FMEA for Six Sigma

Prepared By: ABHIJITH M PILLAI

Date: 11/29/2012

S O
v c
Process Potential Failure Potential Effects Potential Causes
Oper. No r r
description Mode or Failure of Failure
t n
y c

Fixing the incorret

1 uneven surface 6 human error 2
workpiece position
wrong guage
2 Marking wrong position 7 2
dimension calibration

excess removal
3 Filing incorrect speed 3 unskilled labour 2
of material

worn out file no surface finish 7 bad tool 3

incorrect inaccurate non calibrated

4 Measuring 4 1
measurement workpiece scale
EA for Six Sigma
AI
Filing
Action Results

Current Responsibility S O D
R
Controls for Recommended and Target v c t
P
Prevention/Det Action Completion Action Taken r r c
N
ection Date t n t
y c n

4 48 Training 1 week workers trained 6 1 1

5 70 training 3 days training given 5 2 2

recruit only
3 18 skilled labour 2 1 1
skilled labours

3 63 change tool 1 day new tool used 4 2 1

calibrate the calibrated the

7 28 1 week 3 1 2
instrument instrument
sults

R
P
N

20

6
 AIAG Compelled Rating
Rating Severity of Effect
10 Hazardous without Warning
9 Hazardous with Warning
8 Lose of primary function
7 Reduced primary function performance
6 Lose of secondary function
5 Reduced secondary function performance
4 Minor defect noticed by most customers
3 Minor defect noticed by some customers
2 Minor defect noticed by discriminating customers
1 No effect unlikely

Six-Sigma Compelled Rating

Rating Severity of Effect
10 Injure a customer or employ

9 Be illegal

8 Render product or service unfit for use

7 Cause extreme customer dissatisfaction
6 Result in partial malfunction

Cause a loss of performance which is likely to result in

5
a complaint

4 Cause minor performance loss

Cause a minor nuisance but can be overcome with no

3
performance loss
Be unnoticed and have only minor effect on
2
performance

1 Be unnoticed and no effect on performance

 AIAG Compelled Rating
Likelihood of Occurrence
Very high; Failure is almost inevitable
Very high; Failure is almost inevitable
High; Repeated failures
High; Repeated failures
Moderate; Occasional failures
Moderate; Occasional failures
Moderate; Occasional failures
Low; Relatively low failures
Low; Relatively low failures
Remote; Failure is unlikely
Six-Sigma Compelled Rating
Likelihood of Occurrence
More than one per day
Once every 3-4 days
Once every week
Once per month
Once every three months
Once every six months
One per year
Once every 1-3 years
Once every 3-6 years
Once every 6-9 years
Ability to Detect
Can not detect
Very remote chances of detection
Remote chances of detection
Very low chances of detection
Low chances of detection
Moderate chances of detection
Moderate high chances of detection
High chances of detection
Very high chances of detection
Almost certain
Ability to Detect
Defect caused by failure is not detectable
Occasional units are checked for defects
Units are systematically sampled and
inspected
All units are manually inspected
Manual inspection with mistake proofing
modifications
Process is monitored and manually
inspected
SPC is used with an immediate reaction to
out of control conditions
SPC is above 100% inspection surrounding
out of control conditions
All units are automatically inspected
Defect is obvious and can be kept from
affecting the customer