Failure Mode AND Effect Analysis: TPM Secretariat - Orai Factory
Failure Mode AND Effect Analysis: TPM Secretariat - Orai Factory
Failure Mode AND Effect Analysis: TPM Secretariat - Orai Factory
AND
EFFECT ANALYSIS
CHANGE IN PARADIGM
SOLUTION TO PROBLEMS PREVENTION OF PROBLEMS
MONITORING OF WASTE ELIMINATION OF WASTE
QUANTIFICATION OF RELIA- REDUCTION OF UNRELIABILITY
BILITY
BENEFITS:-
Improve the quality,reliability and safety of products/service
Helps select the optimal systems design
Helps identify diagnostic procedures
Provides an early prevention system
Identifies the causes and effects of each failure mode
Provides for problem follow up and corrective actions
Help in reduction in risk of failure
Establishes a priority for design improvement actions
Helps error identification and prevention
Helps that all conceivable failures and their effects on potential success have been
considered
Lists potential failures and identifies relative magnitude of their effect
Provides historical documentation for future reference to aid in the analysis of field
failures and consideration of design, process and service changes.
TPM SECRETARIAT - ORAI FACTORY
FMEA - WHEN TO USE IT
STEP-2 Prepare Functional Block Diagram and/or Process flow chart. This is required so
that everybody understands the design/process
STEP-4 Collect Data - Collect Data on failures,categorize the failures, and the failure modes.
STEP-5 Analyze the data. Information from this step will be used to fill in the columns of the
FMEA Form in relationships to the effect of the failure, existing controls, estimation
of severity, occurrence, and detection
STEP-6 Based on the analysis, results are derived. The information from this step will be
used to quantify the severity,occurrence, detection and RPN.
STEP-7 After the results have been recorded, it is time to confirm, evaluate, and measure the
success or failure. We need to see whether the situation is better, worse or same as
before.
STEP-8 Review for continuous improvement. The long term goal is to completely eliminate
every single failure
STEP-2 Highlight the high-risk areas. Critically examine the Severity and RPN columns in
the FMEA.
STEP-3 Identify the critical,significant and major characteristics.Great care should be taken
when reviewing the RPN because these numbers will indicate whether or not action
should be taken.
STEP-4 Ensure that a control plan exists and is being followed.
STEP-5 After control plan is in place and statistical controls have been established, a
potential capability or long capability must be performed.
STEP-6 Work on processes which have a CpK less than or equal to 1.33
MACHINES HUNAM
RESOURCES
TOOLS TASKS
WORK STATIONS WORK STATIONS
PROD.LINES SERVICE LINES
PROCESSES PERFORMANCES
GAUGES TRAINING
TRAINING
FUNCTION
The task that the system,design,process,component,subsystem,service must
perform.
Example - Lubricate,retain,support.- it should be an ACTIVE VERB
FAILURE
The inability of the system,design,process, service,or subsystems to perform
based on design intent.This inability can be defined as both known and
potential.
FAILURE MODE
The physical description of the manner in which a failure occurs.
Example - open circuit,leak,corroded,broken,dirty,eccentric,bent,misalign
SYSTEM POTENTIAL POTENTIAL S POTENTIAL O DETECTION D R RECOMMENDED ACTION ACTION ACTION RESULTS
FUNCTION FAILURE EFFECTS OF E CAUSES OF C METHOD E P ACTION PLAN AND TAKEN S O D R
MODE FAILURE V FAILURE C T N TARGET E C E P
DATES V C T N
11 12 13 14 15 16 17 18 19 20 21 22 23 24
For each system function one must list down the corresponding failure
of the function
SYSTEM POTENTIAL POTENTIAL S POTENTIAL O DETECTION D R RECOMMENDED ACTION ACTION ACTION RESULTS
FUNCTION FAILURE EFFECTS OF E CAUSES OF C METHOD E P ACTION PLAN AND TAKEN S O D R
MODE FAILURE V FAILURE C T N TARGET E C E P
DATES V C T N
11 12 13 14 15 16 17 18 19 20 21 22 23 24
NO 1 NO EFFECT
DESIGN POTENTIAL POTENTIAL S POTENTIAL O DETECTION D R RECOMMENDED ACTION ACTION ACTION RESULTS
FUNCTION FAILURE EFFECTS OF E CAUSES OF C METHOD E P ACTION PLAN AND TAKEN S O D R
MODE FAILURE V FAILURE C T N TARGET E C E P
DATES V C T N
11 12 13 14 15 16 17 18 19 20 21 22 23 24
NONE 1 NO EFFECT
PROCESS POTENTIAL POTENTIAL S POTENTIAL O DETECTION D R RECOMMENDED ACTION ACTION ACTION RESULTS
FUNCTION FAILURE EFFECTS OF E CAUSES OF C METHOD E P ACTION PLAN AND TAKEN S O D R
MODE FAILURE V FAILURE C T N TARGET E C E P
DATES V C T N
11 12 13 14 15 16 17 18 19 20 21 22 23 24
PROCESS SERVICE
RANK CRITERIA RANK CRITERIA
99%
• Minor Risk 1-2
• Moderate Risk 3 - 8
• Major Risk 9 - 125 Common Scale
• Minor Risk 1-17
• Moderate Risk 18 -63
• Major Risk 64 -125
2 10 3 60
DOME MISALIGNED FIELD 1 STATIC 10 10 100
ASSEMBLY DOME FAILURE FLYOUT NONE 100% INSPECT
LUMP IN 2 10 2 40
WRONG 2 WRONG 10 INCOMING 7 140 INCOMING
SHIM OVERLAY MATERIAL INSPECTION SPC
NO OPERATOR
SHIM COSMETIC 2 7 INSPECTION 8 112 KEEP GOOD 2 7 3 42
ERROR PARTS FOR
COMPARISON
REDESIGN
MISREGIS- DOME 2 OPERATOR 10 INSPECTION 5 100 PART FOR 1 1 1 1
TERED SLIP ERROR FOOL PROOF
RETAINER DESIGN
RETUR
RETUR
NN
TPM SECRETARIAT - ORAI FACTORY