How to fill a Process FMEA - Three columns - Severity, occurrence and Detection

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D

Didgeridoo_

#12
helo Sebastian, thanks for your help. Then, how can I get the AIAG FMEA manual? Or, at least, the examples you have mentioned? It could be really helpful.

Also, I have another doubt regarding Poka-Yoke solutions. Imagine you have to assembly 2 different elements in an assembly machine. You can put one of them on the wrong orientation (180º). But, you cannot assembly it because there is a poka-yoke from the part desing, so you will not be able to fianlly assemble them together.
Then...how to specify it on the PFMEA? I have several options, let's see:
a)
-Issue: "To assembly the parts in a wrong orientation"
-Severity: 4 (Appearence in customer)
-Occurrence: 0 (because it cannot happen from the design)
-Detection: 0 (100% of the times because it cannot happen)
b)
-Issue: "Try to assembly the parts in the opposite orientation"
-Severity: 2 (Minor disruption during process, because the operator will realise this cannot be assembly and will change it)
-Ocurrence: 5 (because the issue is to try to assemble)
-Detection: 1 (100% of the times)

Please let me know what do your think about!

Thanks in advance!
Anybody...?? Please!!
 

qcman

Registered Visitor
#13
Right or wrong if I have truly eliminated the occurrence of a particular defect I would remove it from the FMEA. If you want to use it as a lessons learned you could hide that particular row/column in the document once eliminated.
 

Sebastian

Trusted Information Resource
#14
Dear Didgeridoo_ to get examples of PFMEA, you have to buy AIAG manual.
Failure occurrence is independent from failure detection.
We fill out FMEA form from left side to right. Occurrence is first, followed by Detection. Evaluating occurrence rate you do not take into account what detection means are available, just how often this mistake would happen.
Pokayoke does not lower occurrence, as operator still occasionally mistakenly aligns components each other during assembling, but thanks to pokayoke it is impossible to start assembling operation when components are not properly aligned => Occurrence 5, Detection 1. To confirm it - see logs from PLC connected to pokayoke, counting every case when pokayoke has to be activated due to components misalignment.

Dear qcman removing anything from PFMEA is one of biggest mistakes. First reason is deleting organizational knowledge and second reason is some day someone will ask, why none had analysed this failure yet. So we save his time.
 
D

Didgeridoo_

#15
Dear Didgeridoo_ to get examples of PFMEA, you have to buy AIAG manual.
Failure occurrence is independent from failure detection.
We fill out FMEA form from left side to right. Occurrence is first, followed by Detection. Evaluating occurrence rate you do not take into account what detection means are available, just how often this mistake would happen.
Pokayoke does not lower occurrence, as operator still occasionally mistakenly aligns components each other during assembling, but thanks to pokayoke it is impossible to start assembling operation when components are not properly aligned => Occurrence 5, Detection 1. To confirm it - see logs from PLC connected to pokayoke, counting every case when pokayoke has to be activated due to components misalignment.

Dear qcman removing anything from PFMEA is one of biggest mistakes. First reason is deleting organizational knowledge and second reason is some day someone will ask, why none had analysed this failure yet. So we save his time.
Hello Sebastian, thanks for your reply.

I fully understand your point, thanks. but I still have a doubt in this regard: Severity.

If you have a poka-yoke, severity ranking to DELIVER parts to the customer is high (i.e. 7). However the detection i 100% (detection ranking=1).

On the other hand, to TRY to assembly the parts, severity ranking is low (minor disruption in our line). Detection is lower because there is nothing that avoid you to TRY to assembly. Once you try, you fill realize that the orientation is the opposite.

How should be this situation sopecified?

Thanks!!
 

Sebastian

Trusted Information Resource
#16
Again - left to right approach. Occurrence is independent from detection, severity is independent from occurrence. When failure occurs and wont be found how severe it would be to your customer and/or final user?
 
D

Didgeridoo_

#17
Again - left to right approach. Occurrence is independent from detection, severity is independent from occurrence. When failure occurs and wont be found how severe it would be to your customer and/or final user?
Yes I know about the left to right approach, but what is different is the "Problem" or "issue". Doesn't matter, I will figure out how to do it.

Thanks.
 
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