Popcorn%20Sample%20PFMEA:%20Process%20Flow

1
Popcorn Sample PFMEAProcess Flow

• Review Process Flow Diagram Steps
• Notice Specifications when Present
• Refer to Other Specifications if Required
• Notice Tools Required for Process

2
Popcorn Sample PFMEAPFMEA Body

• Review Process Steps
• Review Associated Potential Failure Modes
• Review Associated Effects
• Review Associated Causes
• Review Associated Controls

3
Popcorn Sample PFMEARisk (RPN)

• Review Severity Ranking
• Review Occurrence Ranking
• Review Detection Ranking
• Review RPN Calculation

4
Popcorn Sample PFMEACorrective Action

• Review High RPN Values (High Risk)
• Review Corrective Actions

5
Popcorn Sample PFMEAControl Plan

• Translate Corrective Actions and Controls into
  a Quality Control Plan

6
Group Project Hose Valve PFMEA

• Develop a Process FMEA for a Garden Hose Valve
  Assembly
• Work Groups of Five
• One Person is the Recorder
• Use Brainstorming Technique, Take Turns
• Remember, There are No Bad Suggestions

7
Hose Valve PFMEAProduct Review

• Review Hose Valve Assembly and Function
• Remove Large Flat O-ring
• Remove Screw and Lever
• Remove Valve Ball
• Remove Small O-ring

8
Hose Valve PFMEASpecifications

• Review Customer Specifications
• Specifications are the Criteria for Failure
  Modes
• Which Specifications are Design and which are
  Process?
• Which Specifications can be Translated into
  Controls?

9
Hose Valve PFMEAProcess Flow Diagram

• Review Process Flow and Operations
• Notice Required Tools/Equipment
• Notice Control Characteristics
• What Needs to be Added...PFMEA to Determine

10
Hose Valve PFMEAProcess Operations

• List Process Steps in FMEA and Number
• One Process Step Per FMEA Page

11
Hose Valve PFMEAFailure Modes

• List Failure Modes Associated with Process Step
• Brainstorm and Discuss...is it Realistic?
• Try Assembling per Process Flow Steps

12
Hose Valve PFMEAEffects, Causes, and Controls

• List the Effects of the Failure Modes
• List the Root Cause of the Failure Modes
• List the Control Mechanisms to Prevent or
  Detect the Failure Mode

13
Hose Valve PFMEADetermine Ranking

• Review Ranking Criteria
• Determine, List Severity Value
• Determine, List Occurrence Value
• Determine, List Detection Value

14
Hose Valve PFMEARPN

• Calculate Risk Priority Number, RPN
• RPN S x O x D
• Immediate Corrective Action for RPN gt 90
• Continuous Improvement for RPN lt 90, Top Three
  Issues

15
Hose Valve PFMEACorrective Action

• Determine Recommended Actions
• Assign Responsibility, Implementation Date
• Implement Actions
• Re-evaluate S, O, D, and RPN for Acceptance

16
Hose Valve PFMEAControl Plan Development

• Translate Control Mechanisms into Control Plan
• Translate Control Mechanisms into Work
  Instructions and Standard Operating Procedures