1. Välkommen, welcome, huān yíng, welkom, Bienvenue, willkommen, fogadtatás, benvenuto, velkommen, powitanie, bem-vindo, croeso, bienvenido, vítejte Advanced Powertrain Control Symposium 9 th July 2013 05/07/2013www.fmea.co.uk1

2. The Effective Application of FMEA Who am I? What is FMEA? Why do FMEA? Application of FMEA A Structured Approach Effective FMEA Use Software for FMEA Use an FMEA Facilitator 05/07/2013www.fmea.co.uk2

3. What is FMEA? Contrary to popular belief FMEA is actually an acronym for a risk analysis called Failure Modes & Effects Analysis, and not Five Men Endlessly Arguing. Failure Modes & Effects Analysis is an activity that brings minds together in a collaborative and pre-emptive way in order to avoid failure of a system! FMEA is a systematic procedure that focuses on a system(s) in order to uncover weaknesses, i.e. what can go wrong, what could possibly cause it and what are the potential effects. FMEA then focuses on these weaknesses with the objective of making them obsolete, or by reducing the likelihood of failure (or risk of failure) though the implementation of corrective methods, which in turn optimises the system. 05/07/2013www.fmea.co.uk3

4. What is FMEA? FMEA is a living document and if used correctly records: intellectual property weaknesses within the system quantified risk of system failure mistakes made solutions to problems responsibility for controls methods Failure are any potential errors or defects within a process, design, or part, especially ones that affect the customer, environment and law. 05/07/2013www.fmea.co.uk4

5. What is FMEA? 1949 – US Military (MIL-P-1649) 1963 – NASA 1965 – Aerospace Industry 1975 – Nuclear Industry 1977 – Ford Motor Company 1980 – DIN 25448 1986 – VDA Volume 4 1992 – Ford, Chrysler & GM 2008 – AIAG Is universally accepted as an engineering tool 05/07/2013www.fmea.co.uk5

6. Why do FMEA? Cost reduction and increased profits Demand for higher quality Extended warranty periods Product liability Quality standard demands Retention of knowledge Make processes more robust Enhanced communication within the business, customer & suppliers Shorter development times Functional Safety & Reliability 05/07/2013www.fmea.co.uk6

7. Application of FMEA 05/07/2013www.fmea.co.uk7

8. Application of FMEA There are two main schools of thought about the methodology to use and which is most effective? Rose with a different name Procedure Document formats Adherence to ISO / TS 16949 Basis for ISO / TS 26262 05/07/2013www.fmea.co.uk8

9. Application of FMEA To get the best out of FMEA you should have: Cross functional team FMEA Moderator / Facilitator Props and documentation Structured approach FMEA Software Management Support! 05/07/2013www.fmea.co.uk9

10. A Structured Approach 05/07/2013www.fmea.co.uk10

11. Effective FMEA Step 1: Visual representation of the scope 05/07/2013www.fmea.co.uk11

12. Effective FMEA Step 2: Runs in line with other engineering techniques, such as Function Analysis System Technique (FAST) How? Why? Effects Causes Mode 05/07/2013www.fmea.co.uk12

13. Effective FMEA Focus on functions provide guidance for the analysis of failures, or step 3. Loss of Voltage stimulus Corrupted Voltage stimulus Voltage stimulus when not required Signal stuck at ground Signal stuck at specified voltage Signal is corrupted Short Open Effects Causes Mode 05/07/2013www.fmea.co.uk13

14. Effective FMEA Step 3: Efficient construction of effective possible failure scenarios EffectsCauses Mode 05/07/2013www.fmea.co.uk14

15. Effective FMEA Step 4: Possible failure scenarios are displayed in a fashion that is consistent with previous steps Failure Effect(s)SFailure ModeFailure Cause(s) 05/07/2013www.fmea.co.uk15

16. Effective FMEA AIAG form can be unintentionally misleading Mode Causes Effects 05/07/2013www.fmea.co.uk16

17. Effective FMEA VDA form is logical Effects Mode Causes E=MC 2 05/07/2013www.fmea.co.uk17

18. Effective FMEA Step 4: Ensuring that only the controls that are currently in fruition are considered when calculating the risk 05/07/2013www.fmea.co.uk18

19. Effective FMEA Step 4: Analysis of the data using RPN is not just 1-1000, there are 120 values that can result from S x O x D, which may not reflect criticality. 05/07/2013www.fmea.co.uk19

20. Effective FMEA Common sense shall prevail by looking at the risk assessment results in a different way e.g.: 05/07/2013www.fmea.co.uk20 Automotive risk model

21. Effective FMEA Step 5: Reduction of the risk is displayed in a Chronological order 05/07/2013www.fmea.co.uk21

22. Effective FMEA Create your own descriptions of the risk factors of Severity (S), Occurrence (O) and Detection (D): Reflect what you do as a business Reflect the product you make Is there a customer mandate? Using rule of thumb statements & benchmark examples Use AIAG descriptions as guidance* 05/07/2013www.fmea.co.uk22

23. Use Software for FMEA Due to the complexities of modern products & processes, software is essential. Many companies use MS Excel, but dedicated software can provide a visual representation of: the system analysed interfaces between sub-systems, plus inputs and outputs complex relationships between the failures 05/07/2013www.fmea.co.uk23

24. Use Software for FMEA In addition to this dedicated software allows the FMEA to: be filtered or colour coded according to your own criteria produce additional statistical data and additional quality documentation as a consequence Switch easily between FMEA form layouts handles variances Supports delegation and tracking of corrective measures 05/07/2013www.fmea.co.uk24

25. Use an FMEA facilitator Experienced FMEA facilitation will ultimately save time and make meetings more focused & constructive. An experienced FMEA facilitation minimises digression into different types of FMEA. An external FMEA facilitator may ask the stupid questions that may have been overlooked as they may be thinking outside of the box An effective FMEA records intellectual capital for the future developments (semantics) 05/07/2013www.fmea.co.uk25

26. 078 999 625 53 - 01785 711 296 gavin@fmea.co.uk Penkridge, Stafford, ST19 5TE. UK tack, thanks, xièxie, dank u wel, merci, danke, köszönöm, grazie, tak, dzi ę kuj ę, obrigado, diolch, gracias, děkuj, ďakujem 05/07/2013www.fmea.co.uk26