FMEATrainingSRGGlobal4109.pptx

FMEATrainingSRGGlobal4109.pptx

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HowIsAParadigmFormed?

Paradigm:

Asetofassumptions,concepts,values,andpracticesthatconstitutesawayofviewingrealityforthecommunity.（Paradigm=Example）Agroupofscientistsplaced5monkeysinacageandinthemiddle,aladderwithbananasonthetop.Everytimeamonkeywentuptheladder,thescientistssoakedtherestofthemonkeyswithcoldwater.Afterawhile,everytimeamonkeywentuptheladder,theothersbeatuptheonewhotriedtogouptheladder.Aftersometime,nomonkeydaretogouptheladderregardlessofthetemptation.Scientiststhendecidedtosubstituteoneofthemonkeys.The1stthingthisnewmonkeydidwastogouptheladder.Immediatelytheothermonkeysbeathimup.Afterseveralbeatings,thenewmemberlearnednottoclimbtheladdereventhoughitneverknewwhy.A2ndmonkeywassubstitutedandthesameoccurred.The1stmonkeyparticipatedonthebeatingforthe2ndmonkey.A3rdmonkeywaschangedandthesamewasrepeated（beatings）.The4thwassubstitutedandthebeatingwasrepeatedandfinallythe5thmonkeywasreplaced.Whatwasleftwasagroupof5monkeysthateventhoughneverreceivedacoldshower,continuedtobeatupanymonkeywhoattemptedtoclimbtheladder.Ifitwaspossibletoaskthemonkeyswhytheywouldbeatupallthosewhoattemptedtogouptheladder.Ibetyoutheanswerwouldbe.“Idontknowthatshowthingsaredonearoundhere”Doesitsoundfamiliar?

SothequestionisHowdowekeepfrommakingthesamemistakesoverandoveragain?

The“ArtOfPerfection”WithAWonderfulFMEAAgendaFMEATrainingSuzhouPlantDay1FMEA&PokeYokeTrainingDay2WorkshopPurposeExplainStandardFMEAPracticeClarifyRolesOfTheFMEATeamMembersDoingaProcessFMEACorrectlyMakeFMEAsValueAddedAndUserFriendlyConcludingthistraining:

definitiveuseofcorrectFMEApractices.DiscussFMEAEffectiveness,andMeasurablesTocaptureanddriveforbestpracticedesignandprocessesEliminateRedundancyIntroduceandexploretheuseofFMEAbuildingblocksWhy?

Severalcrisislaunches,yardcampaigns,8Dsandcustomerconcernsthatresultedinsignificant$losses.80%oftheseissuesareduetopoorFMEAsCrisislaunchesdrainresourcesfrombusinessunits,design,corporatetoolingandplants.Insteadoffirefighting,wecanusetheseresourcesonnewprogramsandspendmoretimeonDesignFMEAsandProcessFMEAs（Workloadinthebeginningofaprogram,notafterthefact）PlanTrainFMEAforallSRGAutomotiveplantsandcorporatesupportDoingworkshopsandworktogetherwithtraineronstandardFMEApracticeGoal=BestpracticeDesignandProcessFMEA.FMEAsarenotgiventocustomerwithPPAPpackageStandardizeAcrossSRGPlants:

EveryoneneedstoapplystandardFMEApracticewithseverity,occurrenceanddetection.UsethebuildingblockapproachAllprocessesneedtohaveaPFMEA,criticalprocessparameters,pokeyokesImprovementInitiativesfortheFMEAprocessResponsibility/Accountability.DesignEngineeringisleadingtheDesignFMEA,andmakessureDFMEAisavailablefortheprocesspeopleandProgramManagersProgramManagersareresponsibleformakingsuretheDFMEAisprovidedtotheplantsProcessEngineeringGroupPlantProcessEngineersareleadingtheProcessFMEA,andmakingsurethePFMEAisavailabletoplantandproductionpersonnel.QualityEngineerassurecontrolplaniscompletedandsignificantcharacteristicsareproperlylinkedfromDesignandProcessFMEAImprovementInitiativesfortheFMEAprocessFMEAduringAQP&GateLaunchProcess.AToolonlyworkswhenyouuseit!

TheFMEAmustbecompletedduringtheAQPphaseatthereresponsiblegates,foranyproductorprocessTheFMEAmustbereviewedandupdatedatastandardfrequencyascontinuousimprovementTheFMEAmustbeusedasatoolforuseinpotentialrootcauseanalysis,lessonslearnedactivityandbestpracticereviewsWheredoestheFMEA“fitinourprocess”ThePDCAcycle:

（Plan,Do,Check,Act）FMEAsaremulti-functionalItworksasatooltoplanforimprovementItisalivingdocumentandshouldbeusedascontinualimprovementItdeterminesyourfailuremodes,goodimplementationavoidsfailuremodesratherthandetectspotentialdefectsFocusinthe“DO”sectionofthecontinuousimprovementcycleFISHFocusImproveSustainHonorHFISFocusinonthehighCriticalorRPNvaluesforimprovementReducetheCriticalorRPNvaluesthroughActionSustaintheImprovement,andreadjusttheOccurrenceorDetectionValuesRecognizetheImprovementonallaffectedFMEAsandmovetorefocusimprovements1OrganizingTheTeam2GettingStartedProcessFMEA3AnalyzingPotentialProblems4IdentifyingCausesandControls5IdentifyingandImplementingCorrectiveActions6PitfallsofFMEAsOrganizingtheTeamMembersAndTheirRolesDesignengineerCoreTeamExtendedTeamRecruitedbyProg.ManagerthroughagreementwithFunctionalSupv.;Onteamuntilde-commissioningCoreteamdefinestaskstocomplete;FunctionalSupv.assignstaskstoextendedteam;Onteamuntilassignedtasksarecompleted.MustattendFMEAAttendFMEAasrequiredbyCoreTeamDesignEngineer&LaunchTeamResponsibleforallaspectsofDesignFMEAMinimumCoreTeam:

LaunchCoordinatorPlantQualityEngineerDesignEngineerProcessEngineerProgramManagerAQPEngineerFunctionalsupport:

AutomationengineerToolingengineerDesignFMEATeamStructureProcessEngineerCoreTeamExtendedTeamRecruitedbyLaunchCoordinatorthroughagreementwithFunctionalSupv.;Onteamuntilde-commissioningCoreteamdefinestaskstocomplete;FunctionalSupv.assignstaskstoextendedteam;Onteamuntilassignedtasksarecompleted.MustattendFMEAAttendFMEAasrequiredbyCoreTeamProcessEngineer&LaunchTeamResponsibleforallaspectsofProcessFMEAMinimumCoreTeam:

LaunchCoordinatorPlantQualityEngineerProcessEngineerOperatorFunctionalsupport:

AutomationengineerSupervisorEnvironmentalToolingengineerDesignengineerProcessFMEATeamStructureProcessFMEAteamswithmembersfromdifferentareasbringvaryingdegreesofexperienceandperspectivetotheproblembeinganalyzed.OrganizingtheTeamTeammembersshouldhaveexperienceworkingwiththeprocessProcessFMEAteamsshouldincludemembersfrom:

ManufacturingorlaunchcoordinatorDesignEngineerAQPEngineerProductionSupervisorOperatorProcessEngineeringQualityEngineeringTask:

Schedulingmeetings2-3meetingsperweek.FMEAshouldnottakelongerthen8weeks.PlanningtheagendaOnehourmaximumOrientingteamEnsuringcompletionFacilitatorrole（preferableQuality/ManuEng.）CapabilityTeambuildingCoach,counsel,mentor,continuallyreviewthefocusofyourteammembersandadjustdirection,andmanage/directteammembersGoodwrittenskillsPromotesdetailandfollowsupUnderstandstheprocessandpotentialprocessfailuresHeisthepersonthatmanagesprocessexpectationsandprocessperformance.UnderstandsprocessrobustnessandprocessflawsManagesandcontrolsallinternalaspectsofcost,timing,deliveryandproductexpectationsLearnedfrompastexperiencepotentialfailures,occurrencesanddetections.Discussopportunitiesofprevention,ifapplicableRoleofProcess/ManufacturingEngineerDesignEngineerAttendsForProcessFMEARelatedToAProductOrPartRoleofDesignengineerUnderstandscriticalfailuremodesfromDesignFMEAUnderstandsSORorspecificationsoftheproduct.KnowsfitandfunctionofthepartverywellandprovidespotentialfailuremodesProvidespotentialhighriskseverityPotentialfailuremodesfromdailyandhandsonexperienceProvidepotentialhandlingdefectsHasexperienceandknowledgeoffailureoccurrencePotentiallyyourmostvaluableteammembersRoleofSupervisor/OperatorRoleofAQPEngineerAuditsProcessFMEAVerifiesthatfailuremodesareprotectedAssurestheHighSeverity,highemphasizeactionsarecomplete1Organizingtheteam2GettingStartedProcessFMEA3AnalyzingPotentialProblems4IdentifyingCausesandControls5IdentifyingandImplementingCorrectiveActions6PitfallsofFMEAGettingStartedIdentifyProcessorfunctionReviewpreviousFMEAsHaveDesignFMEACompleteprocesssteps/functionsConductRiskAnalysisGettingStartedIstartandcompletePFMEAatmydesktoshowProcessFMEAtocustomerforPPAP.Checkinthebox,FMEAcompleteforourAQP6gatelaunchprocessFMEAisawrittendocumentgeneratedbyacrossfunctionalteamtoevaluatethepotentialfailureofaproduct/process/machineandtheeffectsofthefailuresAllFMEAsfocusondesign,regardlessofwhetheritisoftheproduct,machineorprocessItisagainstSRGpolicytoprovideacopyofourProcessFMEAstothecustomerWRONG!

Processflowsincludeallsignificantstepsandaddedvalueontheprocess/productWhentheriskanalysisisperformed,theteamdetermineswhethereachstepisaHIGH,MEDIUM,orLOWrisk.1Organizingtheteam2GettingStartedProcessFMEA3AnalyzingPotentialProblems4IdentifyingCausesandControls5IdentifyingandImplementingCorrectiveActions6PitfallsofFMEAs1Organizingtheteam2GettingStartedProcessFMEA3AnalyzingPotentialProblems4IdentifyingCausesandControls5IdentifyingandImplementingCorrectiveActions6PitfallsofFMEAs1Organizingtheteam2GettingStartedProcessFMEA3AnalyzingPotentialProblems4IdentifyingCausesandControls5IdentifyingandImplementingCorrectiveActions6PitfallsofFMEAsProcessFMEAConsiderationsPotentialfailuremodesImpactonmanufacturingplantImpactoncustomersRootCausesofthePotentialFailureDetectionOnTheRootCause（NotTheEffect）AbilitytodetectrootcauseRecommendcorrectiveactionsEffectssuchasscratch,dirt,nickelshowarenotfailuremodesProcessFunction/RequirementsPotentialFailuremodePotentialeffectoffailureSEVClassPotentialCause（s）MechanismoffailureOccurCurrentProcessControlsPreventionCurrentProcessControlsDetectionDetecRPNRecomm.actionsResp.&TargetdateActiontakenSEVOCCDETRPNInjectionmoldGrilleHighhumiditycondensationSplay8Dryernotworking2PLCAlarmdryernotw