pfmea - Process Failure Modes and Effects Analysis (PFMEA)...

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Unformatted text preview: Process Failure Modes and Effects Analysis (PFMEA) Training November 2003 PFMEA Training 1 1.0 What is a PFMEA? l A Process Failure Modes and Effects Analysis provides a structured, qualitative, analytical framework which taps the multi-disciplined experience of the team to brainstorm answers to such questions as: l How can this process, function, facility, or tooling fail? l What effect will process, function, facility, or tooling failures have on the end product (or customer)? l How can potential failures be eliminated or controlled? l Based on the success of Failure Modes and Effects Analysis (FMEA), the PFMEA concept was developed to incorporate a broader analysis team to accomplish a thorough analysis in a short time l A PFMEA can be used to assess any process. The most common use of the PFMEA involves manufacturing processes l PFMEAs may be performed on new processes or to improve current processes l To maximize its value, a PFMEA should be performed as early in the manufacturing development cycle as possible PFMEA Training 2 1.0 What is a PFMEA? (cont) l Because most PFMEAs involve manufacturing area processes, the manufacturing engineer is usually the team leader l The effectiveness of the team depends upon the expertise of its members, and the quality of the team output depends on the willingness of each team member to give his or her best effort l Teams may include: l Manufacturing Engineer l Design Engineer l Tooling Engineer l System Safety Engineer l Industrial Engineer l Handling Spet l Line Foreman/Operators l Customer l Materials & Process Engineer l Others as required PFMEA Training 3 2.0 How to Conduct an Effective PFMEA l Prior to the first meeting, the team leader should l Establish objectives and scope l Choose experts for the PFMEA team l The team leader is responsible for the effectiveness of the review l Brainstorming used to increase creativity and bring out a wide range of ideas l Discussion allows team to look at things from different view points l A visit(s) to the work area with an overview of the process/ test/ operation gives team members basic understanding of the process l Limit meetings to one hour PFMEA Training 4 2.0 How to Conduct an Effective PFMEA (cont) l STEP 1 l Team leader organizes the team; defines the goals, methods, scope, responsibilities of each team member; and establishes a tentative schedule l After reviewing engineering, drawings, and planning, team develops a flow chart showing the major functions or operations of the process to help team members understand the process l STEP 2 l For each process function, team determines all credible failure modes l Team discusses and records the failure effects, failure causes, and current controls for each potential failure mode l Team rates occurrence, severity, and detection for each failure cause l It is helpful to rate all failure causes for occurrence first, next rate for severity, and then rate for detection l The Risk Priority Number (RPN) is the product of these ratings PFMEA Training...
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This note was uploaded on 05/04/2011 for the course ME 3333 taught by Professor Gao during the Spring '11 term at Minnesota State University, Mankato.

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pfmea - Process Failure Modes and Effects Analysis (PFMEA)...

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