Fmea Template
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Fmea Template as PDF for free.
More details
- Words: 3,734
- Pages: 23
Introduction
Welcome to the FMEA Worksheet This 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: Descriptions - explains the spreadsheet cells FMEA - the actual sheet used to enter data Severity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categories Example - a partial exmample of an FMEA document Sheet Protection: Some sheets are protected. There is no password.
Released for review: A. Dembski
31-Jul-98 rev 1
most attention.
Introduction
Descriptions
Description of FMEA Worksheet Protection:The spreadsheets are not protected or locked. Potential Failure Mode and Effects Analysis (Design FMEA)
System Subsystem Component Design Lead
Key Date
FMEA Number Prepared By FMEA Date Revision Date
Core Team
Page
of
Coolant containment. Hose connection. Coolant fill. M
Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete
Leak
8
Over pressure
8
Burst, validation pressure cycle.
D e t
1
R P N
Recommended Action(s)
0 64 Test included in
prototype and production validation testing.
Responsibility & Target Completion Date
Actions Taken
0 J.P. Aguire 11/1/95 E. Eglin 8/1/96
0
Write down each failure mode and potential consequence(s) of that failure.
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.
Response Plans and Tracking
0
0
0
0
0
Priority Number - The combined weighting of Severity, Likelihood, and Detectability. 0 RPN = Sev X Occ X Det
0 0
0
0
0
0
Detectability -0 Examine the current design, then, 0on a scale of 1-10, rate the Detectability of each failure 0 (10 = least detectable). See 0 Detectability sheet. 0
Page 3
0
0
0 Risk
Severity - On a scale of 110, rate the Severity of each failure (10= most severe). See Severity sheet.
New RPN
Current Design Controls
New Det
S Potential Failure Potential Effect(s) e Mode(s) of Failure v
New Occ
Item / Function
New Sev
Action Results Potential P Cause(s)/ r Mechanism(s) of o Failure b
0 0 0 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 Descriptions (10 = least detectable). See Detectability sheet. 0
Page 4
0
System
Design Verification Process
Subsystem Component Design Lead Core Team
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Houston Mayer See Project III R1 Report
Prepared By FMEA Date
Page
Project III Houston Mayer 10/22/1999 8/21/2000 1
of
6
D e t
R P N
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.
7 Human error
1 Design configuration tool.
3
Requirement entered and verified by Inside Sales in config. tool.
Data entry error System compatability requirements not evaluated by config. tool.
3 Human error
1 Order verified by a configuration tool.
3
9 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.
7 Requirements Overlooked.
3 Customer Inspection Instruction/ Special Handling Codes Process 033-001-02
3
63 Publish comprehensive procedure for the 1st Article Process.
Position of the Loss of business DHR in ICD with the label packet not customer. 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.
1 Requirements Overlooked.
5 CII 033-001-006
1
Houston Mayer Six Sigma Blackbelt August 21, 2000
Current Design Controls
Recommended Action(s)
21 Use configuration tool when available.
5 Revisit contents of GE CII 033001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.
Responsibility & Target Completion Date
Actions Taken
New RPN
P r o b
New Det
Potential Cause(s)/ Mechanism(s) of Failure
Potential Effect(s) of Failure
New Occ
S e v
Potential Failure Mode(s)
Item / Function
New Sev
Action Results
Closed 10/21/99
0
Closed 10/21/99
0
Jun-00
Customer shipping requirements reviewed by quality assurance in 1st Article process.
Sep-00
OPEN 8/21/00
0
5
QA and Pack and Ship Team reviews customer requirements during a 1st Article.
Specific packing, labeling and shipping requirements may not be fully addressed.
Customer's full expectations may not be realized.
Inside sales submits Sales Order Authorization request to TECenter.
Data entry error Order Processing Delay
7 Requirements overlooked.
3 Customer requirements physically verified by quality assurance during the 1st Article process.
3
63 Continue current pracices.
1 Human Error
1 Customer requirements verified by a TECenter engineer.
3
3 Continue current practices.
Closed 10/25/99
0
Closed 1/25/00
0
Closed 10/25/99
0
TECenter Requirements Engineer reviews overlooked by the design to Engineer determain if additional data is required.
Customer's full expectations may not be realized.
3 Requirements Overlooked.
6 Customer requirements verified by a TECenter engineer.
3
54 Continue current practices.
Appropriate individuals are contacted to resolve issues.
Order Processing Delay
1 Process Failure
1 Individuals are contacted to resolve issues.
1
1 Continue current practices.
Closed 1/25/00
0
Design Review is Requirements completed. may not be complete
Customer's full expectations may not be realized.
1 Process Failure
1 Customer requirements verified by a TECenter engineer.
1
1 Continue current pracices.
Closed 1/25/00
0
Another Requirements engineer overlooked by performs quality two Engineer check of the design.
Customer's full expectations may not be realized.
7 Process Failure
3 Customer requirements verified by a TECenter engineer.
3
63 Continue current pracices.
Closed 10/25/99
0
Completed design verification is sent to appropriate organization.
Order Processing Delay
1 Process Failure
1 Verification is sent to appropriate organization.
1
1 Continue current pracices.
Closed 1/25/00
0
Appropriate individuals not available.
Design verification misrouted
Houston Mayer Six Sigma Blackbelt August 21, 2000
6
Customer's full expectations may not be realized.
1 Process Failure
1 Requirements are defined and to meet requirements.
1
1 Continue current pracices.
Closed 1/25/00
0
Inside Sales Wrong price and Customer's full quotes price and availability expectations availability provided to may not be customer realized.
3 Process Failure
1 Price provided to customer
1
3 Continue current pracices.
Closed 1/25/00
0
Customer sends Order misrouted in purchase order. Inside sales Data Entry Error places order on system.
Order Processing Delay
1 Process Failure
1 Reprocess Order
1
Closed 1/27/00
0
Order Processing Delay
3 Human Error
1 Reprocess Order
1
1 Continue current pracices. 3 Continue current pracices.
Closed 1/27/00
0
Order approved by Asset Management.
Approval not timely
Order Processing Delay
1 Process Failure
1 Expidite Process
1
1 Continue current pracices.
Closed 1/27/00
0
Order approved by credit.
Approval not timely
Order Processing Delay
1 Process Failure
1 Expidite Process
1
Closed 1/27/00
0
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.
5 Needed components are not available at the time of need.
3 Assure product availability before the order commitment is given to customer.
1
1 Continue current pracices. 15 Continue current practices.
Closed 10/25/99
0
Inside sales expedites with Asset to provide ship date.
Shipdates may not be accurate
Customer's full expectations may not be realized.
1 Needed components are not available at the time of need.
1 Expidite Process
1
1 Continue current practices.
Closed 1/27/00
0
Order approved by Asset Mgmt. and e-mail sent to Integration.
e-mail may be misrouted
Order Processing Delay
1 Process Failure
1 Expidite Process
1
1 Continue current practices.
Closed 1/27/00
0
Requirements are defined and capability to meet/ accept requirements.
Requirements may be missed or capibilty to meet overestamated
Houston Mayer Six Sigma Blackbelt August 21, 2000
7
Customer and processing needs not identified could prevent timely processing of the order.
3 Processing requirements overlooked.
1 Project Manager order review.
1
3 Continue current practices.
Build document Documents do bill of material not match matched with SCN.
Order Processing Delay
5 Needed components are not available at the time of need.
3 Expidite Process Integration Center Operations Manual 093009-OPSMNL
3
Stock stock availability availability is and dates may checked and be inaccurate delivery dates are aquired for non stock items.
Customer's full expectations may not be realized.
3 Needed components are not available at the time of need.
1 Expidite Process
Order is forwarded to Production Engineer for review. Determanation made for a 1st Article build.
Order may be misrouted
Order Processing Delay
1 Process Failure
1 Expidite Process
Need for 1st build may be overlooked
Customer's full 7 expectations may not be realized. Customer's full 3 expectations may not be realized. Order 3 Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
Requirements Overlooked.
3
Requirements Overlooked.
1
Project Manager reviews order for special or internal instructions.
Order processing requirements may be overlooked
Build document Requirements is reviewed and may be verified. overlooked
Closed 10/25/99
0
45 Continue current practices.
Closed 1/27/00
0
1
3 Continue current practices.
Closed 1/27/00
0
1
1 Continue current practices.
Continue current practices.
5
105 Continue current practices.
Continue current practices.
Individuals are contacted to resolve issues.
3
27 Continue current practices.
Continue current practices.
Individuals are contacted to resolve issues.
1
3 Continue current practices.
Continue current practices.
Project management notifies sales with status of order. Asset management places order for non stock items.
Sales may not receive order status
Items may not be ordered
Order 3 Processing Delay
Needed 1 components are not available at the time of need.
Expidite Process 1
3 Continue current practices.
Closed 1/27/00
Order is scheduled for production.
Order may not be entered in schedule
Order 3 Processing Delay
Requirements Overlooked.
1
Individuals are contacted to resolve issues.
1
3 Continue current practices.
Closed 1/27/00
Whse Operator reviews parts to SOA & SCN.
Parts may not match requirement
Order 3 Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
1
9 Continue current practices.
Closed 1/27/00
Houston Mayer Six Sigma Blackbelt August 21, 2000
8
Whse. Operator All parts may Unpack,Iinspect not reach & Kit order. integration
Order 3 Processing Delay
All components 3 are not available at the time of need.
Individuals are contacted to resolve issues. Integration Kitting and Packing 153001-01
3
27 Continue current practices.
Closed 1/27/00
Techs. Check product against SOW and build instructions.
Parts may not match requirement
Order 5 Processing Delay
All components 3 are not available at the time of need.
Individuals are contacted to resolve issues.
1
15 Continue current practices.
Closed 1/27/00
Integration Techs. inspect parts and chassis.
Materials may Order 7 not be compliant Processing Delay
All components 3 are not available at the time of need.
QA Inspection and Test Procedure 103001-03
3
63 Continue current practices.
Closed 1/27/00
No NT Resource Kit Missing Video Board
Loss of business 1 with the customer.
Requirements Overlooked.
1
QA Inspection and Test Procedure 103001-03
5
Order 7 Processing Delay
Individuals are contacted to resolve issues.
7
QA Inspection and Test Procedure 103001-03
3
147 Continue current practices.
Closed 1/27/00
Integration Techs. Test system.
System and Order 10 Needed 10 QA Inspection parts may not be Processing Delay components are and Test compliant not available at Procedure 103the time of need. 001-03
1
100 Continue current practices.
Closed 1/27/00
Quality techs. inspect product for build requirements.
Specific build requirements may not be fully addressed.
5
25 Continue current practices.
Techs. Integrate System may be & Power-Up integrated System incorrectly
Houston Mayer Six Sigma Blackbelt August 21, 2000
On time delivery 5 and integraty of the product may be compramised if this issue is not addressed.
Requirements Overlooked.
1
Individuals are contacted to resolve issues.
5 Update Build Procedures to clearly define product requirements specific to the model being integrated.
Closed 8/21/00
9
25 Update Build Procedures to clearly define product requirements specific to the model being integrated.
IO panel not Loss of business 1 installed with the Label on CPU customer. Incorrect No feet or other components installed No extension cables Missing cables IO panel gasket not installed Wrong ICD cards provided Dome calibrater included
Human Error
5
Build Procedure 5 for individual PathSpeed Model
Numbers may be Order 3 incorrect Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
1
9 Continue current practices.
Closed 1/27/00
Control of requirements may be lost
Order 1 Processing Delay
Requirements Overlooked.
1
Individuals are contacted to resolve issues.
1
1 Continue current practices.
Closed 1/27/00
Order placed on Shiping hold when deadlines may change is made. not be met
Order 3 Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
1
9 Continue current practices.
Closed 1/27/00
Design Process reinitiates
Control of requirements may not be complete Wrong Shipping method may be used
Order 3 Processing Delay
Process Failure
1
Individuals are contacted to resolve issues.
1
3 Continue current practices.
Closed 1/27/00
On time delivery 7 and integraty of the product may be compramised if this issue is not addressed.
Process Failure
1
Individuals are contacted to resolve issues.
1
7 Continue current practices.
Closed 1/27/00
Specific packing, labeling and shipping requirements may not be fully addressed.
On time delivery 10 Requirements and integraty of Overlooked. the product may be compramised if this issue is not addressed.
3
Customer 3 Inspection Instruction/ Special Handling Codes Process 033-001-02
90 Continue current pracices.
Closed 1/25/00
Product serial numbers scanned into Genesis. Change made after batch release
Whse. invoices and ships order per customer's shipping method.
Quality techs. inspect shipment for CII/SHC requirements.
Houston Mayer Six Sigma Blackbelt August 21, 2000
Closed 8/21/00
10
Label on outside Loss of business 1 of box did not with the match S/N on customer. CPU.
Human Error
3
CII 033-001-006 3
9 Revisit contents of GE CII 033001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.
9/11/2000
Product ships to Products customer. misshipped
On time delivery 7 and integraty of the product may be compramised if this issue is not addressed.
Needed 3 components are not available at the time of need.
Individuals are contacted to resolve issues.
7
147 Continue current practices.
Closed 1/27/00
Coordinator closes project & files quality records.
Documents may 3 not be retrievable
Documents may 1 not be retrievable
Individuals are contacted to resolve issues.
1
3 Continue current pracices.
Closed 1/25/00
Documents not filed correctly
Houston Mayer Six Sigma Blackbelt August 21, 2000
11
Severity
Effect Hazardous without warning Hazardous with warning Very High
SEVERITY of Effect
Ranking 10
High
Very high severity ranking when a potential failure mode affects safe system operation without warning Very high severity ranking when a potential failure mode affects safe system operation with warning System inoperable with destructive failure without compromising safety System inoperable with equipment damage
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
Page 12
9 8 7
Probability
PROBABILITY of Failure Very High: Failure is almost inevitable
High: Repeated failures
Moderate: Occasional failures
Low: Relatively few failures
Remote: Failure is unlikely
Failure Prob Ranking >1 in 2
10
1 in 3
9
1 in 8
8
1 in 20
7
1 in 80
6
1 in 400
5
1 in 2,000
4
1 in 15,000
3
1 in 150,000
2
<1 in 1,500,000
1
Page 13
Detectability
Detection Absolute Uncertainty Very Remote Remote Very Low Low Moderate Moderately High High Very High Almost Certain
Likelihood of DETECTION by Design Control Design control cannot detect potential cause/mechanism and subsequent failure mode Very remote chance the design control will detect potential cause/mechanism and subsequent failure mode Remote chance the design control will detect potential cause/mechanism and subsequent failure mode Very low chance the design control will detect potential cause/mechanism and subsequent failure mode Low chance the design control will detect potential cause/mechanism and subsequent failure mode Moderate chance the design control will detect potential cause/mechanism and subsequent failure mode Moderately High chance the design control will detect potential cause/mechanism and subsequent failure mode High chance the design control will detect potential cause/mechanism and subsequent failure mode Very high chance the design control will detect potential cause/mechanism and subsequent failure mode Design control will detect potential cause/mechanism and subsequent failure mode
Page 14
Ranking 10 9 8 7 6 5 4 3 2 1
EXAMPLE
System Subsystem Component Design Lead Core Team
Item / Function
Potential Failure Mode(s)
Seals Coolant containment. Hose connection. Coolant fill. M Sensor mount. Seal
Compression set
Sensor mount. Seal
Loosen during sensor assembly/servic e
Sensor mount. Seal
Damaged internal thread
Sensor mount. Seal
Damaged external thread
Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete
Page 15
EXAMPLE
System Subsystem Component Design Lead Core Team
Item / Function
Potential Failure Mode(s)
Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete Hold fluid, flow path, Heat transfer structure
Stress crack
Hold fluid, flow path, Heat transfer structure
Stress crack
Hold fluid, flow path, Heat transfer structure
Stress crack
Hold fluid, flow path, Heat transfer structure
Corrosion
Hold fluid, flow path, Heat transfer structure
Corrosion
Page 16
EXAMPLE
System Subsystem Component Design Lead Core Team
Item / Function
Potential Failure Mode(s)
Hold fluid, flow path, Heat transfer structure
Puncture
Hold fluid, flow path, Heat transfer structure
Seam fail
Hold fluid, flow path, Heat transfer structure
Burst fail
Hold fluid, flow path, Heat transfer structure
Plugged
Hold fluid, flow path, Heat transfer structure
Ballooning
Page 17
EXAMPLE
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By FMEA Date
Page
of
Potential Cause(s)/ Mechanism(s) of Failure
P r o b
Current Design Controls
D e t
R P N
Recommended Action(s)
Responsibility & Target Completion Date
0 0
Leak
8 Gasket material
7 Pressure cycle w/cold shock.
1
56 Use imported material
Leak. Fall inside tank
8 Fitting not held in place
2 Added rib.
1
16 Implement holding rib in design. New fitting design. Prototype validation.
Cannot install sensor
5 Damaged during installation or transportation
2
1
10
Cannot install wire nut
4 Damaged during shipment to piracicaba
3
1
12 Damaged fitting not used by Piracicaba
Leak
8
Over pressure
8
Burst, validation pressure cycle.
1
J.P. Aguire 11/1/95
64 Test included in
J.P. Aguire 11/1/95 prototype and E. Eglin 8/1/96 production validation testing.
Page 18
Actions Taken
New Det
S e v
New Occ
Potential Effect(s) of Failure
New Sev
Action Results
EXAMPLE
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By FMEA Date
Page
of
P r o b
Failed mount
5
Vibration
9
Hose leak
6
Overpressure. Poor clamp
5
D e t
R P N
Vibration w/road tapes
3
135 Obtain GMB
Burst, validation pressure cycle w/GMB clamps.
2
Current Design Controls
Recommended Action(s)
vibration road tape.
60 Obtain GMB clamps and clamping specification.
Air conditioning does not work. Sudden refrigerant loss.
This is a test of the ADD POTENTIAL CAUSE/MECHANIS M OF FAILURE system functionality
0 Operator instruction
Air conditioning does not work. Sudden refrigerant loss.
This is a test of the ADD POTENTIAL CAUSE/MECHANIS M OF FAILURE system functionality
0 This is a test of the
Leak. Loss of heat transfer.
8
Air conditioning does not work. Sudden refrigerant loss. Leak. Loss of heat transfer.
Wicking. Material strength
Actions Taken
J.P. Aguire
J.P. Aguire 12/1/95
ADD RECOMMENDED ACTION system functionality
7
Thermal cycle
1
this is a test while dan is here
8
Responsibility & Target Completion Date
Coolant quality. 7 Contamination. Environment - int/ext.
56 Included in Product Specification
E. Eglin 8/1/96
0
SWAT, service simulation. Coolant evaluation.
5
280 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
Page 19
Coolant ordered
New Det
Potential Cause(s)/ Mechanism(s) of Failure
New Occ
S e v
Potential Effect(s) of Failure
New Sev
Action Results
EXAMPLE
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By FMEA Date
Page
of
Leak. Loss of heat transfer.
8
External damage. Coolant velocity. No reinf sawcut.
Leak. Loss of heat transfer.
5
Leak. Loss of heat transfer.
8
P r o b
D e t
R P N
Recommended Action(s)
Responsibility & Target Completion Date
Actions Taken
Leak test. Simulated service.
1
Environment - int/ext. 1
SWAT, service simulation.
1
Over pressure contamination.
2
Burst/leak pressure
5
80 GMB to study engine GMB 12/1/95
Study originated
Loss of heat transfer. 8 Leakage due to increase flow velocity
Contamination. Coolant quality.
7
1
56 GMB coolant to be
Coolant ordered
Leak. Loss of heat transfer.
Over pressure contamination.
9
8
5
10
Current Design Controls
80 100% cores tested in E. Eglin 8/1/96 production. Simulated service included in Product Specificatin.
5 Included in Product Specification.
E. Eglin 8/1/96
cleanliness.
evaluated. GMB to study engine cleanliness.
J.P. Aguirre 11/1/95
360 GMB to study engine GMB 12/1/95 cleanliness. Clustomer profile to be determined.
0 0 0
Page 20
New Det
Potential Cause(s)/ Mechanism(s) of Failure
New Occ
S e v
Potential Effect(s) of Failure
New Sev
Action Results
EXAMPLE
New RPN
on Results
0 0
0 0
0
0
0
Page 21
EXAMPLE
New RPN
on Results
0
0
0
0
0 0
0
Page 22
EXAMPLE
New RPN
on Results
0
0 0 0
0
0 0 0
Page 23
Welcome to the FMEA Worksheet This 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: Descriptions - explains the spreadsheet cells FMEA - the actual sheet used to enter data Severity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categories Example - a partial exmample of an FMEA document Sheet Protection: Some sheets are protected. There is no password.
Released for review: A. Dembski
31-Jul-98 rev 1
most attention.
Introduction
Descriptions
Description of FMEA Worksheet Protection:The spreadsheets are not protected or locked. Potential Failure Mode and Effects Analysis (Design FMEA)
System Subsystem Component Design Lead
Key Date
FMEA Number Prepared By FMEA Date Revision Date
Core Team
Page
of
Coolant containment. Hose connection. Coolant fill. M
Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete
Leak
8
Over pressure
8
Burst, validation pressure cycle.
D e t
1
R P N
Recommended Action(s)
0 64 Test included in
prototype and production validation testing.
Responsibility & Target Completion Date
Actions Taken
0 J.P. Aguire 11/1/95 E. Eglin 8/1/96
0
Write down each failure mode and potential consequence(s) of that failure.
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.
Response Plans and Tracking
0
0
0
0
0
Priority Number - The combined weighting of Severity, Likelihood, and Detectability. 0 RPN = Sev X Occ X Det
0 0
0
0
0
0
Detectability -0 Examine the current design, then, 0on a scale of 1-10, rate the Detectability of each failure 0 (10 = least detectable). See 0 Detectability sheet. 0
Page 3
0
0
0 Risk
Severity - On a scale of 110, rate the Severity of each failure (10= most severe). See Severity sheet.
New RPN
Current Design Controls
New Det
S Potential Failure Potential Effect(s) e Mode(s) of Failure v
New Occ
Item / Function
New Sev
Action Results Potential P Cause(s)/ r Mechanism(s) of o Failure b
0 0 0 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 Descriptions (10 = least detectable). See Detectability sheet. 0
Page 4
0
System
Design Verification Process
Subsystem Component Design Lead Core Team
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Houston Mayer See Project III R1 Report
Prepared By FMEA Date
Page
Project III Houston Mayer 10/22/1999 8/21/2000 1
of
6
D e t
R P N
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.
7 Human error
1 Design configuration tool.
3
Requirement entered and verified by Inside Sales in config. tool.
Data entry error System compatability requirements not evaluated by config. tool.
3 Human error
1 Order verified by a configuration tool.
3
9 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.
7 Requirements Overlooked.
3 Customer Inspection Instruction/ Special Handling Codes Process 033-001-02
3
63 Publish comprehensive procedure for the 1st Article Process.
Position of the Loss of business DHR in ICD with the label packet not customer. 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.
1 Requirements Overlooked.
5 CII 033-001-006
1
Houston Mayer Six Sigma Blackbelt August 21, 2000
Current Design Controls
Recommended Action(s)
21 Use configuration tool when available.
5 Revisit contents of GE CII 033001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.
Responsibility & Target Completion Date
Actions Taken
New RPN
P r o b
New Det
Potential Cause(s)/ Mechanism(s) of Failure
Potential Effect(s) of Failure
New Occ
S e v
Potential Failure Mode(s)
Item / Function
New Sev
Action Results
Closed 10/21/99
0
Closed 10/21/99
0
Jun-00
Customer shipping requirements reviewed by quality assurance in 1st Article process.
Sep-00
OPEN 8/21/00
0
5
QA and Pack and Ship Team reviews customer requirements during a 1st Article.
Specific packing, labeling and shipping requirements may not be fully addressed.
Customer's full expectations may not be realized.
Inside sales submits Sales Order Authorization request to TECenter.
Data entry error Order Processing Delay
7 Requirements overlooked.
3 Customer requirements physically verified by quality assurance during the 1st Article process.
3
63 Continue current pracices.
1 Human Error
1 Customer requirements verified by a TECenter engineer.
3
3 Continue current practices.
Closed 10/25/99
0
Closed 1/25/00
0
Closed 10/25/99
0
TECenter Requirements Engineer reviews overlooked by the design to Engineer determain if additional data is required.
Customer's full expectations may not be realized.
3 Requirements Overlooked.
6 Customer requirements verified by a TECenter engineer.
3
54 Continue current practices.
Appropriate individuals are contacted to resolve issues.
Order Processing Delay
1 Process Failure
1 Individuals are contacted to resolve issues.
1
1 Continue current practices.
Closed 1/25/00
0
Design Review is Requirements completed. may not be complete
Customer's full expectations may not be realized.
1 Process Failure
1 Customer requirements verified by a TECenter engineer.
1
1 Continue current pracices.
Closed 1/25/00
0
Another Requirements engineer overlooked by performs quality two Engineer check of the design.
Customer's full expectations may not be realized.
7 Process Failure
3 Customer requirements verified by a TECenter engineer.
3
63 Continue current pracices.
Closed 10/25/99
0
Completed design verification is sent to appropriate organization.
Order Processing Delay
1 Process Failure
1 Verification is sent to appropriate organization.
1
1 Continue current pracices.
Closed 1/25/00
0
Appropriate individuals not available.
Design verification misrouted
Houston Mayer Six Sigma Blackbelt August 21, 2000
6
Customer's full expectations may not be realized.
1 Process Failure
1 Requirements are defined and to meet requirements.
1
1 Continue current pracices.
Closed 1/25/00
0
Inside Sales Wrong price and Customer's full quotes price and availability expectations availability provided to may not be customer realized.
3 Process Failure
1 Price provided to customer
1
3 Continue current pracices.
Closed 1/25/00
0
Customer sends Order misrouted in purchase order. Inside sales Data Entry Error places order on system.
Order Processing Delay
1 Process Failure
1 Reprocess Order
1
Closed 1/27/00
0
Order Processing Delay
3 Human Error
1 Reprocess Order
1
1 Continue current pracices. 3 Continue current pracices.
Closed 1/27/00
0
Order approved by Asset Management.
Approval not timely
Order Processing Delay
1 Process Failure
1 Expidite Process
1
1 Continue current pracices.
Closed 1/27/00
0
Order approved by credit.
Approval not timely
Order Processing Delay
1 Process Failure
1 Expidite Process
1
Closed 1/27/00
0
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.
5 Needed components are not available at the time of need.
3 Assure product availability before the order commitment is given to customer.
1
1 Continue current pracices. 15 Continue current practices.
Closed 10/25/99
0
Inside sales expedites with Asset to provide ship date.
Shipdates may not be accurate
Customer's full expectations may not be realized.
1 Needed components are not available at the time of need.
1 Expidite Process
1
1 Continue current practices.
Closed 1/27/00
0
Order approved by Asset Mgmt. and e-mail sent to Integration.
e-mail may be misrouted
Order Processing Delay
1 Process Failure
1 Expidite Process
1
1 Continue current practices.
Closed 1/27/00
0
Requirements are defined and capability to meet/ accept requirements.
Requirements may be missed or capibilty to meet overestamated
Houston Mayer Six Sigma Blackbelt August 21, 2000
7
Customer and processing needs not identified could prevent timely processing of the order.
3 Processing requirements overlooked.
1 Project Manager order review.
1
3 Continue current practices.
Build document Documents do bill of material not match matched with SCN.
Order Processing Delay
5 Needed components are not available at the time of need.
3 Expidite Process Integration Center Operations Manual 093009-OPSMNL
3
Stock stock availability availability is and dates may checked and be inaccurate delivery dates are aquired for non stock items.
Customer's full expectations may not be realized.
3 Needed components are not available at the time of need.
1 Expidite Process
Order is forwarded to Production Engineer for review. Determanation made for a 1st Article build.
Order may be misrouted
Order Processing Delay
1 Process Failure
1 Expidite Process
Need for 1st build may be overlooked
Customer's full 7 expectations may not be realized. Customer's full 3 expectations may not be realized. Order 3 Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
Requirements Overlooked.
3
Requirements Overlooked.
1
Project Manager reviews order for special or internal instructions.
Order processing requirements may be overlooked
Build document Requirements is reviewed and may be verified. overlooked
Closed 10/25/99
0
45 Continue current practices.
Closed 1/27/00
0
1
3 Continue current practices.
Closed 1/27/00
0
1
1 Continue current practices.
Continue current practices.
5
105 Continue current practices.
Continue current practices.
Individuals are contacted to resolve issues.
3
27 Continue current practices.
Continue current practices.
Individuals are contacted to resolve issues.
1
3 Continue current practices.
Continue current practices.
Project management notifies sales with status of order. Asset management places order for non stock items.
Sales may not receive order status
Items may not be ordered
Order 3 Processing Delay
Needed 1 components are not available at the time of need.
Expidite Process 1
3 Continue current practices.
Closed 1/27/00
Order is scheduled for production.
Order may not be entered in schedule
Order 3 Processing Delay
Requirements Overlooked.
1
Individuals are contacted to resolve issues.
1
3 Continue current practices.
Closed 1/27/00
Whse Operator reviews parts to SOA & SCN.
Parts may not match requirement
Order 3 Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
1
9 Continue current practices.
Closed 1/27/00
Houston Mayer Six Sigma Blackbelt August 21, 2000
8
Whse. Operator All parts may Unpack,Iinspect not reach & Kit order. integration
Order 3 Processing Delay
All components 3 are not available at the time of need.
Individuals are contacted to resolve issues. Integration Kitting and Packing 153001-01
3
27 Continue current practices.
Closed 1/27/00
Techs. Check product against SOW and build instructions.
Parts may not match requirement
Order 5 Processing Delay
All components 3 are not available at the time of need.
Individuals are contacted to resolve issues.
1
15 Continue current practices.
Closed 1/27/00
Integration Techs. inspect parts and chassis.
Materials may Order 7 not be compliant Processing Delay
All components 3 are not available at the time of need.
QA Inspection and Test Procedure 103001-03
3
63 Continue current practices.
Closed 1/27/00
No NT Resource Kit Missing Video Board
Loss of business 1 with the customer.
Requirements Overlooked.
1
QA Inspection and Test Procedure 103001-03
5
Order 7 Processing Delay
Individuals are contacted to resolve issues.
7
QA Inspection and Test Procedure 103001-03
3
147 Continue current practices.
Closed 1/27/00
Integration Techs. Test system.
System and Order 10 Needed 10 QA Inspection parts may not be Processing Delay components are and Test compliant not available at Procedure 103the time of need. 001-03
1
100 Continue current practices.
Closed 1/27/00
Quality techs. inspect product for build requirements.
Specific build requirements may not be fully addressed.
5
25 Continue current practices.
Techs. Integrate System may be & Power-Up integrated System incorrectly
Houston Mayer Six Sigma Blackbelt August 21, 2000
On time delivery 5 and integraty of the product may be compramised if this issue is not addressed.
Requirements Overlooked.
1
Individuals are contacted to resolve issues.
5 Update Build Procedures to clearly define product requirements specific to the model being integrated.
Closed 8/21/00
9
25 Update Build Procedures to clearly define product requirements specific to the model being integrated.
IO panel not Loss of business 1 installed with the Label on CPU customer. Incorrect No feet or other components installed No extension cables Missing cables IO panel gasket not installed Wrong ICD cards provided Dome calibrater included
Human Error
5
Build Procedure 5 for individual PathSpeed Model
Numbers may be Order 3 incorrect Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
1
9 Continue current practices.
Closed 1/27/00
Control of requirements may be lost
Order 1 Processing Delay
Requirements Overlooked.
1
Individuals are contacted to resolve issues.
1
1 Continue current practices.
Closed 1/27/00
Order placed on Shiping hold when deadlines may change is made. not be met
Order 3 Processing Delay
Requirements Overlooked.
3
Individuals are contacted to resolve issues.
1
9 Continue current practices.
Closed 1/27/00
Design Process reinitiates
Control of requirements may not be complete Wrong Shipping method may be used
Order 3 Processing Delay
Process Failure
1
Individuals are contacted to resolve issues.
1
3 Continue current practices.
Closed 1/27/00
On time delivery 7 and integraty of the product may be compramised if this issue is not addressed.
Process Failure
1
Individuals are contacted to resolve issues.
1
7 Continue current practices.
Closed 1/27/00
Specific packing, labeling and shipping requirements may not be fully addressed.
On time delivery 10 Requirements and integraty of Overlooked. the product may be compramised if this issue is not addressed.
3
Customer 3 Inspection Instruction/ Special Handling Codes Process 033-001-02
90 Continue current pracices.
Closed 1/25/00
Product serial numbers scanned into Genesis. Change made after batch release
Whse. invoices and ships order per customer's shipping method.
Quality techs. inspect shipment for CII/SHC requirements.
Houston Mayer Six Sigma Blackbelt August 21, 2000
Closed 8/21/00
10
Label on outside Loss of business 1 of box did not with the match S/N on customer. CPU.
Human Error
3
CII 033-001-006 3
9 Revisit contents of GE CII 033001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.
9/11/2000
Product ships to Products customer. misshipped
On time delivery 7 and integraty of the product may be compramised if this issue is not addressed.
Needed 3 components are not available at the time of need.
Individuals are contacted to resolve issues.
7
147 Continue current practices.
Closed 1/27/00
Coordinator closes project & files quality records.
Documents may 3 not be retrievable
Documents may 1 not be retrievable
Individuals are contacted to resolve issues.
1
3 Continue current pracices.
Closed 1/25/00
Documents not filed correctly
Houston Mayer Six Sigma Blackbelt August 21, 2000
11
Severity
Effect Hazardous without warning Hazardous with warning Very High
SEVERITY of Effect
Ranking 10
High
Very high severity ranking when a potential failure mode affects safe system operation without warning Very high severity ranking when a potential failure mode affects safe system operation with warning System inoperable with destructive failure without compromising safety System inoperable with equipment damage
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
Page 12
9 8 7
Probability
PROBABILITY of Failure Very High: Failure is almost inevitable
High: Repeated failures
Moderate: Occasional failures
Low: Relatively few failures
Remote: Failure is unlikely
Failure Prob Ranking >1 in 2
10
1 in 3
9
1 in 8
8
1 in 20
7
1 in 80
6
1 in 400
5
1 in 2,000
4
1 in 15,000
3
1 in 150,000
2
<1 in 1,500,000
1
Page 13
Detectability
Detection Absolute Uncertainty Very Remote Remote Very Low Low Moderate Moderately High High Very High Almost Certain
Likelihood of DETECTION by Design Control Design control cannot detect potential cause/mechanism and subsequent failure mode Very remote chance the design control will detect potential cause/mechanism and subsequent failure mode Remote chance the design control will detect potential cause/mechanism and subsequent failure mode Very low chance the design control will detect potential cause/mechanism and subsequent failure mode Low chance the design control will detect potential cause/mechanism and subsequent failure mode Moderate chance the design control will detect potential cause/mechanism and subsequent failure mode Moderately High chance the design control will detect potential cause/mechanism and subsequent failure mode High chance the design control will detect potential cause/mechanism and subsequent failure mode Very high chance the design control will detect potential cause/mechanism and subsequent failure mode Design control will detect potential cause/mechanism and subsequent failure mode
Page 14
Ranking 10 9 8 7 6 5 4 3 2 1
EXAMPLE
System Subsystem Component Design Lead Core Team
Item / Function
Potential Failure Mode(s)
Seals Coolant containment. Hose connection. Coolant fill. M Sensor mount. Seal
Compression set
Sensor mount. Seal
Loosen during sensor assembly/servic e
Sensor mount. Seal
Damaged internal thread
Sensor mount. Seal
Damaged external thread
Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete
Page 15
EXAMPLE
System Subsystem Component Design Lead Core Team
Item / Function
Potential Failure Mode(s)
Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete Hold fluid, flow path, Heat transfer structure
Stress crack
Hold fluid, flow path, Heat transfer structure
Stress crack
Hold fluid, flow path, Heat transfer structure
Stress crack
Hold fluid, flow path, Heat transfer structure
Corrosion
Hold fluid, flow path, Heat transfer structure
Corrosion
Page 16
EXAMPLE
System Subsystem Component Design Lead Core Team
Item / Function
Potential Failure Mode(s)
Hold fluid, flow path, Heat transfer structure
Puncture
Hold fluid, flow path, Heat transfer structure
Seam fail
Hold fluid, flow path, Heat transfer structure
Burst fail
Hold fluid, flow path, Heat transfer structure
Plugged
Hold fluid, flow path, Heat transfer structure
Ballooning
Page 17
EXAMPLE
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By FMEA Date
Page
of
Potential Cause(s)/ Mechanism(s) of Failure
P r o b
Current Design Controls
D e t
R P N
Recommended Action(s)
Responsibility & Target Completion Date
0 0
Leak
8 Gasket material
7 Pressure cycle w/cold shock.
1
56 Use imported material
Leak. Fall inside tank
8 Fitting not held in place
2 Added rib.
1
16 Implement holding rib in design. New fitting design. Prototype validation.
Cannot install sensor
5 Damaged during installation or transportation
2
1
10
Cannot install wire nut
4 Damaged during shipment to piracicaba
3
1
12 Damaged fitting not used by Piracicaba
Leak
8
Over pressure
8
Burst, validation pressure cycle.
1
J.P. Aguire 11/1/95
64 Test included in
J.P. Aguire 11/1/95 prototype and E. Eglin 8/1/96 production validation testing.
Page 18
Actions Taken
New Det
S e v
New Occ
Potential Effect(s) of Failure
New Sev
Action Results
EXAMPLE
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By FMEA Date
Page
of
P r o b
Failed mount
5
Vibration
9
Hose leak
6
Overpressure. Poor clamp
5
D e t
R P N
Vibration w/road tapes
3
135 Obtain GMB
Burst, validation pressure cycle w/GMB clamps.
2
Current Design Controls
Recommended Action(s)
vibration road tape.
60 Obtain GMB clamps and clamping specification.
Air conditioning does not work. Sudden refrigerant loss.
This is a test of the ADD POTENTIAL CAUSE/MECHANIS M OF FAILURE system functionality
0 Operator instruction
Air conditioning does not work. Sudden refrigerant loss.
This is a test of the ADD POTENTIAL CAUSE/MECHANIS M OF FAILURE system functionality
0 This is a test of the
Leak. Loss of heat transfer.
8
Air conditioning does not work. Sudden refrigerant loss. Leak. Loss of heat transfer.
Wicking. Material strength
Actions Taken
J.P. Aguire
J.P. Aguire 12/1/95
ADD RECOMMENDED ACTION system functionality
7
Thermal cycle
1
this is a test while dan is here
8
Responsibility & Target Completion Date
Coolant quality. 7 Contamination. Environment - int/ext.
56 Included in Product Specification
E. Eglin 8/1/96
0
SWAT, service simulation. Coolant evaluation.
5
280 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
Page 19
Coolant ordered
New Det
Potential Cause(s)/ Mechanism(s) of Failure
New Occ
S e v
Potential Effect(s) of Failure
New Sev
Action Results
EXAMPLE
Potential Failure Mode and Effects Analysis (Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By FMEA Date
Page
of
Leak. Loss of heat transfer.
8
External damage. Coolant velocity. No reinf sawcut.
Leak. Loss of heat transfer.
5
Leak. Loss of heat transfer.
8
P r o b
D e t
R P N
Recommended Action(s)
Responsibility & Target Completion Date
Actions Taken
Leak test. Simulated service.
1
Environment - int/ext. 1
SWAT, service simulation.
1
Over pressure contamination.
2
Burst/leak pressure
5
80 GMB to study engine GMB 12/1/95
Study originated
Loss of heat transfer. 8 Leakage due to increase flow velocity
Contamination. Coolant quality.
7
1
56 GMB coolant to be
Coolant ordered
Leak. Loss of heat transfer.
Over pressure contamination.
9
8
5
10
Current Design Controls
80 100% cores tested in E. Eglin 8/1/96 production. Simulated service included in Product Specificatin.
5 Included in Product Specification.
E. Eglin 8/1/96
cleanliness.
evaluated. GMB to study engine cleanliness.
J.P. Aguirre 11/1/95
360 GMB to study engine GMB 12/1/95 cleanliness. Clustomer profile to be determined.
0 0 0
Page 20
New Det
Potential Cause(s)/ Mechanism(s) of Failure
New Occ
S e v
Potential Effect(s) of Failure
New Sev
Action Results
EXAMPLE
New RPN
on Results
0 0
0 0
0
0
0
Page 21
EXAMPLE
New RPN
on Results
0
0
0
0
0 0
0
Page 22
EXAMPLE
New RPN
on Results
0
0 0 0
0
0 0 0
Page 23
Related Documents
Fmea Template
August 2019 23
Fmea Risk Assessment Template
June 2020 11
Fmea
June 2020 35
Fmea
December 2019 41
Fmea
November 2019 46
Fmea
May 2020 27More Documents from ""
Fmea Template
August 2019 23
2019_list Of Equipment, Tools & Materials.docx
December 2019 28
Syllabuss-coc1.docx
December 2019 15
