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Introduction
Welcome to the FMEA WorksheetThis spreadsheet can be used to
1. Identify potential failure modes and their impact on product reliability.2. Rank the potential defects to establish priority - The highest RPN value items deserve the most attention.3. Capture owners, action plans, and status on high RPN items.
Note, FMEA's are living documents and this may be updated periodically.
Organization of Spreadsheet:
Sheet Protection:Some sheets are protected. There is no password. Released for review: 31-Jul-98
A. Dembski rev 1
Descriptions - explains the spreadsheet cellsFMEA - the actual sheet used to enter dataSeverity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categoriesExample - a partial exmample of an FMEA document
Introduction
Rank the potential defects to establish priority - The highest RPN value items deserve the most attention.
Descriptions
Page 3
Description of FMEA Worksheet
System Potential FMEA Number
Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of
Action Results
Item / Function Actions Taken
New
Sev
New
Occ
New
Det
New
RP
N
0 0Leak 8 Over pressure 8 1 64 0
0 00 00 00 00 0
0 0
0 00 00 00 00 00 00 0
Protection:The spreadsheets are not protected or locked.
Potential Failure Mode(s)
Potential Effect(s) of Failure
Sev
Potential Cause(s)/
Mechanism(s) of Failure
Prob
Current Design Controls
Det
RPN
Recommended Action(s)
Responsibility & Target Completion
Date
Coolant containment. Hose connection. Coolant fill. M
Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete
Burst, validation pressure cycle.
Test included in prototype and production validation testing.
J.P. Aguire 11/1/95 E. Eglin 8/1/96
Response Plans and Tracking
Risk Priority Number - The combined weighting of Severity, Likelihood, and Detectability.RPN = Sev X Occ X Det
Likelihood - Write down the potential cause(s), and on a scale of 1-10, rate the Likelihood of each failure (10= most likely). See Likelihood sheet.
Severity - On a scale of 1-10, rate the Severity of each failure (10= most severe). See Severity sheet.
Detectability - Examine the current design, then, on a scale of 1-10, rate the Detectability of each failure(10 = least detectable). See Detectability sheet.
Write down each failure mode and potential consequence(s) of that failure.
Descriptions
Page 4
0 0
Likelihood - Write down the potential cause(s), and on a scale of 1-10, rate the Likelihood of each failure (10= most likely). See Likelihood sheet.
Detectability - Examine the current design, then, on a scale of 1-10, rate the Detectability of each failure(10 = least detectable). See Detectability sheet.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
5
System Design Verification Process Potential FMEA Number Project IIISubsystem Failure Mode and Effects Analysis Prepared By Houston MayerComponent (Design FMEA) FMEA Date 10/22/1999Design Lead Houston Mayer Key Date Revision Date 8/21/2000Core Team See Project III R1 Report Page 1 of 6
Action Results
Item / Function Actions Taken
New
Sev
New
Occ
New
Det
New
RPN
7 Human error 1 3 21 Closed 10/21/99 0
Data entry error 3 Human error 1 3 9 Closed 10/21/99 0
7 3 3 63 Jun-00 0
1 5 CII 033-001-006 1 5 Sep-00 OPEN 8/21/00
Potential Failure Mode(s)
Potential Effect(s) of Failure
Sev
Potential Cause(s)/ Mechanism(s) of
Failure
Prob
Current Design Controls
Det
RPN
Recommended Action(s)
Responsibility & Target Completion
Date
Customer sends in a quote request for product.
System, Software, Integration and Shipping requirements overlooked by customer.
Customer needs not fully met by delivered system.
Design configuration tool.
Use configuration tool when available.
Requirement entered and verified by Inside Sales in config. tool.
System compatability requirements not evaluated by config. tool.
Order verified by a configuration tool.
Continue order verification by configuration tool.
Sales identifies need for CII or SHC
Specific packing, labeling and shipping requirements may not be fully addressed.
On time delivery and integraty of the product may be compramised if this issue is not addressed.
Requirements Overlooked.
Customer Inspection Instruction/ Special Handling Codes Process 033-001-02
Publish comprehensive procedure for the 1st Article Process.
Customer shipping requirements reviewed by quality assurance in 1st Article process.
Position of the DHR in ICD label packet not identified by GE.Requirment in Purchase Specification for mousepad, but not identified on Bill of Material.ICD Card content requirements not identified in Build Procedure.
Loss of business with the customer.
Requirements Overlooked.
Revisit contents of GE CII 033-001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
6
7 3 3 63 Closed 10/25/99 0
Data entry error 1 Human Error 1 3 3 Closed 1/25/00 0
3 6 3 54 Closed 10/25/99 0
1 Process Failure 1 1 1 Closed 1/25/00 0
1 Process Failure 1 1 1 Closed 1/25/00 0
7 Process Failure 3 3 63 Closed 10/25/99 0
1 Process Failure 1 1 1 Closed 1/25/00 0
QA and Pack and Ship Team reviews customer requirements during a 1st Article.
Specific packing, labeling and shipping requirements may not be fully addressed.
Customer's full expectations may not be realized.
Requirements overlooked.
Customer requirements physically verified by quality assurance during the 1st Article process.
Continue current pracices.
Inside sales submits Sales Order Authorization request to TECenter.
Order Processing Delay
Customer requirements verified by a TECenter engineer.
Continue current practices.
TECenter Engineer reviews the design to determain if additional data is required.
Requirements overlooked by Engineer
Customer's full expectations may not be realized.
Requirements Overlooked.
Customer requirements verified by a TECenter engineer.
Continue current practices.
Appropriate individuals are contacted to resolve issues.
Appropriate individuals not available.
Order Processing Delay
Individuals are contacted to resolve issues.
Continue current practices.
Design Review is completed.
Requirements may not be complete
Customer's full expectations may not be realized.
Customer requirements verified by a TECenter engineer.
Continue current pracices.
Another engineer performs quality check of the design.
Requirements overlooked by two Engineer
Customer's full expectations may not be realized.
Customer requirements verified by a TECenter engineer.
Continue current pracices.
Completed design verification is sent to appropriate organization.
Design verification misrouted
Order Processing Delay
Verification is sent to appropriate organization.
Continue current pracices.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
7
1 Process Failure 1 1 1 Closed 1/25/00 0
3 Process Failure 1 1 3 Closed 1/25/00 0
Order misrouted 1 Process Failure 1 1 1 Closed 1/27/00 0
Data Entry Error 3 Human Error 1 1 3 Closed 1/27/00 0
1 Process Failure 1 Expidite Process 1 1 Closed 1/27/00 0
1 Process Failure 1 Expidite Process 1 1 Closed 1/27/00 0
5 3 1 15 Closed 10/25/99 0
1 1 Expidite Process 1 1 Closed 1/27/00 0
1 Process Failure 1 Expidite Process 1 1 Closed 1/27/00 0
Requirements are defined and capability to meet/ accept requirements.
Requirements may be missed or capibilty to meet overestamated
Customer's full expectations may not be realized.
Requirements are defined and to meet requirements.
Continue current pracices.
Inside Sales quotes price and availability
Wrong price and availability provided to customer
Customer's full expectations may not be realized.
Price provided to customer
Continue current pracices.
Customer sends in purchase order.
Order Processing Delay
Reprocess Order
Continue current pracices.
Inside sales places order on system.
Order Processing Delay
Reprocess Order
Continue current pracices.
Order approved by Asset Management.
Approval not timely
Order Processing Delay
Continue current pracices.
Order approved by credit.
Approval not timely
Order Processing Delay
Continue current pracices.
Determaination made that product is available for build.
All product required for the order may not be available at the start of the build.
(1) Product delivery date requirements may not be met. (2) Workspace occupied for an order awaiting Product is not available for integration of other orders.
Needed components are not available at the time of need.
Assure product availability before the order commitment is given to customer.
Continue current practices.
Inside sales expedites with Asset to provide ship date.
Shipdates may not be accurate
Customer's full expectations may not be realized.
Needed components are not available at the time of need.
Continue current practices.
Order approved by Asset Mgmt. and e-mail sent to Integration.
e-mail may be misrouted
Order Processing Delay
Continue current practices.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
8
3 1 1 3 Closed 10/25/99 0
5 3 3 45 Closed 1/27/00 0
3 1 Expidite Process 1 3 Closed 1/27/00 0
1 Process Failure 1 Expidite Process 1 1
7 3 5 105
3 3 3 27
3 1 1 3
3 1 Expidite Process 1 3 Closed 1/27/00
3 1 1 3 Closed 1/27/00
3 3 1 9 Closed 1/27/00
Project Manager reviews order for special or internal instructions.
Order processing requirements may be overlooked
Customer and processing needs not identified could prevent timely processing of the order.
Processing requirements overlooked.
Project Manager order review.
Continue current practices.
Build document bill of material matched with SCN.
Documents do not match
Order Processing Delay
Needed components are not available at the time of need.
Expidite ProcessIntegration Center Operations Manual 093-009-OPSMNL
Continue current practices.
Stock availability is checked and delivery dates are aquired for non stock items.
stock availability and dates may be inaccurate
Customer's full expectations may not be realized.
Needed components are not available at the time of need.
Continue current practices.
Order is forwarded to Production Engineer for review.
Order may be misrouted
Order Processing Delay
Continue current practices.
Continue current practices.
Determanation made for a 1st Article build.
Need for 1st build may be overlooked
Customer's full expectations may not be realized.
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Continue current practices.
Build document is reviewed and verified.
Requirements may be overlooked
Customer's full expectations may not be realized.
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Continue current practices.
Project management notifies sales with status of order.
Sales may not receive order status
Order Processing Delay
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Continue current practices.
Asset management places order for non stock items.
Items may not be ordered
Order Processing Delay
Needed components are not available at the time of need.
Continue current practices.
Order is scheduled for production.
Order may not be entered in schedule
Order Processing Delay
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Whse Operator reviews parts to SOA & SCN.
Parts may not match requirement
Order Processing Delay
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
9
3 3 3 27 Closed 1/27/00
5 3 1 15 Closed 1/27/00
7 3 3 63 Closed 1/27/00
1 1 5 5 Closed 8/21/00
7 7 3 147 Closed 1/27/00
10 10 1 100 Closed 1/27/00
5 1 5 25
Whse. Operator Unpack,Iinspect & Kit order.
All parts may not reach integration
Order Processing Delay
All components are not available at the time of need.
Individuals are contacted to resolve issues.Integration Kitting and Packing 153-001-01
Continue current practices.
Techs. Check product against SOW and build instructions.
Parts may not match requirement
Order Processing Delay
All components are not available at the time of need.
Individuals are contacted to resolve issues.
Continue current practices.
Integration Techs. inspect parts and chassis.
Materials may not be compliant
Order Processing Delay
All components are not available at the time of need.
QA Inspection and Test Procedure 103-001-03
Continue current practices.
No NT Resource KitMissing Video Board
Loss of business with the customer.
Requirements Overlooked.
QA Inspection and Test Procedure 103-001-03
Update Build Procedures to clearly define product requirements specific to the model being integrated.
Techs. Integrate & Power-Up System
System may be integrated incorrectly
Order Processing Delay
Individuals are contacted to resolve issues.
QA Inspection and Test Procedure 103-001-03
Continue current practices.
Integration Techs. Test system.
System and parts may not be compliant
Order Processing Delay
Needed components are not available at the time of need.
QA Inspection and Test Procedure 103-001-03
Continue current practices.
Quality techs. inspect product for build requirements.
Specific build requirements may not be fully addressed.
On time delivery and integraty of the product may be compramised if this issue is not addressed.
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
10
1 Human Error 5 5 25 Closed 8/21/00
3 3 1 9 Closed 1/27/00
1 1 1 1 Closed 1/27/00
3 3 1 9 Closed 1/27/00
3 Process Failure 1 1 3 Closed 1/27/00
7 Process Failure 1 1 7 Closed 1/27/00
10 3 3 90 Closed 1/25/00
IO panel not installedLabel on CPU IncorrectNo feet or other components installedNo extension cablesMissing cablesIO panel gasket not installedWrong ICD cards providedDome calibrater included
Loss of business with the customer.
Build Procedure for individual PathSpeed Model
Update Build Procedures to clearly define product requirements specific to the model being integrated.
Product serial numbers scanned into Genesis.
Numbers may be incorrect
Order Processing Delay
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Change made after batch release
Control of requirements may be lost
Order Processing Delay
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Order placed on hold when change is made.
Shiping deadlines may not be met
Order Processing Delay
Requirements Overlooked.
Individuals are contacted to resolve issues.
Continue current practices.
Design Process reinitiates
Control of requirements may not be complete
Order Processing Delay
Individuals are contacted to resolve issues.
Continue current practices.
Whse. invoices and ships order per customer's shipping method.
Wrong Shipping method may be used
On time delivery and integraty of the product may be compramised if this issue is not addressed.
Individuals are contacted to resolve issues.
Continue current practices.
Quality techs. inspect shipment for CII/SHC requirements.
Specific packing, labeling and shipping requirements may not be fully addressed.
On time delivery and integraty of the product may be compramised if this issue is not addressed.
Requirements Overlooked.
Customer Inspection Instruction/ Special Handling Codes Process 033-001-02
Continue current pracices.
Houston MayerSix Sigma BlackbeltAugust 21, 2000
11
1 Human Error 3 CII 033-001-006 3 9 9/11/2000
7 3 7 147 Closed 1/27/00
3 1 1 3 Closed 1/25/00
Label on outside of box did not match S/N on CPU.
Loss of business with the customer.
Revisit contents of GE CII 033-001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.
Product ships to customer.
Products misshipped
On time delivery and integraty of the product may be compramised if this issue is not addressed.
Needed components are not available at the time of need.
Individuals are contacted to resolve issues.
Continue current practices.
Coordinator closes project & files quality records.
Documents not filed correctly
Documents may not be retrievable
Documents may not be retrievable
Individuals are contacted to resolve issues.
Continue current pracices.
Severity
Page 12
Effect SEVERITY of Effect Ranking10
9
Very High 8
High System inoperable with equipment damage 7
Moderate System inoperable with minor damage 6
Low System inoperable without damage 5
Very Low System operable with significant degradation of performance 4
Minor System operable with some degradation of performance 3
Very Minor System operable with minimal interference 2
None No effect 1
Hazardous without warning
Very high severity ranking when a potential failure mode affects safe system operation without warning
Hazardous with warning
Very high severity ranking when a potential failure mode affects safe system operation with warningSystem inoperable with destructive failure without compromising safety
Probability
Page 13
PROBABILITY of Failure Failure Prob RankingVery High: Failure is almost inevitable >1 in 2 10
1 in 3 9High: Repeated failures 1 in 8 8
1 in 20 7Moderate: Occasional failures 1 in 80 6
1 in 400 51 in 2,000 4
Low: Relatively few failures 1 in 15,000 31 in 150,000 2
Remote: Failure is unlikely <1 in 1,500,000 1
Detectability
Page 14
Detection Likelihood of DETECTION by Design Control Ranking10
Very Remote 9
Remote 8
Very Low 7
Low 6
Moderate 5
Moderately High 4
High 3
Very High 2
Almost Certain 1
Absolute Uncertainty
Design control cannot detect potential cause/mechanism and subsequent failure modeVery remote chance the design control will detect potential cause/mechanism and subsequent failure modeRemote chance the design control will detect potential cause/mechanism and subsequent failure modeVery low chance the design control will detect potential cause/mechanism and subsequent failure modeLow chance the design control will detect potential cause/mechanism and subsequent failure modeModerate chance the design control will detect potential cause/mechanism and subsequent failure modeModerately High chance the design control will detect potential cause/mechanism and subsequent failure modeHigh chance the design control will detect potential cause/mechanism and subsequent failure modeVery high chance the design control will detect potential cause/mechanism and subsequent failure modeDesign control will detect potential cause/mechanism and subsequent failure mode
EXAMPLE
Page 15
System
Subsystem
Component
Design Lead
Core Team
Item / Function
Seals
Potential Failure Mode(s)
Coolant containment. Hose connection. Coolant fill. M
Sensor mount. Seal
Compression set
Sensor mount. Seal
Loosen during sensor assembly/service
Sensor mount. Seal
Damaged internal thread
Sensor mount. Seal
Damaged external thread
Coolant containment. Hose connection. Coolant fill. M
Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete
EXAMPLE
Page 16
System
Subsystem
Component
Design Lead
Core Team
Item / Function Potential Failure Mode(s)
Stress crack
Stress crack
Stress crack
Corrosion
Corrosion
Coolant containment. Hose connection. Coolant fill. M
Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete
Coolant containment. Hose connection. Coolant fill. M
Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
EXAMPLE
Page 17
System
Subsystem
Component
Design Lead
Core Team
Item / Function Potential Failure Mode(s)
Puncture
Seam fail
Burst fail
Plugged
Ballooning
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
Hold fluid, flow path, Heat transfer structure
EXAMPLE
Page 18
Potential FMEA NumberFailure Mode and Effects Analysis Prepared By
(Design FMEA) FMEA Date
Key Date Revision Date
Page of
Action Results
Actions Taken
New
Sev
New
Occ
New
Det
00
Leak 8 Gasket material 7 1 56
8 2 Added rib. 1 16
5 2 1 10
4 3 1 12
Leak 8 Over pressure 8 1 64
Potential Effect(s) of Failure
Sev
Potential Cause(s)/ Mechanism(s) of
Failure
Prob
Current Design Controls
Det
RPN
Recommended Action(s)
Responsibility & Target Completion
Date
Pressure cycle w/cold shock.
Use imported material
Leak. Fall inside tank
Fitting not held in place
Implement holding rib in design. New fitting design. Prototype validation.
J.P. Aguire 11/1/95
Cannot install sensor
Damaged during installation or transportation
Cannot install wire nut
Damaged during shipment to piracicaba
Damaged fitting not used by Piracicaba
Burst, validation pressure cycle.
Test included in prototype and production validation testing.
J.P. Aguire 11/1/95 E. Eglin 8/1/96
EXAMPLE
Page 19
Potential FMEA NumberFailure Mode and Effects Analysis Prepared By
(Design FMEA) FMEA Date
Key Date Revision Date
Page of
Action Results
Actions Taken
New
Sev
New
Occ
New
Det
Potential Effect(s) of Failure
Sev
Potential Cause(s)/ Mechanism(s) of
Failure
Prob
Current Design Controls
Det
RPN
Recommended Action(s)
Responsibility & Target Completion
Date
Failed mount 5 Vibration 9 3 135 J.P. Aguire
Hose leak 6 5 2 60
0 Operator instruction
0
8 7 Thermal cycle 1 56 E. Eglin 8/1/96
0
8 7 5 280 Coolant ordered
Vibration w/road tapes
Obtain GMB vibration road tape.
Overpressure. Poor clamp
Burst, validation pressure cycle w/GMB clamps.
Obtain GMB clamps and clamping specification.
J.P. Aguire 12/1/95
Air conditioning does not work. Sudden refrigerant loss.
This is a test of the ADD POTENTIAL CAUSE/MECHANISM OF FAILURE system functionality
Air conditioning does not work. Sudden refrigerant loss.
This is a test of the ADD POTENTIAL CAUSE/MECHANISM OF FAILURE system functionality
This is a test of the ADD RECOMMENDED ACTION system functionality
Leak. Loss of heat transfer.
Wicking. Material strength
Included in Product Specification
Air conditioning does not work. Sudden refrigerant loss.
this is a test while dan is here
Leak. Loss of heat transfer.
Coolant quality. Contamination. Environment - int/ext.
SWAT, service simulation. Coolant evaluation.
Brazilian coolant to be evaluated. Zince lined tubes may need to be released. Simulated service test w/GMB coolant to be performed.
J.P. Aguirre 11/1/95
EXAMPLE
Page 20
Potential FMEA NumberFailure Mode and Effects Analysis Prepared By
(Design FMEA) FMEA Date
Key Date Revision Date
Page of
Action Results
Actions Taken
New
Sev
New
Occ
New
Det
Potential Effect(s) of Failure
Sev
Potential Cause(s)/ Mechanism(s) of
Failure
Prob
Current Design Controls
Det
RPN
Recommended Action(s)
Responsibility & Target Completion
Date
8 10 1 80 E. Eglin 8/1/96
5 Environment - int/ext. 1 1 5 E. Eglin 8/1/96
8 2 Burst/leak pressure 5 80 GMB 12/1/95 Study originated
8 7 1 56 Coolant ordered
5 9 8 360 GMB 12/1/95
000
Leak. Loss of heat transfer.
External damage. Coolant velocity. No reinf sawcut.
Leak test. Simulated service.
100% cores tested in production. Simulated service included in Product Specificatin.
Leak. Loss of heat transfer.
SWAT, service simulation.
Included in Product Specification.
Leak. Loss of heat transfer.
Over pressure contamination.
GMB to study engine cleanliness.
Loss of heat transfer. Leakage due to increase flow velocity
Contamination. Coolant quality.
GMB coolant to be evaluated. GMB to study engine cleanliness.
J.P. Aguirre 11/1/95
Leak. Loss of heat transfer.
Over pressure contamination.
GMB to study engine cleanliness. Clustomer profile to be determined.