Effective FMEAs

Name: Effective FMEAs | Achieving Safe, Reliable, and Economical Products and Processes using Failure Mode and Effects Analysis
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Achieving Safe, Reliable, and Economical Products and Processes using Failure Mode and Effects Analysis

Carl Carlson(Autor*in)

Wiley (Verlag)

Erschienen am 6. April 2012

464 Seiten

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Inhalt

Intro
Effective FMEAs
Contents
Series Editor's Foreword
Copyrights and Permissions
Acknowledgments
Introduction
Chapter 1: The Case for Failure Mode and Effects Analysis
IN THIS CHAPTER
1.1 THE NEED FOR EFFECTIVE FMEAs
1.2 FMEA APPLICATION BY INDUSTRY
1.3 THE FACTOR OF 10 RULE
1.4 FMEA SUCCESSES
1.5 BRIEF HISTORY OF FMEA
1.6 FMEA STANDARDS AND GUIDELINES
1.7 HOW TO USE THIS BOOK
1.8 WEB COMPANION TO EFFECTIVE FMEAs
1.9 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 2: The Philosophy and Guiding Principles for Effective FMEAs
IN THIS CHAPTER
2.1 WHAT IS PHILOSOPHY AND WHY DOES IT MATTER TO FMEAs?
2.2 GUIDING PRINCIPLES FOR EFFECTIVE FMEAs
2.2.1 Having the Right Objectives
2.2.2 Having the Right Resources
2.2.3 Having the Right Procedures
2.3 THE ROLE OF FMEA IN DESIGN FOR RELIABILITY
2.4 YOU CAN'T ANTICIPATE EVERYTHING
2.5 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 3: Understanding the Fundamental Definitions and Concepts of FMEAs
IN THIS CHAPTER
3.1 DEFINITION OF FMEA
3.2 PRIMARY OBJECTIVE OF FMEA
3.3 DEFINITION OF FAILURE MODE EFFECTS AND CRITICALITY ANALYSIS
3.4 TYPES OF FMEAs
3.5 FMEA DEFINITIONS AND EXAMPLES
3.5.1 Item
3.5.2 Function
3.5.3 Failure Mode
3.5.3.1 Failure Modes at System/Subsystem Level versus Component Level
3.5.4 Effect
3.5.5 Severity
3.5.6 Cause
3.5.7 Occurrence
3.5.8 Controls
3.5.9 Detection
3.5.10 Risk Priority Number
3.5.11 Recommended Actions
3.6 IS IT A FAILURE MODE, EFFECT, OR CAUSE?
3.7 FMEA GLOSSARY
3.8 WEB COMPANION TO EFFECTIVE FMEAs
3.9 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 4: Selection and Timing of FMEA Projects
IN THIS CHAPTER
4.1 GUIDELINES FOR WHEN TO DO FMEAs
4.2 FMEA PROJECT SELECTION CRITERIA
4.3 PRELIMINARY RISK ASSESSMENT
4.4 WHEN TO DO DIFFERENT TYPES OF FMEAs
4.5 RESPONSIBILITY FOR FMEAs BETWEEN OEMs AND SUPPLIERS
4.6 INTRODUCING THE ALL-TERRAIN BICYCLE CASE STUDY
4.7 END OF CHAPTER PROBLEMS
Chapter 5: How to Perform an FMEA Project: Preparation
IN THIS CHAPTER
USE OF THE BICYCLE EXAMPLES IN THE CHAPTER
5.1 THE SUBJECT OF FMEA PREPARATION
5.2 PREPARATION TASKS DONE ONCE FOR ALL FMEA PROJECTS
5.2.1 FMEA Software Selection
5.2.2 Selecting or Modifying FMEA Worksheets and Scales
5.2.3 Identifying Roles and Responsibilities
5.2.4 FMEA Team Training
5.2.5 Legal Guidelines for Doing FMEAs
5.2.6 Meeting Logistics
5.2.7 Defining the System Hierarchy (For System and Design FMEAs)
5.2.8 Defining the Process Steps (for Process FMEAs)
5.2.9 Access to Failure Information
5.3 PREPARATION TASKS FOR EACH NEW FMEA PROJECT
5.3.1 Determine the Scope of the Analysis
5.3.2 Make the Scope Visible (for System and Design FMEAs)
5.3.2.1 FMEA Block Diagram
5.3.2.2 FMEA Interface Matrix
5.3.2.3 Parameter Diagram (P-Diagram)
5.3.2.4 Functional Block Diagram
5.3.3 Make the Scope Visible (for Process FMEAs)
5.3.3.1 Process Flow Diagram (PFD)
5.3.3.2 PFD Worksheet
5.3.4 Assemble the Correct Team
5.3.5 Establish the Ground Rules and Assumptions
5.3.6 Establish the Role of Suppliers
5.3.7 Gather and Review Relevant Information
5.3.7.1 "Gather Information Checklist" (for System and Design FMEAs)
5.3.7.2 "Gather Information Checklist" (for Process FMEAs)
5.3.8 Prepare FMEA Software for First Team Meeting
5.3.9 Ready-for-First-Meeting Checklist
5.4 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 6: How to Perform an FMEA Project: Procedure
IN THIS CHAPTER
USE OF THE BICYCLE EXAMPLES IN THE CHAPTER
6.1 FMEA PROCEDURE SEQUENCE OF STEPS
6.2 BASIC FMEA PROCEDURE
6.2.1 Items
6.2.2 Functions
6.2.2.1 Requirements
6.2.2.2 Checklist of Function Types
6.2.3 Failure Modes
6.2.4 Effects
6.2.5 Severity Ranking
6.2.6 Classification (Optional)
6.2.7 Causes and Failure Mechanisms
6.2.7.1 Failure Mechanisms (for System and Design FMEAs)
6.2.7.2 Five Whys
6.2.8 Occurrence Ranking
6.2.9 Controls
6.2.9.1 Design Controls for System or Design FMEAs
6.2.9.2 Process Controls for Process FMEAs
6.2.9.3 Use of Early Warning Devices and Mitigating Controls
6.2.10 Detection Ranking
6.2.10.1 Detection Scale for Assessing Risk Related to In-Service Detection Systems
6.2.10.2 Limitations and Alternatives to Using Detection Ranking
6.2.11 Risk Priority Number (RPN)
6.2.11.1 Limitations and Alternatives to Using RPN
6.3 FMEA LINKAGES
6.3.1 System or Design FMEA Linkage to Design Verification Plan
6.3.2 Process FMEA Linkage to Process Control Plans
6.3.3 Design FMEA Linkage to Process FMEA
6.3.4 Relationship between System, Subsystem, and Component FMEAs
6.4 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 7: How to Develop and Execute Effective Risk Reduction Actions
IN THIS CHAPTER
USE OF THE BICYCLE EXAMPLES IN THE CHAPTER
7.1 PRIORITIZE ISSUES FOR CORRECTIVE ACTION
7.1.1 Is Action Always Required on High Severity Issues?
7.2 DEVELOP EFFECTIVE RECOMMENDED ACTIONS
7.2.1 Quality and Reliability Resources to Help Formulate FMEA Recommended Actions
7.3 ACTION STRATEGIES TO REDUCE RISK
7.3.1 Action Strategies to Reduce Severity Risk
7.3.2 Action Strategies to Reduce Occurrence Risk
7.3.3 Action Strategies to Reduce Detection Risk
7.3.4 Common Action Strategy Mistakes to Avoid
7.4 EXAMPLES OF RECOMMENDED ACTIONS
7.5 FMEA EXECUTION ENABLERS
7.6 THE ESSENCE OF EXECUTION
7.7 DOCUMENTING ACTIONS TAKEN
7.8 ENSURING RISK IS REDUCED TO AN ACCEPTABLE LEVEL
7.9 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 8: Case Studies
IN THIS CHAPTER
8.1 CASE STUDY: SHOCK ABSORBER ASSEMBLY
8.2 CASE STUDY: STRUDEL PASTRY MANUFACTURING
8.3 CASE STUDY: MOTOROLA SOLUTIONS "PRESS-TO-TALK" FEATURE
8.4 CASE STUDY: FLASHLIGHT
8.5 CASE STUDY: DC-10 CARGO DOOR FAILURE
8.6 CASE STUDY: SPACE SHUTTLE CHALLENGER O-RING FAILURE
8.7 CASE STUDY: PROJECTOR LAMP
8.8 CASE STUDY: ALL-TERRAIN BICYCLE
8.8.1 All-Terrain Bicycle System FMEA
8.8.2 All-Terrain Hand Brake Design FMEA
8.8.3 All-Terrain Brake Cable Design FMEA
8.8.4 All-Terrain Process FMEA (Wheel Spoke Installation)
8.9 CASE STUDY: RESIN LEVER
8.10 CASE STUDY: POWER STEERING
8.11 OTHER CASE STUDIES AND EXAMPLES
8.12 WEB COMPANION TO EFFECTIVE FMEAs
8.13 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 9: Lessons Learned for Effective FMEAs
IN THIS CHAPTER
9.1 THE MOST COMMON FMEA MISTAKES: HOW TO AVOID THEM AND AUDIT THEM
9.2 SUMMARY OF FMEA QUALITY OBJECTIVES
9.3 FMEA QUALITY AUDIT PROCEDURE
9.4 END OF CHAPTER PROBLEMS
Chapter 10: How to Facilitate Successful FMEA Projects
IN THIS CHAPTER
10.1 FMEA FACILITATION
10.2 EFFECTIVE MEETINGS
10.3 PRIMARY FMEA FACILITATION SKILLS
10.3.1 Brainstorming
10.3.2 Asking Probing Questions
10.3.3 Encouraging Participation
10.3.4 Active Listening
10.3.5 Controlling Discussion
10.3.6 Making Decisions
10.3.7 Conflict Management
10.3.8 Facilitator Interventions
10.3.9 Managing Time
10.3.10 Common Facilitation Problems
10.3.11 Attitude
10.4 UNLEASHING TEAM CREATIVITY
10.4.1 Techniques to Stimulate Divergent Thinking
10.5 FMEA FACILITATION ROLES AND RESPONSIBILITIES
10.6 HOW TO REDUCE FMEA IN-MEETING TIME
10.7 DIFFICULTY GETTING CONSENSUS ON COMPETING IDEAS
10.8 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 11: Implementing an Effective Company-Wide FMEA Process
IN THIS CHAPTER
11.1 WHAT IS A COMPANY-WIDE FMEA PROCESS AND WHY IS IT IMPORTANT?
11.2 MANAGEMENT ROLES AND RESPONSIBILITIES
11.3 EFFECTIVE FMEA PROCESS
11.3.1 Planning Stage
11.3.2 Performing FMEAs Stage
11.3.3 Review Stage
11.3.4 Implementation Stage
11.4 LESSONS LEARNED IN IMPLEMENTING A COMPANY-WIDE FMEA PROCESS
11.5 COMPANY CLIMATE FOR SHARING FAILURE INFORMATION
11.6 END OF CHAPTER PROBLEMS
Chapter 12: Failure Mode Effects and Criticality Analysis (FMECA)
IN THIS CHAPTER
12.1 INTRODUCTION TO FMECA
12.2 WHEN TO USE FMECA
12.3 BRIEF HISTORY OF FMECA
12.4 TYPES OF FMECA
12.5 QUANTITATIVE CRITICALITY ANALYSIS
12.6 QUALITATIVE CRITICALITY ANALYSIS
12.7 FMECA CRITICALITY MATRIX
12.8 FMECA WORKSHEET
12.9 SUMMARY OUTPUT OF FMECA
12.10 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 13: Introduction to Design Review Based on Failure Mode (DRBFM)
IN THIS CHAPTER
13.1 WHAT IS DRBFM?
13.2 CHANGE POINT ANALYSIS
13.3 CONDUCTING DRBFM PROJECTS
13.4 HOW DRBFM INTEGRATES WITH FMEA
13.5 DRBFM WORKSHEET
13.6 DRBFM EXAMPLES AND CASE STUDIES
13.6.1 DRBFM Case Study 1
13.6.2 DRBFM Case Study 2
13.6.3 DRBFM Case Study 3
13.7 DESIGN REVIEW BASED ON TEST RESULTS
13.8 DRBFM GLOSSARY
13.9 DRBFM RESOURCES FOR FURTHER STUDY
13.10 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 14: Introduction to Fault Tree Analysis (FTA)
IN THIS CHAPTER
14.1 WHAT IS FAULT TREE ANALYSIS?
14.2 FTA AND FMEA
14.2.1 When Should FTA Be Used in Addition to FMEA?
14.3 BRIEF HISTORY OF FTA
14.4 MODELS
14.5 EVENTS AND GATES
14.6 FTA EXAMPLE
14.7 FTA GLOSSARY
14.8 FTA PROCEDURE
14.9 FTA HANDBOOKS AND STANDARDS
14.10 USE OF FTA ON SOFTWARE
14.11 FTA BENEFITS AND LIMITATIONS
14.12 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 15: Other FMEA Applications
IN THIS CHAPTER
15.1 RELIABILITY-CENTERED MAINTENANCE
15.1.1 RCM and FMEA
15.1.2 RCM: The Seven Basic Questions
15.1.3 RCM Decision Logic Diagrams
15.1.4 RCM Procedure
15.1.5 History of RCM
15.1.6 RCM Definitions
15.1.7 RCM Case Study
15.1.8 RCM Publications and Standards
15.1.9 RCM Benefits
15.1.10 RCM Limitations
15.2 HAZARD ANALYSIS
15.2.1 Hazard Analysis and FMEA
15.2.2 Hazard Analysis Procedure
15.2.3 Hazard Analysis Tables and Examples
15.2.4 Hazard Analysis Definitions
15.2.5 Hazard Analysis References and Standards
15.3 CONCEPT FMEA
15.4 SOFTWARE FMEA
15.4.1 General Procedure for Software FMEAs
15.4.2 Software FMEA Examples
15.4.3 Software FMEA References and Standards
15.5 FAILURE MODES, MECHANISMS, AND EFFECTS ANALYSIS
15.6 FAILURE MODES, EFFECTS, AND DIAGNOSTIC ANALYSIS
15.7 END OF CHAPTER PROBLEMS
REFERENCES
Chapter 16: Selecting the Right FMEA Software
IN THIS CHAPTER
16.1 CHARACTERISTICS OF EXCELLENT FMEA SOFTWARE
16.2 WHY NOT JUST USE SPREADSHEET SOFTWARE?
16.3 ADVANTAGES OF RELATIONAL DATABASE
16.4 USING THE CRITERIA FOR SELECTING RELATIONAL DATABASE SOFTWARE
16.5 END OF CHAPTER PROBLEMS
REFERENCE
Appendices
APPENDIX A: FMEA SCALES
APPENDIX B: FMEA WORKSHEET FORMS
B.1 Design FMEA Worksheet Forms
B.2 Process FMEA Worksheet Forms
APPENDIX C: ALL-TERRAIN BICYCLE DOCUMENTS
APPENDIX D: LISTS AND CHECKLISTS
D.1 FMEA Preparation Checklists
D.1.1 Checklist for FMEA Preparation
D.1.2 Ground Rules and Assumptions Checklist
D.1.3 Gather Information Checklist (for System and Design FMEAs)
D.1.4 Gather Information Checklist (for Process FMEAs)
D.1.5 Ready-for-First-Meeting Checklist
D.2 Lists of Failure Mechanisms (excerpts from book)
D.3 FMEA Quality Objectives
D.4 FMEA Facilitation Checklists
D.4.1 Checklist for Effective Meetings
D.4.2 FMEA Facilitator "Thought-Starter" Questions
D.5 FMEA Action Strategy Checklist
D.6 FMEA Quality Audit Procedure
D.7 FMEA Quality Survey Form
APPENDIX E: FMEA GLOSSARY
REFERENCES
Index

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