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2. 222  Individually  Given your sample of M&Ms, build a Pareto diagram by color  Before you destroy the evidence, be sure you have an accurate count of each color and the total number of M&Ms. Brown= Red= Yellow= Blue= Orange= Green= ------------------------ Total= V-11

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4. 444 Copyright Air Academy Associates V-20

5. 555 Copyright Air Academy Associates V-20

6. 666 Copyright Air Academy Associates V-20

7. 777 A finished document (i.e., unit) contains a total of 4 critical entries (i.e., a critical entry is an opportunity for a defect, mistake, or error). An inspection of 3,000 documents revealed a total of 195 errors, and 94% of the documents were good (i.e., defect free). Calculate the following: dpu = dpm = dpmo = Total Number of Defective Documents = Total Number of Defect-Free Documents = FPY = σ capability = V-56

8. 888  Failure Mode – The manner in which a part or process can fail to meet specification. It is usually associated with a defect or nonconformance.  Effect – The impact on a customer if a failure mode is not prevented or corrected. The customer can be an immediate one or one downstream.  Cause – A deficiency that results in a failure mode. Causes are sources of variability associated with key process input variables.  A FMEA is best when a team prepares it. The team should be made up of people from all areas impacted by the process. The FMEA is useful in a number of applications: in determining X’s, helping to define process improvements and controls, and others.  Reference ◦ AIAG – Potential Failure Mode and Effects Analysis, FMEA ◦ SAE J1739- Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA) V-66

9. 999  System FMEA is used to analyze systems and subsystems in early concept and design stages. It focuses on potential failure modes associated with the functions of a system caused by design.  Design FMEA is used to analyze products before they are release to production.  Process FMEA is used to analyze manufacturing, assembly, and transactional processes.  Product FMEA is used to analyze failure modes that could occur to the product once it gets into the customers hands. FMEA: Identify ways of eliminating or reducing the specific causes and document a plan to prevent the failures. V-66

10. 10 Preparation  A FMEA begins with a process map. Identify the process and map its key steps.  List the key process outputs to satisfy customer requirements.  List the key process inputs for each process step.  Define a matrix relating product outputs to process inputs.  Rank inputs according to their importance. The goal in your preparation is to have a complete understanding of the process you are analyzing. What are its steps? What are its inputs and outputs? How do they relate? **Information for this section taken from: GE Six Sigma Playbook and the AIAG Reference Manual.** V-66

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12. 12  Start with the high level process map for an accounts receivable process: Receive Payment Identify Customer Identify Invoice Apply Payment to Invoice Start End V-66

13. 13  For each Process Input Variable (PIV), determine the ways in which the input can go wrong (failure modes).  There is at least one way that each input can fail. V-66

14. 14  For each failure mode associated with the inputs, determine effects.  These effects are internal requirements for the next process as well as customer effects. V-66

15. 15  Identify potential causes of each failure mode.  In most cases, there will be more than one cause for a failure mode. V-66

16. 16  List the current controls for each cause.  For each cause, we list how we are either preventing or detecting it. List the document number for any SOP’s. This is how the FMEA identifies initial holes in the current control plan. V-66

17. 17  The risk priority number (RPN) is the product of the rankings for: ◦ Severity (SEV) ◦ Probability of Occurrence (OCC) ◦ Difficulty to Detect (DET)  High RPN’s are flags to take effort to reduce the calculated risk  Regardless of RPN, high severity scores (9-10) must be given special attention RPN = SEV x OCC x DET Effects CausesControl s V-66

18. 18 Create a rating system that makes sense for your project, the process, and the defects you’re trying to prevent. V-66

19. 19  Assign severity, occurrence and detection ratings to each cause.  We are now ready to assign appropriate criteria. The team then starts scoring each cause to compute a risk priority number (RPN). V-66

20. 20  Calculate the RPN’s and determine recommended actions to reduce high RPN’s.  High severity scores (9-10) must be given special attention.  Which issues may we want to address first? V-66

21. 21  Determine recommended actions to reduce high RPN’s.  Now fill in recommended actions for high RPN’s.  Ease of Completion (EOC) for each action is optional. V-66

22. 22  Person or group responsible should take on the Actions Recommended and document those actions. Now recalculate your RPN’s. V-66

23. 23  Collaborative effort: Do not try alone, perform in a group.  Action items are required for completion.  Train team ahead of time by explaining scoring criteria.  Summarize often: FMEA is a living document. V-66