Lean six sigma process improvement tools and techniques by donna summers chapter 22

Failure Modes and Effects
Analysis
Chapter 22

Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.


Failure Modes and Effects
Analysis
• Failure Modes and Effects (FMEA)
– Critically examine the system
– Divide the system into its various components
– Examine each individual component
• Record the ways the component may fail
• Rate potential degree of hazard
– Examine all potential failures for each individual component and
decide what effect the failures may have
» Weakness: Human Error Component Missing
» See additional notes

Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.

Failure Modes and Effects
Analysis
• Failure Modes and Effects Analysis
– Design FMEA’s
• used to verify that a product has been properly designed to
meet all of the customer’s requirements and that it can be
manufactured at a target rate, cost, and yield.

– Process FMEA’s
• used to assess the adequacy of a process in producing a
product.

Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.


Failure Modes and Effects
Analysis
• What are Design FMEA’s used for?
– To capture the relationship between:
•
•
•
•

customer requirements and
how a product can fail to meet these requirements and

the effects of the failures and
the problems with the design that cause the failures.

– As a method to ensure that the design will
be changed and tested so that the failures
do not occur.
Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.


Failure Modes and Effects
Analysis
• What are Process FMEA’s used for?
– To identify the process and product controls
that must be implemented to ensure that the
product can be produced within specification.

Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.


Failure Modes and Effects
Analysis
• What are Process FMEA’s used for?

– To capture the relationship between
• each process step and
• the unacceptable process outputs that can be created at
each step and
• the effects of the unacceptable process outputs and
• the causes of the unacceptable outputs and
• how the unacceptable outputs will be either prevented or
detected in the event that they occur.

Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.


Failure Modes and Effects
Analysis
• Steps to Create an FMEA
– Create a form similar to that shown in the chapter
– Study the system, process, or part
•
•
•
•
•

What are the potential failure modes?
What are the potential failure causes?
What are the potential failure consequences?

What are the existing controls?
Identify Risk Priority Code
– Severity
– Probability of Occurrence

• Analyze the document

Lean Six Sigma: Process Improvement Tools and Techniques
Donna C. Summers

© 2011 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.