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Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
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Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?
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Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?


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  Post Number #1  
Old 18th April 2017, 08:59 AM
QualityKRSC

 
 
Total Posts: 4
Question Master FMEA for "like processes" - Does an FMEA have to match the CP and PM directly?

Has anyone created a Master FMEA that covers all possible Item / Functions for "like processes" and then just pulls the relevant Item/Functions into the Control Plan and Process Map for the Individual Processes? Or does a FMEA have to match the CP and PM directly?

Thanks in advance.

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  Post Number #2  
Old 18th April 2017, 04:22 PM
Ron Rompen's Avatar
Ron Rompen

 
 
Total Posts: 528
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

Yes, I have created a 'master' PFMEA and Flow Chart in the past, which I used for any new product by cutting and pasting to match the defined process. The control plan would then be made to match the process as defined in the two preceding documents.

It does take some time (and work) to create a good master document, but in the end it is well worth it.
Thank You to Ron Rompen for your informative Post and/or Attachment!
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  Post Number #3  
Old 19th April 2017, 07:23 AM
QualityKRSC

 
 
Total Posts: 4
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

Thank you Ron, I will bring your response to my team and hope they also agree. I too believe it will drive Standard Work within the plant as a result of a master FMEA.
Jean
  Post Number #4  
Old 24th April 2017, 08:22 AM
Golfman25

 
 
Total Posts: 893
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

We do a master FEMA which allows us to create a one time FEMA for anything. What we were finding is that any changes, upgrades, improvements, etc could be applied accross the board and it was impossible to keep everything updated. Now the master is always current and updated as needed.
Thanks to Golfman25 for your informative Post and/or Attachment!
  Post Number #5  
Old 24th April 2017, 11:03 AM
QualityKRSC

 
 
Total Posts: 4
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

Thank you Golfman25, a 2nd vote of affirmation is great to hear. Our team is on board and everyone is looking forward to exactly the results you mentioned - everything updated and easier maintenance going forward. We are putting in the work now on Master FMEAs.
Jean
  Post Number #6  
Old 16th June 2017, 11:53 AM
Nadaabo's Avatar
Nadaabo

 
 
Total Posts: 10
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

Thanks for asking this. I would love to know how the implementation went I have been to get my team to consider this, but everyone is too scared it's a huge undertaking.
  Post Number #7  
Old 19th June 2017, 01:50 PM
QualityKRSC

 
 
Total Posts: 4
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

Your team is correct, it is a huge undertaking, but today I can speak to the benefits of the work involved. We committed a cross-functional team to 3 meetings a week to stress the importance that once we started this we could not stop until complete.
we have been working for months, but the end is near.

First we listed all individual FMEAs and then grouped them into the Master Families of products. We went from 33 Ind. FMEAs to 16 Master Families FMEAs. ( some groups must stand alone.

The first FMEA was of course was the most difficult to get through. But once we did, we all had a good feeling for what we were about to accomplish. We brought in SMEs from each processes so the scoring was fair and accurate.( Sev., Occ., & Det.)

Our benefits to date: Std. Work improved plant wide; CARS will cover "Like products" easier; Process Audits will be simplified; Future Product Planning will be simplified; Document Updates, time saving and greatly improved; and Internal Audits, redundancy reduced.

Go for it.
  Post Number #8  
Old 30th June 2017, 11:40 AM
Golfman25

 
 
Total Posts: 893
Re: Master FMEA for "like processes" - Does an FMEA have to match the CP and PM direc

Quote:
In Reply to Parent Post by QualityKRSC View Post

Your team is correct, it is a huge undertaking, but today I can speak to the benefits of the work involved. We committed a cross-functional team to 3 meetings a week to stress the importance that once we started this we could not stop until complete.
we have been working for months, but the end is near.

First we listed all individual FMEAs and then grouped them into the Master Families of products. We went from 33 Ind. FMEAs to 16 Master Families FMEAs. ( some groups must stand alone.

The first FMEA was of course was the most difficult to get through. But once we did, we all had a good feeling for what we were about to accomplish. We brought in SMEs from each processes so the scoring was fair and accurate.( Sev., Occ., & Det.)

Our benefits to date: Std. Work improved plant wide; CARS will cover "Like products" easier; Process Audits will be simplified; Future Product Planning will be simplified; Document Updates, time saving and greatly improved; and Internal Audits, redundancy reduced.

Go for it.
That's a pretty good list. And a lot will depend on your processes. Ours are pretty simple -- a punched hole is generally a punched hole regardless of the application.

The only thing I would caution is be careful of what industry you're in. Anything other than automotive (aerospace might have different requirements), IMO modify the concepts to fit you. But in Automotive, people generally freak out if you do something that makes sense when it isn't by the book. So you need to be ready to "explain."
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