Quality Engineer
Starting to get Involved
In our PFMEA template we have Process step, funciton, failure mode and failure mode cause column. I am confused on how to clearly and correctly input every field.
Example 1:
Process step: Adjust the water flow meter to 0.3-0.4 gal/min and monitor the water flow, argon pressure and laser performance (using camera) throughout the cutting process
Function: To set and maintain the appropriate water flow rate and argon pressure while continuously monitoring laser performance to ensure consistent and high-quality cutting results
Failure mode: Water flow out of spec - thermal damage/shock, burn marks (compromised structural integrity)
Failure mode cause:
1. Incorrect adjustment.
2. Defective flow meter.
3. Incorrect set-up of equipment.
Example 2:
Process step: Once the laser is at the welding location, select the weld start and stop point using A and B commands on laser unit
Function: To achieve correct weld alignment
Failure mode: Incorrect weld start and/or stop points - misaligned weld (weld strength compromised)
Failure mode cause: Operator didn't follow the process instructions
According to some team members, water flow out of spec and incorrect weld start and/or stop points is a cause of failure.
What is the opinion of you people here that how the failure mode and casue should be written here?
Also, process excursion and failure mode cause are same thing?
The template guidance on failure mode and failure mode cause is given below:
"A potential Failure Mode represents any manner in which the process step identified previously could fail to meet the process requirements and/or design intent as described in the “Process Step Function / Requirement” column."
"Failure mode cause categories include, but are not limited to:
Machine
Material
Man
Measurement
Method
Environment"
Example 1:
Process step: Adjust the water flow meter to 0.3-0.4 gal/min and monitor the water flow, argon pressure and laser performance (using camera) throughout the cutting process
Function: To set and maintain the appropriate water flow rate and argon pressure while continuously monitoring laser performance to ensure consistent and high-quality cutting results
Failure mode: Water flow out of spec - thermal damage/shock, burn marks (compromised structural integrity)
Failure mode cause:
1. Incorrect adjustment.
2. Defective flow meter.
3. Incorrect set-up of equipment.
Example 2:
Process step: Once the laser is at the welding location, select the weld start and stop point using A and B commands on laser unit
Function: To achieve correct weld alignment
Failure mode: Incorrect weld start and/or stop points - misaligned weld (weld strength compromised)
Failure mode cause: Operator didn't follow the process instructions
According to some team members, water flow out of spec and incorrect weld start and/or stop points is a cause of failure.
What is the opinion of you people here that how the failure mode and casue should be written here?
Also, process excursion and failure mode cause are same thing?
The template guidance on failure mode and failure mode cause is given below:
"A potential Failure Mode represents any manner in which the process step identified previously could fail to meet the process requirements and/or design intent as described in the “Process Step Function / Requirement” column."
"Failure mode cause categories include, but are not limited to:
Machine
Material
Man
Measurement
Method
Environment"
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