FMEA, RPN, and Process Sigma

FMEA: How To Perform a Failure Mode and Effects Analysis Tutorial

FMEA (Failure mode and effects analysis) is a part of DMAIC in Six Sigma

Is a step after C&E Matrix ant it is used for analysis of potential failure modes within a system

Every defect is measured by Severity, Occurrence and Detection. The multiplication of these elements gives the Risk prioritization (Risk Priority Number RPN) for every case.

Uses of FMEA

• Development of system requirements that minimize the likelihood of failures.
• Development of methods to design and test systems to ensure that the failures have been eliminated.
• Evaluation of the requirements of the customer to ensure that those do not give rise to potential failures.
• Identification of certain design characteristics that contribute to failures, and minimize or eliminate those effects.
• Tracking and managing potential risks in the design. This helps avoid the same failures in future projects.
• Ensuring that any failure that could occur will not injure the customer or seriously impact a system.
• To produce world class quality products

Advantages

• Improve the quality, reliability and safety of a product/process
• Improve company image and competitiveness
• Increase user satisfaction
• Reduce system development timing and cost
• Collect information to reduce future failures, capture engineering knowledge
• Reduce the potential for warranty concerns
• Early identification and elimination of potential failure modes
• Emphasis problem prevention
• Minimize late changes and associated cost
• Catalyst for teamwork and idea exchange between functions
• Reduce the possibility of same kind of failure in future

A very useful article about C&E Matrix

Need Help Making Decisions?
by Ron Pereira on June 11th, 2007

Posted using ShareThis

Here is a list of the main Process Analysis methods:

• Cause and Effect - Fishbone
• 5 Whys Analysis
• Process Mapping
• Value Stream Mapping
• Mind Mapping
• SIPOC
• C&E Matrix
• Value-Add Analysis
• Waste Analysis
• FMEA
• Pair-wise Comparison

Lean Manufacturing


Continuous Improvement In Manufacturing

White Belt Program


Lean



Process Control

How to get detailed information for Business process:

People - who is involved?
- Roles
- Employees

Systems - is the task performed by a system?
- which one
- define inputs and outputs

Time - how long the task is performed?

Location - where is the task performed?

Documents - which documents are involved?

Decisions - where are the decisions set?

Information transformation - Are there any changes of the information?
- size
- format
- structure

Control - are there any possibilities for changing the KPIs or changing the rules