1. INCOSE Michigan – May Dinner Meeting
Failure Mode & Effect Analysis (FMEA)
in Half the Time
Howard C Cooper, MS, DFSS-BB
May 13th, 2014
Notes level one
Notes level two
Notes level three
Notes level four

2. Introduction Before they are “baked” into a product
Failure Mode & Effects Analysis (FMEA) is an analytical tool and structured method to:
Recognize and evaluate the potential failure of a product/process and its effects
Identify and prioritize actions which could eliminate or reduce the chance of a potential failure
Document the process
Before they are “baked” into a product
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

3. Common Types of FMEA Design FMEA Process / Manufacturing FMEA
Identify and mitigate potential design problems early in the design cycle
Process / Manufacturing FMEA
Improve quality and reliability, during set-up of initial manufacturing process
Problem Solving / Six Sigma FMEA
Understand failure modes and effects to identify and solve quality or reliability issues
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

4. Where FMEA is Used Product Definition: Mfg: Process Definition:
Customer Reqmts:
Vehicle Tech Specs
Product Definition:
Key product characteristics,
Design FMEA
Process Definition:
Process Flow Diagram (PFD)
Process
Failure Mode Analysis:
Process FMEA
Control Strategy:
Control Plan, Error proofing
Mfg:
Work Instructions &
Process Monitoring
Six Sigma FMEA
Common FMEA Usage
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

5. Example Design FMEA Prioritize Failure Modes by Risk Priority Number
SEV X OCC X DET = (RPN)
Example Design FMEA
Failure Mode
Item
Severity
FM & Effects of each failure mode
Relative Occurrence
Root Cause
Items within the system being analyzed
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

6. Example Process FMEA Steps within the process being analyzed
Item
Potential Failure Mode
Potential Effect(s) of Failure
Sev
Potential Cause(s)/Mechanism(s) of Failure
Occur
Current Process Controls Detection
Detec
RPN
Process Function
3 - Front Door L.H.
Manual application of chromate conversion coatings on exposed aluminum substrate (to retard corrosion)
Insufficient chromate coating over specified surface.
Deteriorated life of part leading to: - Unsatisfactory appearance due to rust through paint over time. - Impaired function of hardware. 5
Manually inserted spray head not inserted far enough. 3
Visual check each hour - 1/shift for film thickness (depth meter) and coverage. 75
Spray head clogged - Viscosity too high - Temperature too low - Pressure too low. 2 30
Spray head deformed due to impact. 20
Spray time insufficient. 1
Operator instructions and lot sampling (10 doors/shift) to check for coverage of critical areas. 10
Steps within the process being analyzed
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

7. Typical FMEA Process
Assemble team of people with diverse knowledge of process & product
Bound the problem
Identify functions
Identify potential failure modes
Populate FMEA details
Prioritize failure modes based on RPN
Mitigate failure modes
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

8. Mission to Improve FMEA Development
Challenge
Current FMEA problems:
Opportunity:
Time consuming
Rapid (> 2x faster)
High rate of missed critical failure modes
Critical failure modes are given top-priority
Ad hoc identification of failure modes
Process-driven identification of all failure modes
Disjointed, undirected time-consuming discussion
Focused, efficient development effort
Allows prioritization only after FMEA development
Prioritization can happen before FMEA development
Is difficult to use
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

9. Block / Process Diagram
Improved FMEA Process
In 2012, GDLS developed process to prepare ‘efficient’ and ‘effective’ FMEA at greatly reduced time and cost
Process involves four primary tools:
Block / Process Diagram
p-Diagram
Decomposition Table
FMEA
Major innovation:
Decomposition Table identifies and prioritizes Failure Modes (FMs) into FMEA. Focuses analysis on critical failure modes
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

10. Boundary Diagram / Process Flow
Step 1: Bound the System
Boundary Diagram / Process Flow
What
Identifies and verifies:
System functions: lines crossing the dotted boundary
“Items” within the dotted line system boundary
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

11. Step 2: Characterize the Process
P-Diagram
What (From Boundary Diagram)
Why
Green blocks, identify functions of the system (or process) Yellow blocks ~ Noise Factors, Blue block, Control Factors, Pink blocks ~ Error States
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

12. Outstanding Problem & Opportunity
Boundary or Process Flow Diagram
Identifies “Items” for the FMEA, but not the Failure Modes (FM) of those “items”
P-Diagram
Identifies system functions or requirements (even noise factors) but not the function or FMs of the “items”
Opportunity
Develop a table that will identify and link “items” to their functions, and to their functional FMs
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

13. Step 3: Map Functions to Failure Modes
System Functions
P-Diagram
Boundary / Process Diagram
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

14. Step 3: Map Functions to Failure Modes
System Functions
P-Diagram
Need to Identify Item / HW Functions
Boundary / Process Diagram
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

15. Step 3: Map Functions to Failure Modes
System Functions
P-Diagram
Identify Functions
Boundary / Process Diagram
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

16. Step 3: Map Functions to Failure Modes
System Functions
P-Diagram
Identify Functions
Boundary / Process Diagram
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

17. Step 3: Map Functions to Failure Modes
System Functions
P-Diagram
Identify Functions
Boundary / Process Diagram
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

18. Decomposition Table Structures FMEA
System Functions
functions translate to FMs
3-4 FMs per Function
From
B-Diagram or Pr-Flow Chart
“X” indicates a Function (and 4 FMs in the FMEA)
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

19. 3 Purposes of the Decomposition Table
Ensures all items are captured into the FMEA
Ensures multiple function items and their potential failure modes are identified into the FMEA
Provides opportunity to identify and prioritize by criticality of hardware or process functions before populating failure modes into the FMEA
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

20. Decomposition Table Prioritizes Functions
System
Criticality # rather than “X”
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

21. Preparation Flow into Decomp Table
System
1. P-Diagram Ideal Functions – to Design Functions in F-H Decomp.
3. Identify all ‘Item’ Functions needed to accomplish each System Function
4. Mark with an “X” or with a “Criticality #”
2. B-Diagram or Process Flow inner blocks go to Decomp. Table
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

22. Step 4: Use Decomp Table to Fill FMEA
System 1 1 3 3 1 4 2 2 1 4 2 3
FMEA filled in from F-H Decomp Table
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

23. Benefits of Improved FMEA Development
Pareto Chart (80/20 Rule)
Four Step FMEA Process:
Organizes and speeds FMEA failure mode identification
Ensures all hardware-functions and FMs are identified
Prioritizes critical hardware-functions for FMEA analysis
Provides power of 80/20 Rule on FMs for best Reliability Growth
Focuses attention and time on mitigation of “significant few” (the most critical failure modes (FMs)
F-H Decomp Table now being used on multiple GDLS Contracts: for DFR, to facilitate earlier diagnostics planning, to meet Weight and Testability Requirements
Addressing most critical FMs yields greatest reliability growth.
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

24. Cost Savings Attributed to New Process
Before vs, After Facilitator Cost
Savings on Facilitator Cost
Facilitator Savings X 3 for FMEA Team, X 3 Programs in 2013 = Total Savings
Approved for Public Release, Distribution Unlimited, LogNo , 26 FEB 14

25. Questions? Presenters: Howard C Cooper, MS, DFSS-BB
DFR Reliability Engineer
Mark Petrotta, MS, DFSS-MBB
Engineering Process Excellence