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UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
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UNCLASSIFIED / FOUO
National GuardBlack Belt Training
Module 32
Failure Modes and Effects Analysis (FMEA)
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CPI Roadmap – Analyze
Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive.
TOOLS•Value Stream Analysis•Process Constraint ID •Takt Time Analysis•Cause and Effect Analysis •Brainstorming•5 Whys•Affinity Diagram•Pareto •Cause and Effect Matrix •FMEA•Hypothesis Tests•ANOVA•Chi Square •Simple and Multiple Regression
ACTIVITIES
• Identify Potential Root Causes
• Reduce List of Potential Root Causes
• Confirm Root Cause to Output Relationship
• Estimate Impact of Root Causes on Key Outputs
• Prioritize Root Causes
• Complete Analyze Tollgate
1.Validate the
Problem
4. Determine Root
Cause
3. Set Improvement
Targets
5. Develop Counter-
Measures
6. See Counter-MeasuresThrough
2. IdentifyPerformance
Gaps
7. Confirm Results
& Process
8. StandardizeSuccessfulProcesses
Define Measure Analyze ControlImprove
8-STEP PROCESS
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3Failure Modes and Effects Analysis
Learning Objectives
Understand why we use Failure Modes and Effects Analysis (FMEA)
Summarize the different types of FMEAs
Learn how to link the FMEA to other LSS tools
Learn the steps necessary to work through an FMEA
Complete an exercise to create an FMEA
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4Failure Modes and Effects Analysis
Unintended Consequences
For any new or redesigned process…
Your solution has to be aligned with your organization’s strategic and tactical goals in order to yield benefits that will be judged significant
You want to know about any unintended consequences or problems related to your solution before you implement or promote it
Awareness of potential difficulties will allow you to prevent or mitigate the effects of any failure
You want to minimize any “start up” problems and move to full implementation in the shortest possible time
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5Failure Modes and Effects Analysis
Risk Management
Any significant issues identified in the FMEA must then beaddressed by taking:
Preventive Action
Steps that reduce the likelihood of a problem occurring at all
Focused on reducing/eliminating root causes prior to occurrence
Contingent Action
Measures implemented to limit the damage caused by a potential problem should it occur
Focused on achieving the goal in spite of difficulties
We can mistake proof our new or revised processes by proactively focusing on the “meaningful many”….
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6Failure Modes and Effects Analysis
Example: Risk Management
Pizza Delivery Process
Task – Assign a van to each delivery driver
Potential Problem – Not enough drivers with vehicles to meet order demand (due to less flexibility in moving drivers to vehicles)
Preventive Action – Review volume patterns and match staff/vehicle schedules to ensure adequate coverage/capacity
Contingent Action – Identify “on-call” delivery staff and short-term vehicle rentals for expected or unexpected demand spikes (e.g., Super bowl)
Alarm – Delivery times >28 minutes and/or driver/vehicle shortages
Use FMEA in Analyze to find potential
causes of a problem and evaluate from a
risk perspective
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7Failure Modes and Effects Analysis
FMEA
Stands for Failure Modes and Effects Analysis.
FMEA is a structured approach to: Identifying the areas and ways in which a process or system can
fail (failure mode)
Identifying potential root causes and estimating the risk associated with theses causes
Identifying and prioritizing the actions that should be taken to reduce those risks
Evaluating and documenting proposed improvement plans or current control plans
FMEA is used to identify and reduce risk, and therefore unintended consequences, in the problem solving process
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8Failure Modes and Effects Analysis
When to Conduct an FMEA
When existing designs or processes are being changed
When new systems, products and processes are being designed.
When carry-over designs are used in new applications
After system, product or process functions are defined, but before beginning detailed final design
When the improvement idea has been decided
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9Failure Modes and Effects Analysis
Types of FMEAs
System
Analyzes systems and subsystems in early concept and design stages
Design
Analyzes new process, product or service design before rollout
Process
Used to improve existing transactional and operational processes
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10Failure Modes and Effects Analysis
FMEA
FMEA
SIPOCSupplier-Input-Process-
Output-Customer
Process Map
C & EMatrix
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11Failure Modes and Effects Analysis
FMEA Procedure
1. For each process step (start with steps that give highest value from C&E Matrix) determine the ways in which the input to the step or the function of the step can go wrong (failure mode)
2. For each failure mode, determine effects
Select a severity rating for each effect (1-10 scale)
Any failure with a severity rating of 9 or 10 should be worked immediately
3. Identify potential causes of each failure mode
Select an occurrence rating for each cause (1-10 scale)
4. List current monitoring and controls for each cause
Select a detection rating for each cause (1-10 scale)
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12Failure Modes and Effects Analysis
FMEA Procedure (Cont.)
5. Calculate the Risk Priority Number (RPN) by multiplying the 3 ratings together (Max Score = 1000)
6. In the Improve phase, develop recommended actions, assign responsible persons, and note actions taken.
Prioritize so the highest RPNs are addressed first
Some level of risk may be accepted and no action is taken on RPNs below an established limit
7. Implement solutions from the first round of actions, create a re-prioritized FMEA and analyze for further necessary action
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13Failure Modes and Effects Analysis
FMEA Inputs and Outputs
Determine by utilizing the following CPI tools as needed:
FMEA
BrainstormingC&E MatrixProcess Map
Process HistoryProceduresKnowledgeExperience
List of actions to prevent causes or
detect failure modes
History of actions taken
Inputs Outputs
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14Failure Modes and Effects Analysis
Failure Modes and Effects
The relationship between failure modes and effects is not always 1 to 1.
Failure Mode 1
Failure Mode 2
Effect 1
Effect 2
Failure Mode 1
Failure Mode 2Effect 1
Failure Mode 1Effect 1
Effect 2
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15Failure Modes and Effects Analysis
Severity, Occurrence, and Detection
Severity
Importance of the effect on customer requirements
Often can’t do anything about this without fundamentally changing the system or design
Occurrence
Frequency with which a given cause occurs and creates failure modes (or probability it will occur)
Detection
The ability of the current monitoring and control method to detect before or after occurrence of a given cause
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16Failure Modes and Effects Analysis
Rating Scales and RPN
Rating formats can be quantitative or qualitative
The rating scales provided in this module were adopted from the Automotive Industry Action Group, AIAG – may need to be adjusted for transactional or service CPI projects
Typically:
1 = Not severe, not likely to occur or likely to detect
10 = Very severe, very likely to occur or not likely to detect
RPN is a product of the severity, occurrence and detection ratings:(Severity) x (Occurrence) x (Detection) = RPN (maximum of 1000)
A customized rating scale may be created or the RPN level at which action is taken may be adjusted for your particular organization
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17Failure Modes and Effects Analysis
Severity Scale 1 of 2
Effect Criteria: Severity of Effect Defined Ranking
Hazardous:
Without
Warning
May endanger operator or others. Failure mode affects safe
product operation and / or involves noncompliance with
government regulation. Failure will occur WITHOUT warning.
10
Hazardous:
With
Warning
May endanger operator or others. Failure mode affects safe
product operation and / or involves noncompliance with
government regulation. Failure will occur WITH warning.
9
Very High
Major disruption to production line. 100% of product may have to
be scrapped. Product inoperable, loss of primary function.
Customer very dissatisfied.
8
High
Minor disruption to production line. Product may have to be sorted
and a portion (less than 100%) scrapped. Product operable, but at
a reduced level of performance. Customer dissatisfied.
7
Moderate
Minor disruption to production line. A portion (less than 100%)
may have to be scrapped (no sorting). Product operable, but
some comfort / convenience item(s) inoperable. Customers
experience discomfort.
6
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18Failure Modes and Effects Analysis
Effect Criteria: Severity of Effect Defined Ranking
Low
Minor disruption to production line. 100% of product may have to
be reworked. Item operable, but some comfort / convenience
item(s) operable at reduced level of performance. Customer
experiences some dissatisfaction.
5
Very Low
Minor disruption to production line. The product may have to be
sorted and a portion (less than 100%) reworked. Fit / finish /
squeak / rattle item does not conform. Defect noticed by most
customers.
4
Minor
Minor disruption to production line. A portion (less than 100%) of
the product may have to be reworked on-line but out-of-station. Fit
/ finish / squeak / rattle item does not conform. Defect noticed by
average customers.
3
Very Minor
Minor disruption to production line. A portion (less than 100%) of
the product may have to be reworked on-line but in-station. Fit /
finish / squeak / rattle item does not conform. Defect noticed by
discriminating customers.
2
None No effect. 1
Severity Scale 2 of 2
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19Failure Modes and Effects Analysis
Likelihood of Occurrence Scale
Probability of Failure Possible Failure Rates Cpk Ranking
Very High: > 1 in 2 < 0.33 10
Failure is almost inevitable 1 in 3 > 0.33 9
High: Generally associated with
processes similar to previous1 in 8 > 0.51 8
processes that have often failed 1 in 20 > 0.67 7
Moderate: Generally associated
with processes similar to1 in 80 > 0.83 6
previous processes which have 1 in 400 > 1.00 5
experienced occasional failures,
but not in major proportions1 in 2,000 > 1.17 4
Low: Isolated failures associated
with similar processes1 in 15,000 > 1.33 3
Very Low: Only isolated failures
associated with almost identical
processes
1 in 150,000 > 1.5 2
Remote: Failure is unlikely. No
failures ever associated with
almost identical processes< 1 in 1,500,000 > 1.67 1
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20Failure Modes and Effects Analysis
Detection Criteria: Likelihood the existence of a defect
will be detected by test content before product
advances to next or subsequent process
Ranking
Almost
Impossible
Test content detects < 80 % of failures 10
Very Remote Test content must detect 80 % of failures 9
Remote Test content must detect 82.5 % of failures 8
Very Low Test content must detect 85 % of failures 7
Low Test content must detect 87.5 % of failures 6
Moderate Test content must detect 90 % of failures 5
Moderately High Test content must detect 92.5 % of failures 4
High Test content must detect 95 % of failures 3
Very High Test content must detect 97.5 % of failures 2
Almost Certain Test content must detect 99.5 % of failures 1
Detection Scale
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21Failure Modes and Effects Analysis
FMEA Example
We will conduct an FMEA on the All Ranks Club coffee example
A Black Belt wants to improve customer satisfaction with the coffee served at the All Ranks Club
Use the process map and completed C&E matrix follow
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22Failure Modes and Effects Analysis
All Ranks Club Coffee Process Map
Inputs OutputsInputs Outputs
Hot Water
Soap
Scrubber
Clean Carafe
Cold Water
Measuring Mark
Full Carafe
Filter
Maker w/Filter
Fresh Coffee
Dosing Scoop
Maker w/Filter &
Coffee
Brewing Coffee
Cleaned Carafe
Dirty Water
Wet Scrubber
Full Carafe
Filled Maker
Empty Carafe
Maker w/Filter
Maker w/Filter &
Coffee
Operating Maker
Heat
Brewed Coffee
Hot Coffee
Customer
Order
Size Specification
Complete Order
Hot Coffee
Cup
Filled Cup
Customer
Cream
Sugar
Amount Desired
Complete Order
Money
Coffee Delivery
Complete Order
Filled Cup
Customer Reply
Amount Specified
Complete Order
Make Change
Temperature
Taste
Strength
Smile
Happy Customer
Pour Coffee
into Cup
Offer
Cream &
Sugar
Complete
Transaction
Say Thank You
Receive
Coffee OrderClean Carafe
Fill Carafe
w/Water
Pour Water into
Maker
Place Filter in Maker
Put Coffee in
Filter
Select Temperature
Setting
Turn Maker On
Primary Y = TasteSelect process steps with biggest impact on taste
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23Failure Modes and Effects Analysis
Step 1. Determine Potential Failure Modes
Process Step/
InputPotential
Failure
Mode
Potential
Failure EffectsS
E
V
E
R
I
T
Y
Potential
CausesO
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
TakenS
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
N
What is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the
actions for
reducing the
occurrence of the
cause, or
improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe
with water
Wrong
amount of
water
Water too
warm
Carafe not
clean
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
A FMEA is a vertical process. Each step should be completed for the entire process before
proceeding to the next step.
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24Failure Modes and Effects Analysis
Step 2. Identify Failure Effects and Severity
Process Step/
Input
Potential
Failure ModePotential
Failure
Effects
S
E
V
E
R
I
T
Y
Potential
CausesO
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
TakenS
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
N
What is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the
actions for
reducing the
occurrence of the
cause, or
improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe
with water
Wrong
amount of
water
Coffee too
strong or too
weak
Water too
warm
Coffee too
strong
Carafe not
clean
Foreign
objects in
coffee
Bad taste
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
UNCLASSIFIED / FOUO
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25Failure Modes and Effects Analysis
Process Step/
Input
Potential
Failure ModePotential
Failure
Effects
S
E
V
E
R
I
T
Y
Potential
CausesO
C
C
U
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
TakenS
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
N
What is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the
actions for
reducing the
occurrence of the
cause, or
improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe
with water
Wrong
amount of
water
Coffee too
strong or too
weak
5
Water too
warm
Coffee too
strong
5
Carafe not
clean
Foreign
objects in
coffee
6
Bad taste 6
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
Step 2. Identify Failure Effects and Severity
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26Failure Modes and Effects Analysis
Step 3. Identify Potential Causes/Occurrence
Process Step/
Input
Potential
Failure Mode
Potential
Failure EffectsS
E
V
E
R
I
T
Y
Potential
Causes
O
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
Taken
S
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
N
What is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the
existing controls
and procedures
(inspection and test)
that prevent either
the cause or the
Failure Mode?
What are the
actions for
reducing the
occurrence of
the cause, or
improving
detection?
What are the
completed
actions taken
with the
recalculated
RPN?
Fill carafe with
water
Wrong amount of
water
Coffee too strong or
too weak
5 Faded level
marks on
carafe
4
5 Water spilled
from carafe
5
Water too
warm
Coffee too strong 5 Faucet not
allowed to run
and cool
8
5 Employee not
aware of new
need for cool
water
7
Carafe not clean Foreign objects in
coffee
6 Carafe not
washed
4
Bad taste 6 Carafe stored
improperly
7
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
UNCLASSIFIED / FOUO
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27Failure Modes and Effects Analysis
Step 4. List Current Controls and Score
Process Step/
Input
Potential
Failure Mode
Potential
Failure Effects
S
E
V
E
R
I
T
Y
Potential
Causes
O
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
TakenS
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
NWhat is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the
actions for
reducing the
occurrence of the
cause, or
improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe with
water
Wrong amount of
water
Coffee too strong or
too weak
5 Faded level
marks on carafe 4 Visual inspection 4
5 Water spilled
from carafe
5 None 10
Water too
warm
Coffee too strong 5 Faucet not
allowed to run
and cool
8 Finger 4
5 Employee not
aware of new
need for cool
water
7 None 10
Carafe not clean Foreign objects in
coffee
6 Carafe not
washed
4 Visual inspection 4
Bad taste 6 Carafe stored
improperly
7 Visual Aid 5
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
28Failure Modes and Effects Analysis
Step 5. Calculate RPNs
Process Step/
Input
Potential
Failure Mode
Potential
Failure Effects
S
E
V
E
R
I
T
Y
Potential
Causes
O
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
Taken
S
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
N
What is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the
actions for
reducing the
occurrence of the
cause, or
improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe with
water
Wrong amount of
water
Coffee too strong or
too weak
5 Faded level
marks on carafe
4 Visual inspection 4 80
5 Water spilled
from carafe
5 None 10 250
Water too
warm
Coffee too strong 5 Faucet not
allowed to run
and cool
8 Finger 4 160
5 Employee not
aware of need
for cool water
7 None 10 350
Carafe not clean Foreign objects in
coffee
6 Carafe not
washed
4 Visual inspection 4 96
Bad taste 6 Carafe stored
improperly
7 Visual Aid 5 210
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
In the Analyze phase, FMEA is used to help
identify potential causes of process
problems related to the Primary Y. Sort by RPN to find most
critical Xs for further analysis.
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29Failure Modes and Effects Analysis
Step 6. Develop Recommended Actions
Process Step/
Input
Potential
Failure Mode
Potential
Failure Effects
S
E
V
E
R
I
T
Y
Potential
Causes
O
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
Taken
S
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
N
What is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the actions
for reducing the
occurrence of the
cause, or improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe with
water
Wrong amount of
water
Coffee too strong or
too weak
5 Faded level
marks on carafe
4 Visual inspection 4 80
5 Water spilled
from carafe
5 None 10 250 Train employees Flo Employees trained
Water too
warm
Coffee too strong 5 Faucet not
allowed to run
and cool
8 Finger 4 160
5 Employee not
aware of new
need for cool
water
7 None 10 350 Train employees Mel Employees trained
Carafe not clean Foreign objects in
coffee
6 Carafe not
washed
4 Visual inspection 4 96
Bad taste 6 Carafe stored
improperly
7 Training 5 210 Create storage bin &
train employees
Alice New storage bin &
employees trained
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
Complete this section of the FMEA
in the Improvephase.
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
30Failure Modes and Effects Analysis
Step 7. Compare RPN Before and After
Process Step/
Input
Potential
Failure Mode
Potential
Failure Effects
S
E
V
E
R
I
T
Y
Potential
Causes
O
C
C
U
R
R
E
N
C
E
Current Controls D
E
T
E
C
T
I
O
N
R
P
N
Actions
Recommended
Resp. Actions
TakenS
E
V
E
R
I
T
Y
O
C
C
U
R
A
N
C
E
D
E
T
E
C
T
I
O
N
R
P
NWhat is the
process step
and input
under
investiga-
tion?
In what ways
does the Key
Input go
wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes
the Key Input
to go wrong?
What are the existing
controls and
procedures
(inspection and test)
that prevent either the
cause or the Failure
Mode?
What are the
actions for
reducing the
occurrence of the
cause, or
improving
detection?
What are the
completed actions
taken with the
recalculated RPN?
Fill carafe with
water
Wrong amount of
water
Coffee too strong or
too weak
5 Faded level
marks on carafe
4 Visual inspection 4 80
5 Water spilled
from carafe
5 None 10 250 Train employees Flo Employees trained 5 2 7 70
Water too
warm
Coffee too strong 5 Faucet not
allowed to run
and cool
8 Finger 4 160
5 Employee not
aware of new
need for cool
water
7 None 10 350 Train employees Mel Employees trained 5 1 8 40
Carafe not clean Foreign objects in
coffee
6 Carafe not
washed
4 Visual inspection 4 96
Bad taste 6 Carafe stored
improperly
7 Training 5 210 Create storage bin &
train employees
Alice New storage bin &
employees trained
6 2 3 36
Process or
Product Name:
Responsible:
Prepared by: Page ___ of ___
FMEA Date (Orig) _____________ (Rev) ______________
Process/ProductFMEA Form
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
31
Exercise: Prepare an FMEA
Objective
Create an FMEA for the GGA's Budget Department
Instructions
Select one process step critical to improving the Primary Y
Complete the FMEA through the first RPN calculation
Sort by RPN to determine critical Xs for further analysis
Be prepared to report results to the group
Time = 20 Minutes
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
Process or
Product Name:Prepared by:
Pag
e
____
Responsible: FMEA Date (Orig) ______________ (Rev) _____________
Process
Step / Input
Potential Failure
Mode
Potential Failure
EffectsPotential Causes Current Controls
What is the
process
step and
Input under
investiga-
tion?
In what ways does
the Key Input go
wrong?
What is the impact
on the Key Output
Variables (Customer
Requirements)?
What causes the Key
Input to go wrong?
What are the existing
controls and procedures
(inspection and test) that
prevent either the cause
or the Failure Mode?
0
0
0
0
0
0
0
0
0
0
0
0
S
E
V
E
R
I
T
Y
O
C
C
U
R
R
E
N
C
E
D
E
T
E
C
T
I
O
N
RP
N
Process/Product
Failure Modes and Effects Analysis Form
(FMEA)
FMEA Template
Required Deliverable
UNCLASSIFIED / FOUO
UNCLASSIFIED / FOUO
33Failure Modes and Effects Analysis
Takeaways
Use FMEA in the Analyze phase to determine potential and significant Xs impacting Y from a risk perspective
Include significant Xs identified here in the improvement plan
Show impact of improvements using before and after RPN calculations
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UNCLASSIFIED / FOUO
What other comments or questions
do you have?