Failure Mode and Effects Analysis. FMEA Fundamentals. Objective. U nderstand FMEA i s a risk assessment tool Present an overview of FMEA Review history of the tool Introduce terms, structure, types of FMEA’s Present a road map for construction
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Developed in the 60’s by NASA to identify single point failures on the Apollo project. SPF = any single piece of equipment that, if it fails, can bring your entire operation to a halt. (managed with redundancy)
US Navy adopted it in the 70’s for weapons programs.
In the 80’s, the automotive industry implemented FMEA and required its suppliers to do the same.
Current Controls All means of detecting the cause or the failure mode before it reaches the customer.
Let’s make a cup of coffee
Errors setting up work pieces
Processing wrong work piece
Equipment not set up properly
Tools or fixtures improperly prepared
Poor control procedures
Improper equipment maintenance
Lack of safety
Failure to enforce controls
Poor FMEA’sProcess Failure Causes
Methods and procedures?
Maintenance errors or the absence of maintenance?
Inaccuracies or malfunction of the measurement device?
Environment - chemicals, dust, vibration, temperature, humidity, shock?
Use the 6M’s to help brainstorm and organize potential causes of failures.
Mother Nature (Mileau)Questions to Help Identify Causes
Errors due to misunderstanding
Errors in identification
Errors made by amateurs
Errors due to slowness
Lack of standards
Establish a routine
Training for behavior modification
Training engagement and attentiveness
Training skill building,
Basic education, life experience
DisciplineAlmost all errors are caused by humans
Fixtures and jigs
Job sheets or process routings
Bar coding with software integration and control
Training and educational safeguards
Automation (real time control)
Statistical Process Control (SPC)
Post-process inspection or testingProcess Control Examples