fmea - template .xls - lehigh universityintribos/resources/fme… · xls file · web view ·...

Introduction

Welcome to the FMEA WorksheetThis spreadsheet can be used to

1. Identify potential failure modes and their impact on product reliability.2. Rank the potential defects to establish priority - The highest RPN value items deserve the most attention.3. Capture owners, action plans, and status on high RPN items.

Note, FMEA's are living documents and this may be updated periodically.

Organization of Spreadsheet:

Sheet Protection:Some sheets are protected. There is no password. Released for review: 31-Jul-98

A. Dembski rev 1

Descriptions - explains the spreadsheet cellsFMEA - the actual sheet used to enter dataSeverity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categoriesExample - a partial exmample of an FMEA document

Introduction

Rank the potential defects to establish priority - The highest RPN value items deserve the most attention.

Descriptions

Description of FMEA Worksheet

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By

Component (Design FMEA) FMEA Date

Design Lead Key Date Revision Date

Core Team Page of

Action Results

Item / Function Actions Taken

New

Sev

New

Occ

New

Det

New

RP

N

0 0Leak 8 Over pressure 8 1 64 0

0 00 00 00 00 0

0 0

0 00 00 00 00 00 00 0

Protection:The spreadsheets are not protected or locked.

Potential Failure Mode(s)

Potential Effect(s) of Failure

Sev

Potential Cause(s)/

Mechanism(s) of Failure

Prob

Current Design Controls

Det

RPN

Recommended Action(s)

Responsibility & Target Completion

Date

Coolant containment. Hose connection. Coolant fill. M

Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete

Burst, validation pressure cycle.

Test included in prototype and production validation testing.

J.P. Aguire 11/1/95 E. Eglin 8/1/96

Response Plans and Tracking

Risk Priority Number - The combined weighting of Severity, Likelihood, and Detectability.RPN = Sev X Occ X Det

Likelihood - Write down the potential cause(s), and on a scale of 1-10, rate the Likelihood of each failure (10= most likely). See Likelihood sheet.

Severity - On a scale of 1-10, rate the Severity of each failure (10= most severe). See Severity sheet.

Detectability - Examine the current design, then, on a scale of 1-10, rate the Detectability of each failure(10 = least detectable). See Detectability sheet.

Write down each failure mode and potential consequence(s) of that failure.

Descriptions

0 0

Likelihood - Write down the potential cause(s), and on a scale of 1-10, rate the Likelihood of each failure (10= most likely). See Likelihood sheet.

Detectability - Examine the current design, then, on a scale of 1-10, rate the Detectability of each failure(10 = least detectable). See Detectability sheet.

Houston MayerSix Sigma BlackbeltAugust 21, 2000

5

System Design Verification Process Potential FMEA Number Project IIISubsystem Failure Mode and Effects Analysis Prepared By Houston MayerComponent (Design FMEA) FMEA Date 10/22/1999Design Lead Houston Mayer Key Date Revision Date 8/21/2000Core Team See Project III R1 Report Page 1 of 6

Action Results

Item / Function Actions Taken

New

Sev

New

Occ

New

Det

New

RPN

7 Human error 1 3 21 Closed 10/21/99 0

Data entry error 3 Human error 1 3 9 Closed 10/21/99 0

7 3 3 63 Jun-00 0

1 5 CII 033-001-006 1 5 Sep-00 OPEN 8/21/00



Sev

Potential Cause(s)/ Mechanism(s) of

Failure

Prob


Det

RPN



Date

Customer sends in a quote request for product.

System, Software, Integration and Shipping requirements overlooked by customer.

Customer needs not fully met by delivered system.

Design configuration tool.

Use configuration tool when available.

Requirement entered and verified by Inside Sales in config. tool.

System compatability requirements not evaluated by config. tool.

Order verified by a configuration tool.

Continue order verification by configuration tool.

Sales identifies need for CII or SHC

Specific packing, labeling and shipping requirements may not be fully addressed.

On time delivery and integraty of the product may be compramised if this issue is not addressed.

Requirements Overlooked.

Customer Inspection Instruction/ Special Handling Codes Process 033-001-02

Publish comprehensive procedure for the 1st Article Process.

Customer shipping requirements reviewed by quality assurance in 1st Article process.

Position of the DHR in ICD label packet not identified by GE.Requirment in Purchase Specification for mousepad, but not identified on Bill of Material.ICD Card content requirements not identified in Build Procedure.

Loss of business with the customer.


Revisit contents of GE CII 033-001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.


6

7 3 3 63 Closed 10/25/99 0

Data entry error 1 Human Error 1 3 3 Closed 1/25/00 0

3 6 3 54 Closed 10/25/99 0

1 Process Failure 1 1 1 Closed 1/25/00 0




QA and Pack and Ship Team reviews customer requirements during a 1st Article.


Customer's full expectations may not be realized.

Requirements overlooked.

Customer requirements physically verified by quality assurance during the 1st Article process.

Continue current pracices.

Inside sales submits Sales Order Authorization request to TECenter.

Order Processing Delay

Customer requirements verified by a TECenter engineer.

Continue current practices.

TECenter Engineer reviews the design to determain if additional data is required.

Requirements overlooked by Engineer





Appropriate individuals are contacted to resolve issues.

Appropriate individuals not available.


Individuals are contacted to resolve issues.


Design Review is completed.

Requirements may not be complete




Another engineer performs quality check of the design.

Requirements overlooked by two Engineer




Completed design verification is sent to appropriate organization.

Design verification misrouted


Verification is sent to appropriate organization.



7



Order misrouted 1 Process Failure 1 1 1 Closed 1/27/00 0

Data Entry Error 3 Human Error 1 1 3 Closed 1/27/00 0

1 Process Failure 1 Expidite Process 1 1 Closed 1/27/00 0


5 3 1 15 Closed 10/25/99 0

1 1 Expidite Process 1 1 Closed 1/27/00 0


Requirements are defined and capability to meet/ accept requirements.

Requirements may be missed or capibilty to meet overestamated


Requirements are defined and to meet requirements.


Inside Sales quotes price and availability

Wrong price and availability provided to customer


Price provided to customer


Customer sends in purchase order.


Reprocess Order


Inside sales places order on system.


Reprocess Order


Order approved by Asset Management.

Approval not timely



Order approved by credit.

Approval not timely



Determaination made that product is available for build.

All product required for the order may not be available at the start of the build.

(1) Product delivery date requirements may not be met. (2) Workspace occupied for an order awaiting Product is not available for integration of other orders.

Needed components are not available at the time of need.

Assure product availability before the order commitment is given to customer.


Inside sales expedites with Asset to provide ship date.

Shipdates may not be accurate




Order approved by Asset Mgmt. and e-mail sent to Integration.

e-mail may be misrouted




8

3 1 1 3 Closed 10/25/99 0

5 3 3 45 Closed 1/27/00 0

3 1 Expidite Process 1 3 Closed 1/27/00 0

1 Process Failure 1 Expidite Process 1 1

7 3 5 105

3 3 3 27

3 1 1 3

3 1 Expidite Process 1 3 Closed 1/27/00

3 1 1 3 Closed 1/27/00

3 3 1 9 Closed 1/27/00

Project Manager reviews order for special or internal instructions.

Order processing requirements may be overlooked

Customer and processing needs not identified could prevent timely processing of the order.

Processing requirements overlooked.

Project Manager order review.


Build document bill of material matched with SCN.

Documents do not match



Expidite ProcessIntegration Center Operations Manual 093-009-OPSMNL


Stock availability is checked and delivery dates are aquired for non stock items.

stock availability and dates may be inaccurate




Order is forwarded to Production Engineer for review.

Order may be misrouted




Determanation made for a 1st Article build.

Need for 1st build may be overlooked






Build document is reviewed and verified.

Requirements may be overlooked






Project management notifies sales with status of order.

Sales may not receive order status






Asset management places order for non stock items.

Items may not be ordered




Order is scheduled for production.

Order may not be entered in schedule





Whse Operator reviews parts to SOA & SCN.

Parts may not match requirement






9

3 3 3 27 Closed 1/27/00

5 3 1 15 Closed 1/27/00

7 3 3 63 Closed 1/27/00

1 1 5 5 Closed 8/21/00

7 7 3 147 Closed 1/27/00

10 10 1 100 Closed 1/27/00

5 1 5 25

Whse. Operator Unpack,Iinspect & Kit order.

All parts may not reach integration


All components are not available at the time of need.

Individuals are contacted to resolve issues.Integration Kitting and Packing 153-001-01


Techs. Check product against SOW and build instructions.

Parts may not match requirement





Integration Techs. inspect parts and chassis.

Materials may not be compliant



QA Inspection and Test Procedure 103-001-03


No NT Resource KitMissing Video Board




Update Build Procedures to clearly define product requirements specific to the model being integrated.

Techs. Integrate & Power-Up System

System may be integrated incorrectly





Integration Techs. Test system.

System and parts may not be compliant





Quality techs. inspect product for build requirements.

Specific build requirements may not be fully addressed.






10

1 Human Error 5 5 25 Closed 8/21/00

3 3 1 9 Closed 1/27/00

1 1 1 1 Closed 1/27/00

3 3 1 9 Closed 1/27/00

3 Process Failure 1 1 3 Closed 1/27/00

7 Process Failure 1 1 7 Closed 1/27/00

10 3 3 90 Closed 1/25/00

IO panel not installedLabel on CPU IncorrectNo feet or other components installedNo extension cablesMissing cablesIO panel gasket not installedWrong ICD cards providedDome calibrater included


Build Procedure for individual PathSpeed Model

Update Build Procedures to clearly define product requirements specific to the model being integrated.

Product serial numbers scanned into Genesis.

Numbers may be incorrect





Change made after batch release

Control of requirements may be lost





Order placed on hold when change is made.

Shiping deadlines may not be met





Design Process reinitiates

Control of requirements may not be complete




Whse. invoices and ships order per customer's shipping method.

Wrong Shipping method may be used




Quality techs. inspect shipment for CII/SHC requirements.




Customer Inspection Instruction/ Special Handling Codes Process 033-001-02



11

1 Human Error 3 CII 033-001-006 3 9 9/11/2000

7 3 7 147 Closed 1/27/00

3 1 1 3 Closed 1/25/00

Label on outside of box did not match S/N on CPU.


Revisit contents of GE CII 033-001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.

Product ships to customer.

Products misshipped





Coordinator closes project & files quality records.

Documents not filed correctly

Documents may not be retrievable

Documents may not be retrievable



Severity

Effect SEVERITY of Effect Ranking10

9

Very High 8

High System inoperable with equipment damage 7

Moderate System inoperable with minor damage 6

Low System inoperable without damage 5

Very Low System operable with significant degradation of performance 4

Minor System operable with some degradation of performance 3

Very Minor System operable with minimal interference 2

None No effect 1

Hazardous without warning

Very high severity ranking when a potential failure mode affects safe system operation without warning

Hazardous with warning

Very high severity ranking when a potential failure mode affects safe system operation with warningSystem inoperable with destructive failure without compromising safety

Probability

PROBABILITY of Failure Failure Prob RankingVery High: Failure is almost inevitable >1 in 2 10

1 in 3 9High: Repeated failures 1 in 8 8

1 in 20 7Moderate: Occasional failures 1 in 80 6

1 in 400 51 in 2,000 4

Low: Relatively few failures 1 in 15,000 31 in 150,000 2

Remote: Failure is unlikely <1 in 1,500,000 1

Detectability

Detection Likelihood of DETECTION by Design Control Ranking10

Very Remote 9

Remote 8

Very Low 7

Low 6

Moderate 5

Moderately High 4

High 3

Very High 2

Almost Certain 1

Absolute Uncertainty

Design control cannot detect potential cause/mechanism and subsequent failure modeVery remote chance the design control will detect potential cause/mechanism and subsequent failure modeRemote chance the design control will detect potential cause/mechanism and subsequent failure modeVery low chance the design control will detect potential cause/mechanism and subsequent failure modeLow chance the design control will detect potential cause/mechanism and subsequent failure modeModerate chance the design control will detect potential cause/mechanism and subsequent failure modeModerately High chance the design control will detect potential cause/mechanism and subsequent failure modeHigh chance the design control will detect potential cause/mechanism and subsequent failure modeVery high chance the design control will detect potential cause/mechanism and subsequent failure modeDesign control will detect potential cause/mechanism and subsequent failure mode

EXAMPLE

System

Subsystem

Component

Design Lead

Core Team

Item / Function

Seals



Sensor mount. Seal

Compression set

Sensor mount. Seal

Loosen during sensor assembly/service

Sensor mount. Seal

Damaged internal thread

Sensor mount. Seal

Damaged external thread



EXAMPLE

System

Subsystem

Component

Design Lead

Core Team

Item / Function Potential Failure Mode(s)

Stress crack

Stress crack

Stress crack

Corrosion

Corrosion





Hold fluid, flow path, Heat transfer structure





EXAMPLE

System

Subsystem

Component

Design Lead

Core Team

Item / Function Potential Failure Mode(s)

Puncture

Seam fail

Burst fail

Plugged

Ballooning






EXAMPLE

Potential FMEA NumberFailure Mode and Effects Analysis Prepared By

(Design FMEA) FMEA Date

Key Date Revision Date

Page of

Action Results

Actions Taken

New

Sev

New

Occ

New

Det

00

Leak 8 Gasket material 7 1 56

8 2 Added rib. 1 16

5 2 1 10

4 3 1 12

Leak 8 Over pressure 8 1 64


Sev


Failure

Prob


Det

RPN



Date

Pressure cycle w/cold shock.

Use imported material

Leak. Fall inside tank

Fitting not held in place

Implement holding rib in design. New fitting design. Prototype validation.

J.P. Aguire 11/1/95

Cannot install sensor

Damaged during installation or transportation

Cannot install wire nut

Damaged during shipment to piracicaba

Damaged fitting not used by Piracicaba

Burst, validation pressure cycle.

Test included in prototype and production validation testing.

J.P. Aguire 11/1/95 E. Eglin 8/1/96

EXAMPLE




Page of

Action Results

Actions Taken

New

Sev

New

Occ

New

Det


Sev


Failure

Prob


Det

RPN



Date

Failed mount 5 Vibration 9 3 135 J.P. Aguire

Hose leak 6 5 2 60

0 Operator instruction

0

8 7 Thermal cycle 1 56 E. Eglin 8/1/96

0

8 7 5 280 Coolant ordered

Vibration w/road tapes

Obtain GMB vibration road tape.

Overpressure. Poor clamp

Burst, validation pressure cycle w/GMB clamps.

Obtain GMB clamps and clamping specification.

J.P. Aguire 12/1/95

Air conditioning does not work. Sudden refrigerant loss.

This is a test of the ADD POTENTIAL CAUSE/MECHANISM OF FAILURE system functionality


This is a test of the ADD POTENTIAL CAUSE/MECHANISM OF FAILURE system functionality

This is a test of the ADD RECOMMENDED ACTION system functionality

Leak. Loss of heat transfer.

Wicking. Material strength

Included in Product Specification


this is a test while dan is here


Coolant quality. Contamination. Environment - int/ext.

SWAT, service simulation. Coolant evaluation.

Brazilian coolant to be evaluated. Zince lined tubes may need to be released. Simulated service test w/GMB coolant to be performed.

J.P. Aguirre 11/1/95

EXAMPLE




Page of

Action Results

Actions Taken

New

Sev

New

Occ

New

Det


Sev


Failure

Prob


Det

RPN



Date

8 10 1 80 E. Eglin 8/1/96

5 Environment - int/ext. 1 1 5 E. Eglin 8/1/96

8 2 Burst/leak pressure 5 80 GMB 12/1/95 Study originated

8 7 1 56 Coolant ordered

5 9 8 360 GMB 12/1/95

000


External damage. Coolant velocity. No reinf sawcut.

Leak test. Simulated service.

100% cores tested in production. Simulated service included in Product Specificatin.


SWAT, service simulation.

Included in Product Specification.


Over pressure contamination.

GMB to study engine cleanliness.

Loss of heat transfer. Leakage due to increase flow velocity

Contamination. Coolant quality.

GMB coolant to be evaluated. GMB to study engine cleanliness.

J.P. Aguirre 11/1/95


Over pressure contamination.

GMB to study engine cleanliness. Clustomer profile to be determined.

EXAMPLE

Action Results

New

RPN

00

0

0

0

0

0

EXAMPLE

Action Results

New

RPN

0

0

0

0

0

0

0

EXAMPLE

Action Results

New

RPN

0

0

0

0

0

000