FMEATrainingSRGGlobal4109.pptx

1、How Is A ParadigmFormed?Paradigm:A set of assumptions,concepts,values,and practices that constitutes a way of viewing reality for the community.(Paradigm=Example)A group of scientists placed 5 monkeys in a cage and in the middle,a ladder with bananas on the top.Every time a monkey went up the ladder

2、,the scientists soaked the rest of the monkeys with cold water.After a while,every time a monkey went up the ladder,the others beat up the one who tried to go up the ladder.After some time,no monkey dare to go up the ladder regardless of the temptation.Scientists then decided to substitute one of th

3、e monkeys.The 1st thing this new monkey did was to go up the ladder.Immediately the other monkeys beat him up.After several beatings,the new member learned not to climb the ladder even though it never knew why.A 2nd monkey was substituted and the same occurred.The 1st monkey participated on the beat

4、ing for the 2nd monkey.A 3rd monkey was changed and the same was repeated(beatings).The 4th was substituted and the beating was repeated and finally the 5th monkey was replaced.What was left was a group of 5 monkeys that even though never received a cold shower,continued to beat up any monkey who at

5、tempted to climb the ladder.If it was possible to ask the monkeys why they would beat up all those who attempted to go up the ladder.I bet you the answer would be.“I dont know thats how things are done around here”Does it sound familiar?So the question isHow do we keep from making the same mistakes

6、over and over again?The“Art Of Perfection”With A Wonderful FMEAAgenda FMEA Training Suzhou Plant Day 1 FMEA&Poke Yoke TrainingDay 2WorkshopPurposeExplain Standard FMEA Practice Clarify Roles Of The FMEA Team MembersDoing a Process FMEA Correctly Make FMEAs Value Added And User FriendlyConcluding thi

7、s training:definitive use of correct FMEA practices.Discuss FMEA Effectiveness,and Measurables To capture and drive for best practice design and processesEliminate RedundancyIntroduce and explore the use of FMEA building blocksWhy?Several crisis launches,yard campaigns,8Ds and customer concerns that

8、 resulted in significant$losses.80%of these issues are due to poor FMEAsCrisis launches drain resources from business units,design,corporate tooling and plants.Instead of fire fighting,we can use these resources on new programs and spend more time on Design FMEAs and Process FMEAs(Work load in the b

9、eginning of a program,not after the fact)Plan Train FMEA for all SRG Automotive plants and corporate supportDoing work shops and work together with trainer on standard FMEA practiceGoal=Best practice Design and Process FMEA.FMEAs are not given to customer with PPAP packageStandardize Across SRG Plan

10、ts:Everyone needs to apply standard FMEA practice with severity,occurrence and detection.Use the building block approach All processes need to have a PFMEA,critical process parameters,poke yokes Improvement Initiatives for the FMEA processResponsibility/Accountability.Design Engineering is leading t

11、he Design FMEA,and makes sure DFMEA is available for the process people and Program ManagersProgram Managers are responsible for making sure the DFMEA is provided to the plants Process Engineering Group Plant Process Engineers are leading the Process FMEA,and making sure the PFMEA is available to pl

12、ant and production personnel.Quality Engineer assure control plan is completed and significant characteristics are properly linked from Design and Process FMEAImprovement Initiatives for the FMEA processFMEA during AQP&Gate Launch Process.A Tool only works when you use it!The FMEA must be completed

13、during the AQP phase at there responsible gates,for any product or processThe FMEA must be reviewed and updated at a standard frequency as continuous improvementThe FMEA must be used as a tool for use in potential root cause analysis,lessons learned activity and best practice reviewsWhere does the F

14、MEA“fit in our process”The PDCA cycle:(Plan,Do,Check,Act)FMEAs are multi-functionalIt works as a tool to plan for improvementIt is a living document and should be used as continual improvement It determines your failure modes,good implementation avoids failure modes rather than detects potential def

15、ectsFocus in the“DO”section of the continuous improvement cycleFISHFocusImproveSustainHonorHFISFocus in on the high Critical or RPN values for improvementReduce the Critical or RPN values through ActionSustain the Improvement,and readjust the Occurrence or Detection ValuesRecognize the Improvement o

16、n all affected FMEAs and move to refocus improvements1Organizing The Team2Getting StartedProcess FMEA 3Analyzing Potential Problems4Identifying Causes and Controls5Identifying and Implementing Corrective Actions6Pitfalls of FMEAsOrganizing the Team Members And Their RolesDesign engineerCore TeamExte

17、nded Team Recruited by Prog.Manager through agreement with Functional Supv.;On team until de-commissioning Core team defines tasks to complete;Functional Supv.assigns tasks to extended team;On team until assigned tasks are completed.Must attend FMEAAttend FMEA as required by Core TeamDesign Engineer

18、&Launch Team Responsible for all aspects of Design FMEAMinimum Core Team:Launch CoordinatorPlant Quality EngineerDesign EngineerProcess EngineerProgram ManagerAQP EngineerFunctional support:Automation engineerTooling engineerDesign FMEA Team StructureProcess EngineerCore TeamExtended Team Recruited

19、by Launch Coordinator through agreement with Functional Supv.;On team until de-commissioning Core team defines tasks to complete;Functional Supv.assigns tasks to extended team;On team until assigned tasks are completed.Must attend FMEAAttend FMEA as required by Core TeamProcess Engineer&Launch Team

20、Responsible for all aspects of Process FMEAMinimum Core Team:Launch CoordinatorPlant Quality EngineerProcess EngineerOperatorFunctional support:Automation engineerSupervisorEnvironmentalTooling engineerDesign engineerProcess FMEA Team StructureProcess FMEA teams with members from different areas bri

21、ng varying degrees of experience and perspective to the problem being analyzed.Organizing the TeamTeam members should have experience working with the processProcess FMEA teams should include members from:Manufacturing or launch coordinatorDesign EngineerAQP EngineerProduction SupervisorOperatorProc

22、ess EngineeringQuality EngineeringTask:Scheduling meetings 2-3 meetings per week.FMEA should not take longer then 8 weeks.Planning the agendaOne hour maximum Orienting team Ensuring completionFacilitator role(preferable Quality/Manu Eng.)Capability Team buildingCoach,counsel,mentor,continually revie

23、w the focus of your team members and adjust direction,and manage/direct team members Good written skills Promotes detail and follows upUnderstands the process and potential process failures He is the person that manages process expectations and process performance.Understands process robustness and

24、process flawsManages and controls all internal aspects of cost,timing,delivery and product expectationsLearned from past experience potential failures,occurrences and detections.Discuss opportunities of prevention,if applicableRole of Process/Manufacturing EngineerDesign Engineer Attends For Process

25、 FMEA Related To A Product Or PartRole of Design engineer Understands critical failure modes from Design FMEAUnderstands SOR or specifications of the product.Knows fit and function of the part very well and provides potential failure modesProvides potential high risk severity Potential failure modes

26、 from daily and hands on experienceProvide potential handling defectsHas experience and knowledge of failure occurrencePotentially your most valuable team membersRole of Supervisor/OperatorRole of AQP EngineerAudits Process FMEAVerifies that failure modes are protectedAssures the High Severity,high

27、emphasize actions are complete1Organizing the team2Getting StartedProcess FMEA 3Analyzing Potential Problems4Identifying Causes and Controls5Identifying and Implementing Corrective Actions6Pitfalls of FMEAGetting StartedIdentify Process or functionReview previous FMEAsHave Design FMEA Complete proce

28、ss steps/functionsConduct Risk AnalysisGetting StartedI start and complete PFMEA at my desk to show Process FMEA to customer for PPAP.Check in the box,FMEA complete for our AQP 6 gate launch processFMEA is a written document generated by a cross functional team to evaluate the potential failure of a

29、 product/process/machine and the effects of the failuresAll FMEAs focus on design,regardless of whether it is of the product,machine or processIt is against SRG policy to provide a copy of our Process FMEAs to the customer WRONG!Process flows include all significant steps and added value on the proc

30、ess/productWhen the risk analysis is performed,the team determines whether each step is a HIGH,MEDIUM,or LOW risk.1Organizing the team2Getting StartedProcess FMEA 3Analyzing Potential Problems4Identifying Causes and Controls5Identifying and Implementing Corrective Actions6Pitfalls of FMEAs1Organizin

31、g the team2Getting StartedProcess FMEA 3Analyzing Potential Problems4Identifying Causes and Controls5Identifying and Implementing Corrective Actions6Pitfalls of FMEAs1Organizing the team2Getting StartedProcess FMEA 3Analyzing Potential Problems4Identifying Causes and Controls5Identifying and Impleme

32、nting Corrective Actions6Pitfalls of FMEAsProcess FMEA Considerations Potential failure modes Impact on manufacturing plant Impact on customers Root Causes of the Potential Failure Detection On The Root Cause(Not The Effect)Ability to detect root cause Recommend corrective actions Effects such as sc

33、ratch,dirt,nickel show are not failure modesProcess Function/RequirementsPotentialFailure modePotential effect of failureSEVC l a s sPotential Cause(s)Mechanism of failureOccurCurrent Process Controls PreventionCurrent Process Controls DetectionDetecRPNRecomm.actionsResp.&Target dateAction takenSEVOCCDETRPNInjection mold GrilleHigh humidity condensationSplay8Dryer not working2PLC Alarm dryer not w