FMEA Presentation For Training(20100208)

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learn by failing
learn by thinking and anticipating
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A Member of the Hong Leong Group
Introduction :
Failure Modes and Effect Analysis FMEA
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Content:
1.
Introduction – What is FMEA ? Benefit of FMEA
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FMEA protects your company
- Protects against huge liability. - Improve the COQ ( Cost of Quality )
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Success Stories – case 1
1. Gerdau Ameristeel – Steel Mini-Mills
Initial situation: Gerdau Ameristeel ran equipment to failure or performed minimal calendarbased maintenance on the equipment. Result: - Frequent unplanned equipment downtime - Ad hoc response of maintenance staff to emergency repairs. After FMEA FMEA on critical equipment was carried out to determine : - the equipment failure modes - the risk of the failure occurring - the preventive measures Result : - The team learnt how to think about and prevent failure. - FMEAs become additional knowledge base for the company.
Faulty ‘O-Ring’ Seal Flames leaked thru the failed seal Flames burned thru shuttle’s external fuel tank
Chain Effects
Liquid hydrogen & oxygen fuels ignited Shuttle torn apart 7 crew members died End Effects (Safety to human)
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Origins
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Why do we need FMEA?
Case 1: Challenger Disaster
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Why do we need FMEA?
Case 3: Firestone’s Recalled Tires
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How FMEA will help? - 3P
To Protect the company
- Protects against huge liability. - Improves the COQ (Cost of Quality).
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… learn to avoid them
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Failures
Errors or defects in process, design, or item, especially those that affect the customer potential or actual
Analysis ( A ) - To review and assess the above with Action identified in order to Reduce or Prevent Potential failures.
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Case 2: DC 10 Crash
Cargo Door Failure DC10 Crash n Paris (1974) 329 people killed
No Design Fool Proof for Cargo Door Resulted in Disaster
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Establishes priorities for actions
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Example of Success Stories: Case 1: Steel
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What is FMEA?- Con’t
Definition:
An Analytical methodology identify Potential problems throughout the product & process development Anticipate Risks ; assessed, reduced & controlled. A Preventive Tool not only used at manufacturing / engineering, but also can be applied to Admin/ Resource Functions
To Prevent failures
- Do the right thing, right the first time. - Emphasize on Poke-Yoke measures.
To Predict risks
- Establishes priorities for defects elimination. - Provide historic record for risk mitigation.
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Benefits of FMEA
Anticipating potential problems, risks & prevention prior to product shipment or process installation
Protects against liability
Improves quality, cost & safety of the product / process
Catalyst for teamwork and idea exchange between functions
Reduce system development timing and cost Provides historical records: Best practices retention Enhance customer satisfaction by reducing the occurrence of product failure.
Prevent Failure
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Predict Risk
FMEA Use in Medical
Medical devices & drug delivery has added FMEA as the mean to understand the risk.
Failure Interface of System, Sub-system & Component
A simple Component - Resulted In Death!
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Why do we need FMEA?
FMEA allows a team of person to review the design at key points of product development and make changes to product / process well in advance of actually experiencing the failure.
5.
Summary of Changes in AIAG FMEA 4th Edition