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Välkommen, welcome, huān yíng, welkom, Bienvenue,

willkommen, fogadtatás, benvenuto, velkommen, powitanie, bem-vindo, croeso, bienvenido, vítejte

Advanced Powertrain Control Symposium 9th

July 2013

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The Effective Application of FMEA

• Who am I?• What is FMEA?• Why do FMEA?• Application of FMEA• A Structured Approach• Effective FMEA• Use Software for FMEA• Use an FMEA Facilitator

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What is FMEA?Contrary to popular belief FMEA is actually an acronym for a risk analysis called Failure Modes & Effects Analysis, and not ‘Five Men Endlessly Arguing’.

“Failure Modes & Effects Analysis is an activity that brings minds together in a collaborative and pre-emptive way in

order to avoid failure of a system!”

FMEA is a systematic procedure that focuses on a system(s) in order to uncover weaknesses, i.e. what can go wrong, what could possibly cause it and what are the potential effects. FMEA then focuses on these weaknesses with the objective of making them obsolete, or by reducing the likelihood of failure (or risk of failure) though the implementation of corrective methods, which in turn optimises the system.

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What is FMEA?

FMEA is a living document and if used correctly records:

• intellectual property

• weaknesses within the system

• quantified risk of system failure

• mistakes made

• solutions to problems

• responsibility for controls methods

Failure are any potential errors or defects within a process, design, or part, especially ones that affect the ‘customer’, environment and law.

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What is FMEA?

• 1949 – US Military (MIL-P-1649)

• 1963 – NASA• 1965 – Aerospace Industry• 1975 – Nuclear Industry• 1977 – Ford Motor Company• 1980 – DIN 25448• 1986 – VDA Volume 4 • 1992 – Ford, Chrysler & GM • 2008 – AIAG

Is universally accepted as an engineering tool05/07/2013

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Why do FMEA?

• Cost reduction and increased profits• Demand for higher quality• Extended warranty periods• Product liability• Quality standard demands• Retention of knowledge• Make processes more robust• Enhanced communication within the business,

customer & suppliers• Shorter development times• Functional Safety & Reliability05/07/2013

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Application of FMEA

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Application of FMEA

There are two main schools of thought about the methodology to use and which is most effective?• Rose with a different name• Procedure• Document formats• Adherence to ISO / TS 16949• Basis for ISO / TS 26262

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Application of FMEA

To get the best out of FMEA you should have:• Cross functional team • FMEA Moderator / Facilitator• Props and documentation• Structured approach• FMEA Software• Management Support!

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A Structured Approach

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Effective FMEA

Step 1: Visual representation of the scope

CV Joint

Inner Race

Inner Race Spline

Inner Race Track

Inner Race Sphere

Outer Race

Outer Race Sphere

Outer Diameter

Outer Race Track

Outer Race Spline

Thread

Cage

Windows

Cage Sphere

Hole

ABS Ring

Ball Bearing

Grease

Clip

Shield

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Effective FMEA

Step 2: Runs in line with other engineering techniques, such as Function Analysis System Technique (FAST)

How?Why?Effects Causes

Accelerator input circuit Provides specified voltage stimulus for the accelerator pedal target point

Capacitor #38Filter noise

Monolithic integrated low dropout voltage trackerMirrors input voltage to output voltage

Capacitor #39Filter noise

Diode #6Protection

Programmed MicrocontrollerProvides accelerator target stimulus

PCB circuit trackMaintain electrical continuity

Accelerator input circuit Conditions accelerator target wiper signal

Electronic drive controlSends a timely motor speed target to thecontrollers

Mode

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Accelerator input circuit Provides specified voltage stimulus for the accelerator pedal target point

Capacitor #38Filter noise

Monolithic integrated low dropout voltage trackerMirrors input voltage to output voltage

Capacitor #39Filter noise

Diode #6Protection

Programmed MicrocontrollerProvides accelerator target stimulus

PCB circuit trackMaintain electrical continuity

Accelerator input circuit Conditions accelerator target wiper signal

Electronic drive controlSends a timely motor speed target to thecontrollers

Effective FMEA

Focus on functions provide guidance for the analysis of failures, or step 3.

• Loss of Voltage stimulus

• Corrupted Voltage stimulus

• Voltage stimulus when not required

• Signal stuck at ground• Signal stuck at

specified voltage• Signal is corrupted

• Short• Open

Effects CausesMode

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Effective FMEA

Step 3: Efficient construction of effective possible failure scenarios

Effects Causes

Accelerator input circuit Loss of voltage stimulus for accellerator pedal target point

Capacitor #38Short

Monolithic integrated low dropout voltage trackerOutput loss when input is high

Diode #6Shorted to ground

Diode #6Open

Programmed MicrocontrollerOutput stuck low

PCB circuit trackLoss of electrical continuity

Accelerator input circuit Point of target wiper signal stuck at ground

Mode

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Effective FMEA

Step 4: Possible failure scenarios are displayed in a fashion that is consistent with previous steps

Failure Effect(s) S Failure Mode Failure Cause(s)

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Effective FMEA

AIAG form can be unintentionally misleading

Mode Causes

Effects

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Effective FMEA

VDA form is logical

Effects Mode Causes

E=MC2

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Effective FMEA

Step 4: Ensuring that only the controls that are currently in fruition are considered when calculating the risk

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Effective FMEA

Step 4: Analysis of the data using RPN is not just 1-1000, there are 120 values that can result from SxOxD, which may not reflect criticality.

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Effective FMEA

Common sense shall prevail by looking at the risk assessment results in a different way e.g.:

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Automotive risk model

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Effective FMEA

Step 5: Reduction of the risk is displayed in a Chronological order

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Effective FMEA

Create your own descriptions of the risk factors of Severity (S), Occurrence (O) and Detection (D):• Reflect what you do as a business• Reflect the product you make• Is there a customer mandate?• Using ‘rule of thumb’ statements &

benchmark examples• Use AIAG descriptions as guidance*

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Use Software for FMEA

Due to the complexities of modern products & processes, software is essential. Many companies use MS Excel, but dedicated software can provide a visual representation of:• the system analysed• interfaces between sub-systems, plus

inputs and outputs• complex relationships between the

failures

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Use Software for FMEA

In addition to this dedicated software allows the FMEA to:• be filtered or colour coded according to your

own criteria• produce additional statistical data and

additional quality documentation as a consequence

• Switch easily between FMEA form layouts• handles variances• Supports delegation and tracking of

corrective measures05/07/2013

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Use an FMEA facilitator

• Experienced FMEA facilitation will ultimately save time and make meetings more focused & constructive.

• An experienced FMEA facilitation minimises digression into different types of FMEA.

• An external FMEA facilitator may ask the ‘stupid questions’ that may have been overlooked as they may be thinking outside of the box

• An effective FMEA records intellectual capital for the future developments (semantics)

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078 999 625 53 - 01785 711 296gavin@fmea.co.uk

Penkridge, Stafford, ST19 5TE. UK

tack , thanks , xièxie , dank u wel , merci , danke ,

köszönöm , g raz ie , tak , dziękuję , obrigado , diolch , gracias ,

děkuj , ďakujem

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