Better Methods for FMEA Development From Requirements to

Better Methods for FMEA Development From Requirements to

Better Methods for FMEA Development From Requirements to Standardized Work and Everything in Between. Opening Content Produced by Joseph M. Adams Perceptions - Perspectives - Points of View Top View Frontal 3D View Left Profile Opening Content Produced by Joseph M. Adams Front View Quality Tools Processes / Methods System FMEA

Design of Experiments, DOE Design Record Design Review Design FMEA Dimensional Results Parameter (P) diagram(s) Product Reliability Studies Characteristics Matrix V-Model Methods Math Models Design for Assembly, DFA Trial Runs Engineering Specifications Bill of Material Product / Process Benchmarking Functional Block (Boundary) Model Management Review Qualified Laboratory Documentation Schematics Process FMEA Interface Block (Boundary) diagram(s) Management Support Value Stream Mapping, VSM Production Part Approval Process, PPAP Preventive Action Reports, PAR's

Initial Process Studies, Cpk of Special Characteristics Checking Aids Design for Experiments, DOE Long Term Process Studies, Ppk of Special Characteristics Quality System Design Verification Plan and Report, DVP&R Segmentation SPC Processing Specifications Business Plan / Marketing Strategy Control Plan, CP Kano Model Assembly Build Variation Analysis 4-Phase Quality Function Deployment, QFD Corrective Action Reports, CAR's Run at Rate Failure Mode & Effects Analysis, FMEA Interrelationship matrices Floor Layout Lean Training System Team Building Process Flow Diagram(s), PFD Design for Manufacturing, DFM Product Quality Timing Plan / Program Management, PMP Authorized Engineering Change Documents Historical Warranty and Quality Information

Interface diagram(s) Measurement System Analysis Studies, MSA Gages / Testing Equipment Requirements Sample Production Parts Appearance Approval Report, AAR PDCA Customer Engineering Approval Material / Performance Test Results Records Kaizen Part Submission Warrant, PSW Material Specifications Authorized Engineering Change Documents Work Instructions Mistake Proofing (Poke Yoke, Jidoka) Team Feasibility Commitment Technology Planning Design for Recycling, DFR Customer-Specific Requirements Intraface diagram(s) Assembly FMEA Lessons Learn / Best Practices Retention 5 Whys / 8D's Engineering Drawings Master Samples Cause-and-Effect / Fishbone (Ishikawa) Diagrams Design for Dis-Assembly, DFdA Toyota Production System, TPS Purchasing Specifications Opening Content Produced by Joseph M. Adams But, How Do These Tools Link and Interact with Each Other?

What are the key pieces/tools/forms? Where do they fit? How Do We Put These Puzzle Pieces Together? Opening Content Produced by Joseph M. Adams When Management and Leaders identify their performance puzzle with processes that complete their execution, they achieve predictable results for their customers. Management, Leaders Lean Tools and Processes Six Sigma Tools and Processes Which are Lean! Which have Six Sigma Capability! And Build Collaborative, Team Environments! Which minimize the

Risk of Customer Dis-satisfaction! Predictable Results Opening Content Produced by Joseph M. Adams Various Types of FMEAs Concept D&P FMEAs Design FMEA Process FMEA Machinery MFMEA Process Family PFMEA Product Family DFMEA Software DFMEA Medical Device D&P FMEAs Medical D&P FMEAs Service D&P FMEAs Environmental D&P FMEAs System D&P FMEAs Sub-System D&P FMEAs Component D&P FMEAs Opening Content Produced by Joseph M. Adams

NASA FMEA FMEA Resources An offshoot of Military Procedure MIL-P-1629, titled Procedures for Performing a Failure Mode, Effects and Criticality Analysis, dated November 9, 1949. Reference Manuals are written by Committee. Slightly different terms for same concepts are throughout the Manuals. Service PPAP Opening Secondary Manual Content Produced by Joseph M. Adams Primary Manual AIAG APQP pg. xx

AIAG PPAP pg. xx SAE pg. xx pg. xx AIAG FMEA pg. xx FMEA Resources Information on Presentation Slides will provide bookmarks to resource material. For the AIAG FMEA Manual look for the tab: AIAG FMEA pg. xx For the AIAG APQP and Control Plan Manual look for the tab: AIAG APQP pg. xx For the AIAG PPAP Manual Look for the tab: AIAG PPAP pg. xx For the Ford FMEA Handbook look for the tab: pg. xx For the SAE J1739 Technical Standard look for the tab:

SAE pg. xx Opening Content Produced by Joseph M. Adams Ineffective APQP 90% of an organizations execution problems are the result of an inadequate APQP system or its incomplete execution. It is how the RED beads get into Demings RED Bead Experiment / Demonstration Opening Content Produced by Joseph M. Adams Demings Red Bead Experiment Desire, effort,

training, and tools take the Red Beads out of the mix. Production System Willing Workers Management unknowingly puts the Red Beads into the mix. Opening Content Produced by Joseph M. Adams Most of the Red Beads are due to Poor FMEA Scope (definition), its boundaries. Not understanding the interfaces of your product to other products. Poor working relationships between Product and Process Teams, Customer and Supplier Teams, and less

than necessary management oversight. Poor FMEA data construction by the responsible team. Poor analysis and P-diagram execution Lack of follow-up and timely reviews. This training will address these and other issues Opening Content Produced by Joseph M. Adams SAFETY AND LIABILITY Opening Content Produced by Joseph M. Adams RISK: Safety & Liability Opening Good:

Document safety issues; Determine Recommended Actions; Complete Actions; Document Results. Bad: Worse1: Document safety issues; Recommended Actions; Stop there. Worse2: Worse3: Document safety issues; Determine

Recommended Actions; Document results about why you are not going to complete the Actions (especially if reasons are financial). Dont write down safety issues. Determine Document safety issues; Stop there. Content Produced by Joseph M. Adams

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