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Describe Function
Generate Control Dispense Retain Prevent
Light Speed Fuel Seat Track Rust
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Describe Function

• Thought Starters ...
• Satisfy user
• Attract user
• Assure convenience
• Assure dependability
• Governmental requirements
• Safety requirements

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Brainstorming

• Exercise in creative thinking
• Method to generate ideas

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Brainstorming -- Guidelines

• Warm up
• Suspend judgment
• Anything goes
• Quantity counts
• Springboard
• Persevere
• Warm down

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Brainstorming -- Pitfalls

• Low team trust
• Broad task definition
• Criticism, competition, defensiveness
• Silliness, lack of focus
• Questions and explanations
• Organizing ideas during creative stage

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Brainstorming -- Agreement

• Everyone explains view(s)
• Identify needs of individuals
• If you cant meet a need, say so
• Check out feelings -- yours / others
• Dont compromise, average, or split the
  difference

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Function Trees

• Provide an organized approach to identify the
  essential features of a product (or process
  sometimes)
• Help ensure that unspoken and spoken
  requirements are defined
• Provide a graphical representation of functions
  to ensure clear, total team understanding

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Constructing Function Trees
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Vertical Trimmer Function Tree
Adjust Headlamp
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Guidelines

• Brainstorm all functions (VERB - NOUN)
• Document individual functions by asking HOW is
  function achieved?
• Repeat left to right, until actionable level
• Use worksheet to check that actionable level is
  measurable
• Work right to left and check structure by asking
  WHY is function included?

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Practice Exercise 1

• Block diagram
• Brainstorming
• Function Tree

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(No Transcript)
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Presentation -- Practice 1
Team Debrief
Technical Debrief
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Design FMEA Functions
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Section Summary

• Identify FMEA Team
• Establish Scope
• Describe Function
• Brainstorming
• Function Trees
• Practice Exercise 1

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Design FMEA Path 1

• Failure Modes
• Effects -- Severity
• Recommended Actions
• Potential Special Characteristics
• Practice Exercise 2

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Design FMEA -- Path 1
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Potential Failure Modes
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Potential Failure Modes
Failure Mode Type Potential Failure Mode
No function Partial function Intermittent
function Unintended function
Not operational Not all of function
operating Occasionally does not
function Unexpected function occurs
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Failure Modes -- Vertical Trimmer
Failure Mode Adjust Light Beam X in Both
Directions
Failure Mode Type Potential Failure Mode
No function No adjustment Partial
function Adjustment in one direction Intermittent
function Adjustment sometimes and not at
others Unintended function Trimmer itself
produces light
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Effects of Failure Modes
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Effects of Failure Modes
Failure Mode 1
Function 1
Failure Mode n
Function 2
Function n
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Design FMEA -- Effects Table
Vertical Trimmer
Failure Mode Doesnt Retain Setting
Vehicle (-) Impaired Night/Fog Perforsmance
Govt Regs Road Vehicle Light Regs 89 F/CMVSS
Non-Compliance
Custmr Driver Impaired Night/Fog Vision
Part / SC Trimmer May Be Stripped By Adjustment
Attempt
Assbly Headlamp Cannot be Adjusted
System Lt System Misaligned Lightbeam
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Design FMEA -- Severity
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Suggested Severity Evaluation Criteria
Criteria Severity of Effect
Ranking
Effect
Hazardous Without Warning
... affects safe vehicle operation and/or
government regulation without warning
10
... affects safe vehicle operation and/or
government regulation with warning
Hazardous With Warning
9
operable at reduced level of performance.
Customer experience some dissatisfaction
5
Low
No Effect
None
1
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DFMEA Severity Rating Example
Item
Vertical Trimmer/ Retains Setting
Potential Failure Mode Does not maintain
adjustment
SEV
Potential Effects of Failure Part May be
stripped during adjustment (7) Assembly
Headlamp cannot be adjusted
(6) System Misaligned lightbeam (8) Vehicle
Impaired night/fog performance (7) Govt Regs
Non-compliance (10) Customer Impaired night/
fog (7)
Function
10
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DFMEA -- Recommended Actions
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Select and Manage Actions
Consider This Action
To Accomplish This
To Reduce


Eliminate failure mode(s) ...
Severity
Change the design ...






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Identify Potential Special Characteristics
Design FMEA
S9 S10
YC
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Practice Exercise 2
Failure Modes Effects Severity
Recommended Actions Classifications
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Break
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Managing FMEAs
FMEAplus
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Presentation -- Practice 2
Team Debrief
Technical Debrief
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Section Summary

• Failure Modes
• Effects -- Severity
• Recommended Actions
• Potential Special Characteristics
• Practice Exercise 2

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Warm-Down -- Day 1
Others
Self
Place
Team
Agenda
Purpose

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Course Purpose
These three days are designed to ... help you
function effectively as an FMEA team member,
but not to leave as an FMEA team leader or an
FMEA expert
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Day 1
Failure Mode and Effects Analysis