Emmforce Inc. Plot No. 3 & 5, Phase I, EPIP, Jharmajri.: Item / Process Step
Emmforce Inc. Plot No. 3 & 5, Phase I, EPIP, Jharmajri.: Item / Process Step
A characteristic designated in the design record as special without an associated design failure mode identified
in the DFME is an indication a a weakness in the design process.
Each function may have multiple failure modes. A large number of failure modes identified for a single function
may indicate that the requirement is not well defined.
The assumption is made that the failure could occur, but may not necessarily occur, consequently the use of
the word "potential".
Potential failure modes that could occur only under certain operating conditions (i.e., hot, cold, dry, dusty, etc.)
and under certain iusage conditions (i.e., above-average mileage, rough terrain, city driving only, etc.) whould
be considered.
After determining all the failure moders, a validation of the completeness of the analysis can be made through
a review of past things-gone-wrong, concerns, reports, and group brainstrorming.
The potential failure mode may also be the cause of a potential failure mode in a higher level subsystem or
system, or lead to the effect of one in a lower level compoenent.
Severity
Severity is the value associated with the most serous effect for a given failure code. Severity is a relative ranking within the sco
The team should agree on evaluation criteria and a ranking system and apply them consistently, even if modified for individual
It is not recommended to modify criteria ranking values of 9 and 10. Failure modes with a rank of severity 1 should not be anal
Potential Cause(s)/Mechanism(s) of F
In the development of the FMEA, the identification of all potential causes of the failure mode is key to
subsequent analysis. Although varied techniques (such as brainstorming) can be used to determine the
potential cause(s) of the failire mode, it is recommended that the team should focus on an understanding of
the failure mechanism for each failure mode.
A failure mechanism is the physical, chemical, electrical, thermal, or other process that results in the failure
mode. It is important to make the distinction that a failure mode is an "observed" or "external" effect so as not
to confuse failure mode with failure mechanism, the actual physical phenomenon behind the failure mode or
the process of degradation or chain of events leading to and resulting in a particular mode.
To the extent possible, list every potential mechanism for each failure mode. The mechanism should be listed
as concisely and completely as possible.
For a system, the failure mechanism is the process of error propagation following a component failure which
leads to a system failure.
A product or a process can have several failure modes which are correlated to each other because of a
common failure mechanism behind them.
Ensure that process effects are considered as part of the DFMEA process.
Potential cause of failure is defined as an indication of how the design process could allow the failure to occur,
described in terms of something that can be corrected or can be controlled. Potential cause of failure may be
an indication of a design weakness, the consequence of which is the failure mode.
Causes ate the ciscumstances that induce or activate a failure mechanism.
In identifying potential causes of failure, use concise descriptions of the specific causes of failures, e.g.,
specified bold plating allows for hydrogen embrittlement. Ambiguous phrases such as, poor design of improper
design, should not be used.
Investigation of causes needs to focus on the failure mode and not the effect(s). In determining the cause(s),
the team should assume the existence of the cause under discussion will result in the failure mode (i.e., the
failure mode does not require multiple causes to occur).
Typically, there may be several causes each of which can result in the failure mode. This results in multiple lines
(cause branches) for the failure mode.
To the extent possible, list every potential cause for each failure mode/failure mechanism. The cause should be
listed as concisely and completely as possible. Separating the causes will result in a focused analysis for each
cause and may yield different measurement, controls, and action plans.
In preparing the DFMEA, assume that the design will be manufactured and assembled to the design intent.
Exception can be made at the team's discretion where historical data indicate defifiencies in the manufacturing
process.
Occurrence
Occurrence is the likelihood that a specific cause/mechanism will occur resulting in the failure mode within the design life.
The likelihood of the occurrence ranking number has a relative meaning rather than an absolute value.
A consistent occurrence ranking system should be used to ensure continuity. The occurrence number is a relative ranking withi
The team should
not reflect agree
the actual on evaluation
likelihood criteria and a ranking system and apply them consistenly, even if modified for individual p
of occurrence.
be estimated using a 1 to 10 scale.
In determining this estimate, questions such as the following should be considered:
* What is the service history and field experience with similar components, subsystems, or systems?
* Is the item a carryover or similar to a previous level item?
* How significant are changes from a previous level item?
* Is the item radically different from a previous level item?
* Is the item completely new?
* What is the application or what are the environmental changes?
* Has an engineering analysis (e.g., reliability) been used to estimate the expected comparable
occurrence rate for the application?
* Have preventive controls been put in place?
Detection
Detection is the rank associated witht the best detection control listed in the Current Design Control Detection column. When
control be included as part of the description of the control. Record the lowest ranking value in the Detection column.
A suggested approach to Current Design Control Detection is to assume the failure has occurred and then assess the capabilitie
Do not automatically presume that the detection ranking is low because the occurrence is low. It is important to assess the cap
them going further in the design release process.
Detection is a relative ranking within the scope of the individual FMEA. In order to achieve a lowe ranking, generally the design
activities) has to be
The team should improved.
agree on evaluation criteria and a ranking system and apply them consistently, even if modified for individual
be estimated using the following table as a guideline:
Detection
The ranking value of one (1) is reserved for failure prevention through proven design solutions.
The initial focus of the team should be oriented towards failure modes with the highest severity rankings. When the severity is
design controls or recommended actions (as documented in FMEA).
For failure modes with severities 8 or below the team should consider causes having higherst occurrence or detaction rankings
approach, and determine how to best prioritize the risk reduction efforts that best serve their organization and customers.
During every review ,Suitable Action shall be taken on the reduction of RPNs(if Possible). Top Five RPNs shall be consider
Recommended Actions
In general, prevention actions (i.e., reducing the occurrence) are preferable to detection actions. An example of this is the use o
design freeze.
The intent of recommended actions is to improve the design. Identifying these actions should consider reducing rankings in the
occurrence, and detection.
* To reduce severity ranking: only a design revision can bring about a reduction in the severity ranking.
For maximum effectiveness and efficiency of this approach, changes to the product and process design should be implemented
* To reduce occurrence ranking: A reduction in the occurrence ranking can be accepted by removing or controlling one or mor
but not limited to, the following should be considered:
o Error proof the design to eliminate the failure mode
o Revised design geometry and tolerances
o Revised design to lower the stress or replace weak (high failure probability) components
o Add redundancy
o Revised material specification
* To reduce detection ranking: the preferred method is the use of error/mistake proofing. An increase in design validation/ver
design change to a specific part may be required to increase the likelihood of detection (i.e., reduce the ditection ranking). Add
o Revised test plan
If the assessment leads to no recommended actions for a specific failure mode/cause/control combination, indicate this by ent
especially in case of high severity.
For design actions consider using the following:
* Results of reliability testing
* Design analysis (reliability, structural or physics of failure) that would confirm that the solution is
effective and does not introduce new potential failure modes
* Drawing, schematics, or model to confirm physical change of targeted feature
* Results from a design review
* Changes to a given Engineering Standards or Design Guidelines
* Reliability analysis results
Action Results
This section identifies the results of any completed actions and their effect on Severity, Occurrence and Detection rankings and
cteristics (Requirements)
List the requirements for each process function of the process step or operation being analyzed.
Requirements are thus inputs to the process specified to meet design intent and other customer
requirements. If there are multiple requirements with respect to a given function, each should be
aligned on the form with the respective associated failure modes in order to facilitate the analysis.
Process Function
List the process function that corresponds to each process step or operation being analyzed. The process
function describes the purpose or intent of the operation. A risk analysis recommended in order to limit
the number of steps to be included to only those that add value or otherwise are seen as likely to have a
negative impact on the product. If there are multiple process functions being analyzed with respect to a
given operation, each should be aligned on the form with its respective "Requirements" to aid in the
development of the associated failure modes.
Assume that the failure could occur but may not necessarily occur. Potential failure modes should be
described in technical terms, not as a symptom noticeable by the customer.
If the requirements have been well defined, then the potential failure mode is readily identifiable by
determining the condition when a specific requirement is not met. Each requirement may have multiple
failure modes. A large number of failure modes identified for a single requirement usually indicates that
the requirement is not well defined.
The assumption is made that the failure could occur but may not necessarily occur - consequently the
used of the word "potential".
Verification of completeness of the potential failure modes can be made through a review of past things-
gone-wrong, concerns, reports, and group brainstrorming. Sources for this should also include a
comparison of similar processes and a review of customer (End User and subsequent operation) claims
relating to similar components.
failure modes. A large number of failure modes identified for a single requirement usually indicates that
the requirement is not well defined.
The assumption is made that the failure could occur but may not necessarily occur - consequently the
used of the word "potential".
Verification of completeness of the potential failure modes can be made through a review of past things-
gone-wrong, concerns, reports, and group brainstrorming. Sources for this should also include a
comparison of similar processes and a review of customer (End User and subsequent operation) claims
relating to similar components.
al Effects of Failure
s).
ring that the customer may be an internal customer as well
ulations.
The product effects in the PFMEA should be consistent with those in the corresponding DFMEA.
For the End User, the effects should be stated in terms of product or system performance. If the
customer is the next operation or subsequent operation(s)/location(s), the effects should be stated in
terms of process/operation performance.
In order to determine the Potential Effect(s), the following questions should be asked:
1. Does the Potential Failure Mode physically prevent downstream processing or cause potential harm
to equipment or operators? (The location, station or operation at which the effect occures should be
identified. If at a customer's facility, this should be stated).
2. What is the potential impact on the End User?
3. What would happen if an effect was detected prior to reaching the End User?
Severity
e ranking within the scope of the individual FMEA.
modified for individual process analysis.
rity 1 should not be analyzed further.
To the extent possible, identify and document every potential cause for each failure mode. The cause
should be detailed as concisely and completely as possible. Separating the causes will result in a focused
analysis for each and may yield different measurements, controls, and action plans. There may be one or
more causes that can result in the failure mode being analyzed.
In preparing the PFMEA, the team should assume that the incoming part(s)/material(s) are correct.
Exceptions can be made at the team's discretion where historical data indicate deficiencies in incoming
part quality.
Only specific errors or malfunctions (e.g., seal not installed or seal installed inverted) should be listed,
Ambiguous phrases (e.g., operator error or seal mis-installed, etc) should not be used.
Occurrence
ithin the design life.
esign/Process Controls
mpleted or committed to and that will assure the design
Detection
etection column. When more than one control is identified, it is recommended that the detection ranking of each
tection column.
en assess the capabilities of the current design controls to detect this failure mode.
portant to assess the capability of the design controls to detect low frequency failure modes or reduce the risk of
gs. When the severity is 9 or 10, it is imperative that the team must ensure that the risk is addressed through existing
ce or detaction rankings. It is the team's responsibility to look at the information identified, decide upon an
tion and customers.
RPNs shall be consider for review. In case of same RPNs, highest severity level shall be taken into consideration.
mmended Actions
ample of this is the use of proven design standard or best practice rather than product verification/validation after
in design validation/verification actions should result in a reduction of the detection ranking only. In some cases, a
e ditection ranking). Additionally, the following should be considered:
tion, indicate this by entering "None" in this column. It may be useful to also include a rational if "None" is entered,
ction Results
d Detection rankings and RPN.
i.e., cause addressed), thus an appropriate analysis or test should be completed as verification. If further action is
FMEA
RISK PRIORITY NUMBER = S x O x D
Within each FMEA shall be continuously worked on the reduction of the highest RPN numbers.
Special attention shall be given to the RPNs where the Severity Score is ≥ 8,
SEVERITY (S)
Effect Ranking
DESIGN FMEA PROCESS FMEA (Manufacturing/Assembly
PROCESS FMEA (Customer Effect) Effect)
Hazarduous without Potential failure mode effects safe Failure may endanger operator (machine or 10
warning
Hazarduous with warning operation and/ormode
Potential failure non-compliance
effects safe assembly)
Failure maywithout
endangerwarning.
operator (machine or 9
Very High operation and/or non-compliance
Item inoperable (loss of primary assembly) with warning.
Major disruption to production line. 8
High function). 100%line.
Item operable but at reduced level of Minor disruption to production of product may
7
Moderate performance.
Item operable but comfort/ Product may have to
Minor disruption to production line. 6
Low convenience
Item operableitem(s)
but inoperable. No sorting,
Minor disruption to production line. les than 5
Very Low comfort/convenience
Fit & Finish item doesoperable at
not conform. 100 % may have to be
Minor disruption to production line. 4
Minor Fit & Finish item does not conform. Product
Minor disruption to production to be sorted,
line. 3
Very Minor Fit & Finish item does not conform. Less than
Minor disruption to production line.100% may 2
None Less than or
Slight inconvenience to operation 100% may
operator,
No discernible effect 1
or no effect.
OCCURRENCE (O)
Probability of Failure Ranking
DESIGN/PROCESS PROCESS
Possible failure rates CPK When
Very High: Persistent >100 per thousand vehicles/items < 0,55 Always 10
Failures
50 per thousand items >= 0,55 9
High: Frequent Failures 20 per thousand items >= 0,78 Daily 8
10 per thousand items >= 0,86 7
Moderate: Occasional 5 per thousand items >= 0,94 Weekly 6
failures
2 per thousand items >= 1,00 5
1 per thousand items >= 1,10 4
Low: Relatively few 0,5 per thousand items >= 1,20 Monthly 3
failures
Very Low: Isolated failures 0,1 per thousand items >= 1,30 Yearly 2
Remote: Failure is unlikely < 0,010 per thousand items >= 1,67 Never 1
DETECTION (D)
1 5 Average 5.20
2 5.2
3 5 Std Dev 0.17
4 5
5 5.5 Nominal dim
6 5.2 Lower level tol
7 5.3 Upper level tol
8 5.3
9 5.2 Cp 0.00
10 5.1
11 5.4 Cpo 10.36
12 Cpb -10.36
13
14 Cpk -10.36
15
16
17 PPM Over ULT 1000000
18
19 PPM Over LLT 0
20
21 PPM total 1000000
22
23
24
25 Only blue cells to fill out
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27
28
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50
PARTS
Appraiser/Trial #
AVG'S
Range
AVG'S
Range
AVG'S
Range
Part average
RANGE VARIATION:
Ra No. Trials D4 R x (D4)
Rb 2 3.267 #N/A
Rc 3 2.575 Note: LCLR is zero with < 7 trials
Max X 0.000
Min X 0.000 Note:
X Diff. 0.0000
DATE
STUDY PERFORMED BY
Components of variations
1200%
1000%
800%
NaN NaN
600%
400%
200%
0%
800%
NaN NaN
600%
400%
200%
0%
Range chart
12.000
10.000
Range
8.000
6.000
4.000
2.000
0.000
1 2 3 Column
4 R 5 6 7 8 Column
9 S 10 11 12 13Column
14 T 15 16 17 18Column
19V 20 21 22 23Column
24U 25 26 27 28 2
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
ODUCIBILITY STUDY ✘ Obrazec v ANG jeziku
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3 0.5231
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