Failure Mode and Effect Analysis

Lecture 3-1
Design Review
Concurrent Engineering
MIL STD 1629

Design Process Errors FMEA

Incomplete: errors made by designers or engineers where they do
not follow the guidelines comprehensively
Inadequate: errors in the design guidelines where they do not
comprehensively inform designers and engineers of all steps
necessary to prevent error
Omission: a task is skipped completely by designers or engineers
Misperform: performance of a task by engineers though done
incorrectly or in such a way that an error is created
Incorrect: an error in the guidelines such that performance of the task
as specified results in an error Often, the corrective actions were the
implementation of additional guidelines, design reviews, or
documentation. However, these remedies tend to allow errors
themselves, so this is hardly the most effective approach to
eliminating errors from the design process.

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 Survey Results FMEA
‰ A structured design process strategy is in place.
‰ Your organization documents previous designs and processes
and makes them accessible to design teams.
‰ Your organization uses guidelines, checklists, or documentation
of best practices.
‰ Your design teams explicitly record observations and
assumptions throughout the design process.
‰ There are regularly scheduled design reviews.
‰ The design managers use performance metrics to evaluate the
design process.

DESIGN PROCESS ERROR-PROOFING: INTERNATIONAL INDUSTRY SURVEY

AND RESEARCH ROADMAP, Lawrence P. Chao, Kurt A. Beiter (Corresponding
Author), Kosuke Ishii, Proceedings of DETC ’01 2001 ASME Design Engineering
Technical Conferences
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Survey Results FMEA

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Common Causes of Error
FMEA

Reliability Analysis Methods

FMEA
100 93
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60 50
50 43
40 36 36
30 21 21
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Typical Survey Comments
FMEA
• “[Design errors are the result of working to schedules that are
often unrealistic and not well-designed by project managers.”
• “Recently, there has been a change in policy that NO redlined
drawings are to be accepted for producing production or
prototype parts. This should be common sense, but with schedule
pressure/deadlines, rules get bent.”
• “Design reviews are the only means of identifying and preventing
design errors. In the 6 years that I have been here, I have never
done nor have been asked to do a FMEA.”
• “Have attempted [FMEA-type analysis on design process] on
several occasions but have not committed enough resources or
time to see it through.”
• In the past, this [FMEA] has not been a regular process, but this
analysis has been encouraged and is being done by some, but it is
far from what I would call standard operating procedure.”
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Reliability Analysis Methods

FMEA

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Reliability Analysis Methods
FMEA

System Engineering and FMEA

FMEA

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Design Review FMEA
• Early Warning of New Product Problems
New Product Phase Early Warning
Concept, feasibility Concept Review

Prototype Design Design Review

Reliability prediction
DFMEA, PFMEA
Prototype Construction Environmental Stress
DFMEA, PFMEA
Pre-production Pilot runs
Tolerance analysis
PFMEA
Early production, ramp Failure analysis results

Full production Ongoing reliability testing

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Successful Design Review FMEA

• Emphasis on constructive feedback to
engineering, not criticism
• Avoid technological competition
• Realistic Schedules
• Sufficient resources
• Adequate planning to DR meetings
• Focus on untried and unproven design features
• Structure in the design review process
• Open mind to interdepartmental conflicts
• Management directive
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Today’s Environment FMEA
Modern products need a structured program
• DR’s are mandatory - customer or management
• Conducted by a team of specialists not directly
associated with the development of the design
• Ultimate decision rests with the designer
• DR’s are formal
• Topics include reliability, performance, producibility,
serviceability, maintainability, interchangeability,
safety, appearance, cost, value
• Reviews made to defined criteria
• Conducted at several phases of the design

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Operations Readiness FMEA

Design review includes:
• Clarity of all requirements
• Relative importance of various product characteristics
• Design for Manufacturability
• Process robustness
• Availability of process to meet requirements
• Identification of special requirements - handling, in-
process protection, etc.
• Availability of measurement equipment to meet
special needs
• Special skill required of operations personnel

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 Concurrent Engineering FMEA
1. A systematic approach
2. to the integrated, concurrent development of a
product and its related processes
3. that emphasizes response to customer expectations
4. and embodies team values of cooperation, trust and
sharing
5. in such a manner that decision making proceeds with
large intervals of parallel working
6. by all lifecycle perspectives
7. synchronized by comparatively brief exchanges to
produce consensus

Concurrent Engineering Research Center, Univ. of West Virginia, Morgantown, WV.

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Integrated Product Development Model FMEA

Determining
User Market Preparation
the basic Sales
Investigation Investigation for Sales
need

The Determining Product Preliminary Modification

Product
Product Principle Product for
Adaptation
Need Type Design Design Manufacture

Consideration Determining Determining Preparation

or Process Type of Production for Production
Type Production Principles Production

Integrated Product Development, Andreasen, M.M. and L. Hein, Berlin: Springer, 1987

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Concurrent Engineering Toolbox FMEA
Taking into account all lifecycle perspectives requires
structured working methods. Various tools have been
developed to support these working methods:

• Rapid prototyping is a tool to produce prototypes in

a matter of hours instead of weeks.
• Quality Function Deployment (QFD) is a tool to
translate customer demands into functional
requirements
• Failure Mode and Effects Analysis (FMEA) is a
method to detect possible failures of the product as
early as possible in the product creation process.

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Concurrent Engineering Toolbox FMEA

• Robust design is a method for tolerance management.
Influences of tolerancing are minimized by determining
their effects on the product's functionality.
• Design for Manufacturing and Assembly (DFMA) is a
method that leads to a product design that is fit for the
manufacturing processes and leads to fewer and easier
assembly operations.
• Design for Logistics takes the DFMA concept a step
further. The product design has been analyzed for easy
shop floor control and material management.
• Design for Cost is a tool that analyzes each design step
for its cost effects and thus tries to establish the product
functionality for the lowest possible cost.
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Quality Function Deployment FMEA

• It is a tool to translate the wishes of the

customer into technical demands for the
product.

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Robust Process FMEA

• A process is robust if it is
– flexible,
– easy to operate,
– error-proof
– its performance will tolerate uncontrollable
variations in external and internal factors

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Design for Manufacturability FMEA
Design for Manufacturability (DFM) may be defined as
an approach for designing products so that:

• the design is quickly transitioned into production,

• the product is manufactured at minimum cost,
• the product is manufactured with a minimum
effort in terms of processing and handling
requirements, and
• the manufactured product attains its designed
level of quality.

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Design for Manufacturability and Assembly FMEA

• DFM rules suggest that you can

improve efficiency by minimizing the
number of parts that have to be
assembled
• Product life cycle is shortening rapidly
so that time to market is a critical metric
• Significantly different that the traditional
approach to product development.

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Where Did the Org Chart Come From? FMEA

Look familiar?
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See speaker’s notes

“Over the Wall” Engineering FMEA

DESIGN PROCESS MANUFACT.

ENIGNEERING PLANNING ENGINEERING TOOLING

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Concurrent Engineering FMEA

DESIGN ENIGNEERING

PROCESS PLANNING

MANUFACT. ENGINEERING

TOOLING

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Concurrent Engineering FMEA

• Requires Systems Thinking

• Main intent is to use synergy of the
organization to reach a time to market
goal
• Global Optimization replaces
Suboptimization

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The Danger of Suboptimization FMEA
Optimization - is a process of orchestrating the efforts of all
components toward achievement of a stated aim. Optimization
is management’s job. Everyone wins with optimization.
Suboptimization - the maximizing or fine-tuning of a part of
the system
We need to work together to optimize the system as
a whole, not seek to optimize separate pieces. -
Deming
Optimizing separate pieces
destroys the effectiveness
of the whole.

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Suboptimization FMEA
Anything less than optimization of the whole system will
bring eventual loss to every component in the
system. Any group should have as its aim
optimization of the larger system that the group
operates in.

The obligation of any component is to contribute its best to the

system, not to maximize its own production, profit or sales, nor
any other competitive measure. Some components may
operate at a loss themselves in order to optimize the whole
system, including the components that take a loss.

W. Edwards Deming
The New Economics for Industry, Government and Education
MIT Center for Advanced Engineering Study, 1993
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DFMA FMEA

DFMA is an integration of the techniques of

Design for Manufacturability (DFM) and
Design for Assembly (DFA).
DFM analyzes the product concept on
ability to manufacture.
DFA requires that every part be checked to
determine if the part is really necessary

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DFA FMEA

• DFA can contribute to lower costs and

time to market by:
– reducing scrap and rework
– creating efficiencies in purchasing,
assembly and inventory
– allowing the organization to learn more
quickly. (Learning curves and shorter)

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DFMA FMEA
DFMA contributes to competitive success
by matching product demands to
manufacturability and assembly capability

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DFMA FMEA
Major characteristics of DFMA include:
• both manufacturing and assembly are
taken into consideration in the
optimization of the design.
• By parallel execution, the effect of a
design decision on production can be
evaluated, at the moment that the decision
is made
• Commitment to continuous production
and process optimization.

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 FMEA

Process FMEA

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Process FMEA FMEA

A Process FMEA is an analytical technique
utilized by manufacturing engineering as a
means to ensure that, to the extent
possible, potential failure modes and their
associated causes have been considered
and addressed.

End items, along with subassemblies and

detail parts, should be evaluated.

Handbook Pg. 30
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Process FMEA FMEA
‹ identifies potential product related process failure
modes,

‹ assesses the potential customer effect of these

failures,

‹ identifies the potential causes, and identifies

significant process variables to focus controls for
reduction or detection.

‹ It develops a list of potential failure modes ranked

according to their effect on the "customer," thus
establishing a priority system for corrective
action.
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Process FMEA FMEA

The Process FMEA is a living

document and should be initiated at
or by the feasibility stage, prior to the
development of production tooling.

It will take into account all

manufacturing and assembly
operations, from individual
components and subassemblies to
final assemblies.
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Understanding variation FMEA

Fitness for Use Specifications

and Tolerances Control Chart

5000 BC 1800 AD 1924

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