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(PFMEA)
HISTORY:
Created by the aerospace industry in the 1960s. Ford began using FMEA in 1972. Incorporated by the Big Three (General Motors, Ford, Chrystler) in 1988. Automotive Industry Action Group (AIAG) and American Society for Quality (ASQ) copyright standards in 1993. PURPOSE: To take preventive actions (action to prevent occurrence of potential cause of failure) for manufacturing of products.
5 6
7 7 7 7
Process Flow Diagram: Oprn. no. Process name Flow diagram Product characteristics Process characteristics Remarks
3. Effect analysis:
1. 2. 3.
This is done to identify the potential effects that a failure mode will create on further downstream processes / customer processes / application. Write the specific effects in following categories (do not write rejection as effect):
Effect on next processes Effect on internal assembly line or on customer assembly line Effect on application
The seriousness of the effect is ranked using Severity Number on a 1 10 scale as given in the following table (Severity Table). If the severity number is 9 or 10, mark CC (critical characteristics) in the class column and if the severity number is 8, mark SC (significant characteristics) in the class column.
Severity table:
Sev. No. 10 Effect on next processes / Assy. Can lead to accident and loss of life Effect on customer assy. line Can lead to accident and loss of life Effect on application / usage Can lead to accident and loss of life and will happen without warning
9
8 7 6 5 100% scrap Some scrap & some rework 100% rework Some rework and some accepted with deviation Fitment not at all possible Fitment possible with difficulty
Can lead to accident and loss of life but will happen with warning
Will completely stop the primary function of the application Will deteriorate the primary function of the application Will stop the functioning of the comfort / convenience items Will deteriorate the functioning of the comfort / convenience items Appearance problem and will be noticed by most of the customers
3
2 1 No effect No effect
7
6 5 4 3 2
Table B
Rejection data for potential failure modes
Very High: Persistent failures High: Frequent failures Moderate: Occasional failures Low: Relatively few failures Remote: Failure is unlikely
Occurrence number
10, 9 8, 7 6, 5, 4 3, 2 1
7
6 5 4 3 2
For all detective controls, sample size and frequency of check to be written in the FMEA column.
By taking actions, the detection number and occurrence number will be reduced and so RPN will also reduce. The severity number remains unchanged. After implementation of actions, the date of implementation and description of action to be written is FMEA column. Sev, Occ and Det numbers to be reassessed and RPN to be recalculated after implementation of actions. Control plan to be update based on changes in control methods in FMEA.
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