Lean Manufacturing using the FMEA?

[jewelsm]

I want to develop a FMEA that will identify potential failure modes for Lean Manufacturing.
Does anyone have any experiance with this process?
My angle is that Lean Manufacturing saves $$$. Failure would be loss of $$$.
I want to use the FMEA as a tool to Prevent and Detect $$ loss due to Lean manufacturing failures....
What do you think?
Thanks,

[Jim Wynne]

Originally Posted by jewelsm

I want to develop a FMEA that will identify potential failure modes for Lean Manufacturing.
Does anyone have any experiance with this process?
My angle is that Lean Manufacturing saves $$$. Failure would be loss of $$$.
I want to use the FMEA as a tool to Prevent and Detect $$ loss due to Lean manufacturing failures....
What do you think?
Thanks,

Welcome to the Cove

I think you're wise to try and identify pitfalls before you actually fall into the pits. I'm not clear on exactly what you're trying to do, though. Are you looking to do an AIAG-type FMEA process? Are you trying to identify potential failure modes of the process of establishing a Lean system, or for the Lean system itself? Both? Give us a little bit clearer picture of your idea and I'm sure we can help you along.

[jewelsm]

I have been in the Automotive Manufacturing enviroment all of my career, so the AIAG FMEA format is familar. Are there other FMEA formats that I should be considering?

I have recently left the Automotive Quality forum and now preside in the Engineered Products Lines- no automotive, mostly oil fields, chem plants, some aircraft and areo space......

So far I have successfuly implemented an In-process inspection that is working better than anticipated. (i used the FMEA and lesons learned models to prevent, protect and predict).

Now I want to look into improvements in the manufacturing eviroment. Lean manufacturing opportunities. The problem is, this company has never documented or track any Manufacturing improvements. I want to change this. This is a very successful - establilshed company and I want to capture the things that have been done and start on the path of utilizing the FMEA tools to help prevent, protect and predict lean manufacturing opportunities.

With all Lean activities the bottom line will be cost. I want to identify using FMEA tools any Potential cost due to lean failures.

I know this sound broad, but after reading your response, the AIAG FMEA may not be the best tool- I know this kind of process has been done- I just did not want to try and re-create the wheel.

Thanks for the advice!

[Jim Wynne]

Originally Posted by jewelsm

I have been in the Automotive Manufacturing enviroment all of my career, so the AIAG FMEA format is familar. Are there other FMEA formats that I should be considering?

I know that others might be tired of hearing me say this, but FMEA is a process, and the AIAG/SAE format is just a record of the process--it's not the FMEA itself. Just this morning I posted a list of what a typical FMEA process looks like; how you record the progress and results is a matter of personal convenience and what makes good sense for you (assuming the absence of customer requirements).

Originally Posted by jewelsm

I have recently left the Automotive Quality forum and now preside in the Engineered Products Lines- no automotive, mostly oil fields, chem plants, some aircraft and areo space......

Great--your experience will be valuable here.

Originally Posted by jewelsm

So far I have successfuly implemented an In-process inspection that is working better than anticipated. (i used the FMEA and lesons learned models to prevent, protect and predict).

Well, when something works better than you expected it to, you must be doing something right.

Originally Posted by jewelsm

I want to capture the things that have been done and start on the path of utilizing the FMEA tools to help prevent, protect and predict lean manufacturing opportunities.

Excellent. Too many people forget about the "predict" part, imo.

Originally Posted by jewelsm

With all Lean activities the bottom line will be cost. I want to identify using FMEA tools any Potential cost due to lean failures.

Then I guess you need to start with a clear picture of what Lean success is supposed to look like, and try to identify everything that has the potential to impede progress in that direction.

Originally Posted by jewelsm

I know this sound broad, but after reading your response, the AIAG FMEA may not be the best tool- I know this kind of process has been done- I just did not want to try and re-create the wheel.

Keep in mind my advice about FMEA being a process and not a document. I'm not a Lean expert by any means, but I do know that one of the initial phases of Lean implementation is constructing a Value Stream Map. A VSM is specialized form of process flow diagram. That being the case, and knowing that the basis of a PFMEA process is also a PFD, perhaps if you start with a VSM you can examine each process category and apply AIAG-like FMEA techniques. Even if you don't use the AIAG format, you can still use the VSM as your basis for identifying potential failure modes.

[Bev D]

Jim's last piece of advice is critical. FMEA is not intended to be a primary player in Lean implementations. mapping, 5S, etc. are better initial tools.
FMEA is a good tool - dont' get me wrong. but using it as a starting point for Lean is like using a bus to drive a screw.

FMEA has immediate applicability when trying to determine mistake proofing opportunities - but again it is probably overkill: using a bus to kill a flying bug.

What is your experience level with Lean and it's methodology and philosophy?