Generic Molding FMEA - Can some one provide me with an example?

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Bill Ryan - 2007

#11
JSW05 said:
The page you posted addresses receiving verification. I advise our suppliers to stick with potential failures that are caused in the operation in question. In other words, insofar as the PFMEA is concerned, I'm not especially interested in sub-supplier errors because they are not controlled by the receiving verification process. I want to see what can potentially go wrong in my supplier's process. In this case, it's possible that "bad" material may be accepted, or "good" material may be rejected. Depending on materials procedures, it's also possible to misidentify incoming material. I want to see the controls in place for those possibilities.

The other thing I noticed is that the potential causes listed are essentially the same as the modes. For example, the potential failure mode of "Sow chemistry inaccurate" is essentially repeated as the cause--"Supplier sent out of spec material." The first rule of thumb in PFMEA construction is that failures don't cause themselves. The problem here also speaks to my first observation; it's not possible to identify the cause because it's a sub-tier error; what I want to know is how that material is kept from being accepted (the potential failure mode of your process).
I'm in full agreement with you. In our case (provided as a poor "excuse") the customer working with us as we started working with this software, decided that this was how he wanted it represented. As we have moved along in our PFMEA methodology, "Receiving" and "Inspection" steps are being dealt with as you described. Because we were in a "spreadsheet train of thought" at the outset, it's taken a while to get the "global" sense for PFMEAs and each document must be updated individually.

It took me a while to see what you meant by the Failure Mode "repeating itself" as the Cause. I guess I never looked at it that way. Nice observation - and Thanks. I've attached a couple of more pages showing the "two column" approach and how we have addressed "preventive" controls for process parameters in our casting operation.

I, also, would be interested in reading your article. Some of our suppliers have had issues following the AIAG format. I, typically, do not get very critical of whatever format they employ - as long as they can show they have performed some sort of process analysis and documented improvements to "protect" us from receiving noncoforming material. Of course, if my customer demands one of my suppliers' PFMEAs in the AIAG format, I will try to work with the supplier to get it done that way.
 

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Jim Wynne

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#12
Bill Ryan said:
Some of our suppliers have had issues following the AIAG format. I, typically, do not get very critical of whatever format they employ - as long as they can show they have performed some sort of process analysis and documented improvements to "protect" us from receiving noncoforming material. Of course, if my customer demands one of my suppliers' PFMEAs in the AIAG format, I will try to work with the supplier to get it done that way.
Thank you. I think I have a little insight only because I've been on both sides of the customer/supplier fence, and like you I tend to give suppliers a rather wide berth so long as they're conscientious and making sense. For the last several years I've been working in an OEM SQE and have had some time to both theorize on the subject of PFMEA and prove, more or less, that the methods I promote are more likely to result in defect prevention than the orthodox AIAG/SAE methods insofar as job shops are concerned. And now I have a little incentive to end the procrationation over writing about it. Thanks again.
 
B

Bill Ryan - 2007

#13
Jim Wynne said:
Thank you. I think I have a little insight only because I've been on both sides of the customer/supplier fence, and like you I tend to give suppliers a rather wide berth so long as they're conscientious and making sense. For the last several years I've been working in an OEM SQE and have had some time to both theorize on the subject of PFMEA and prove, more or less, that the methods I promote are more likely to result in defect prevention than the orthodox AIAG/SAE methods insofar as job shops are concerned. And now I have a little incentive to end the procrationation over writing about it. Thanks again.
I know this is old, but....
Just wondering if you're still plucking along with your writings???
 
D

Dave.C

#14
Ragnar said:
Hello All! Can some one provide me with a sample of a molding FMEA. Our company molds (Injection) fascia for the big three. I'm hopeing some one can provide me with a list of potential failures within the molding process. Our molding techs insist the potential failures are very few, and the things I suggest with my limited (But not that limited) knowledge of the molding process can NEVER possibly happen, and yet they do and we have a parking lot full of scrap to proove it. Any help would be greatly appreciated.
Thank-you: :thanx:
Kindly:
Ragnar.
Attachment is an injection moulding DFMEA from when I used to work in the plastics industry. It's a bit old now and the format may not be to the latest standards but you could glean some useful info from it.
 

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B

brutas

#15
Incoming materials...

Jim Wynne said:
The page you posted addresses receiving verification. I advise our suppliers to stick with potential failures that are caused in the operation in question. In other words, insofar as the PFMEA is concerned, I'm not especially interested in sub-supplier errors because they are not controlled by the receiving verification process. I want to see what can potentially go wrong in my supplier's process. In this case, it's possible that "bad" material may be accepted, or "good" material may be rejected. Depending on materials procedures, it's also possible to misidentify incoming material. I want to see the controls in place for those possibilities.
This is a question I planned to post long ago.
AIAG manual (page 39, 10. Potential Failure Mode) says: "However, in preparing FMEA, assume that the incoming part(s)/material(s) are correct."

I have seen many PFMEAs which consider reception of non-conforming materials and as a Failure modes are described week points in the suppliers' manufacturing process. I think this is wrong approach and I agree with Jim - we have to focus on our own process - that "bad" material may be accepted, or "good" material may be rejected (for example). Supplier process is subject to the supplier PFMEA...
 
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