How to handle Incoming (Receiving) Inspection as a PFMEA item?

A

anil123

#11
Failure mode is depends on the inspection characteristics as we have to analyse the risk if it happens what will be the impact of it during the manufacturing. Also FMEA will analyse the detection of the failure of the part characteristics during inward inspection.
It is basically the risk assessment tool.
Failure mode may be as under:
1. Dimensional variation
 
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Jim Wynne

Staff member
Admin
#12
Failure mode is depends on the inspection characteristics as we have to analyse the risk if it happens what will be the impact of it during the manufacturing. Also FMEA will analyse the detection of the failure of the part characteristics during inward inspection.
It is basically the risk assessment tool.
Failure mode may be as under:
1. Dimensional variation
No, if the cause of the failure is ascribed to the supplier, it shouldn't be addressed in the PFMEA. PFMEA failure modes should be limited to those caused by (or in) the present process. Remember--what you're trying to do in the PFMEA process is anticipate how your process(es) might fail.
 
D

DrM2u

#13
I agree with Jim. Failure mode is not limited only to product related failures, but it encompases process related failures that have an impact on the organization's ability to meet customer's requirements as well. Way too many organizations, teams and individuals limit their analysis to product failure modes and totally ignore the process. The main idea is to controll the PROCESS to ensure that PRODUCT characteristics are consistently and capably met. Most product failures are analyzed in Design FMEA. FMEA principles can also be applied to equipment maintenance, safety, etc.

To get back to the focus of this discussion, analyze and control the receiving process steps. The 'product inspection' is the actual verification that you received what you ordered and is just a part of the whole receiving process. There are many other failure modes in the process that should be considered in order to ensure an effective and efficient receiving process. Keep in mind that the purpose of having a receiving process is not only to verify incoming product but to also handle, process, evaluate, disposition, contain and/or store said product.
 
T

treesei

#14
I agree the PFMEA should focus on the process and the DFMEA should focus on the product. But please help me with this: A wrong material from the supplier, if not caught, can lead to product failure or non-conformance. Eg, a RoHS solder vs a non-RoHS solder. Will this potential supplier mistake be considered in DFMEA? I personally do not think so because supplier mistake is not a design flaw which I think should be the subject of DFMEA. Supplier problems will be better handled in supplier management or overall risk management. However, I have heard different voices and have seen such DFMEA putting "wrong part shipped from supplier" as a failure mode and the detection is incoming inspection.
 

Jim Wynne

Staff member
Admin
#15
I agree the PFMEA should focus on the process and the DFMEA should focus on the product. But please help me with this: A wrong material from the supplier, if not caught, can lead to product failure or non-conformance. Eg, a RoHS solder vs a non-RoHS solder. Will this potential supplier mistake be considered in DFMEA? I personally do not think so because supplier mistake is not a design flaw which I think should be the subject of DFMEA. Supplier problems will be better handled in supplier management or overall risk management. However, I have heard different voices and have seen such DFMEA putting "wrong part shipped from supplier" as a failure mode and the detection is incoming inspection.
I can see some such things being addressed in a DFMEA. For example, there might be a purchased component that's similar in appearance to a different component that won't work in the present assembly. A DFMEA might address this by having the supplier use special markings or packaging, or by making sure that the component is properly verified before use. There are no strict rules in situations like this.
 
R

Richard Pike

#16
A basic principle of FMEA is that one must "assume" that the previous process is correct. Once this is accepted one is simply looking at the "mistakes" that can happen at that particular point of the process. In this instance receiving Inspection. That having been said there is often merit in including suppliers in the FMEA team for receiving. ps I do take exception to the "customer" who tries to dictate what they "want". The customer should stick to seeing if the FMEA is effective and not impose their "wants" unless of course by including those wants in their contract>
 

Jim Wynne

Staff member
Admin
#17
A basic principle of FMEA is that one must "assume" that the previous process is correct. Once this is accepted one is simply looking at the "mistakes" that can happen at that particular point of the process. In this instance receiving Inspection.
Receiving inspection (and inspection in general) is an exception; you can't assume that the incoming material is what it should be, otherwise there would be no need for receiving inspection.
 
D

DrM2u

#18
I agree the PFMEA should focus on the process and the DFMEA should focus on the product. But please help me with this: A wrong material from the supplier, if not caught, can lead to product failure or non-conformance. Eg, a RoHS solder vs a non-RoHS solder. Will this potential supplier mistake be considered in DFMEA? I personally do not think so because supplier mistake is not a design flaw which I think should be the subject of DFMEA. Supplier problems will be better handled in supplier management or overall risk management. However, I have heard different voices and have seen such DFMEA putting "wrong part shipped from supplier" as a failure mode and the detection is incoming inspection.
The explanation for what you have seen regarding 'wrong product' in DFMEA is that the DFMEA is actually a major input to the PFMEA. The 'design' group established that on way for the product to fail is by using the wrong material. Assuming that you do not make that material, then the failure mode is the supplier shipping the wrong material and that not being detected. This becomes an input to the PFMEA for the receiving process, which should therefore include in it the detection methods for the correct/wrong material, among other things. There might not be much that you can do for prevention, other that the specifications you have in the purchase agreement.
 
R

Richard Pike

#19
Receiving inspection (and inspection in general) is an exception; you can't assume that the incoming material is what it should be, otherwise there would be no need for receiving inspection.
Point taken. However I would maintain that the "Purpose" of inspection is to prevent defects from being processed further. So it remains to be established what would the "Causes" would be of the inspection process allowing defects to be processed further. I think we are in agreement and apologize if my choice of words confused the issue.
 

Harigovindan

Starting to get Involved
#20
Re: How to handle incoming inspection as a PFMEA item?

You are right, incoming inspection is not required to include in the FMEA, if you want to include the transportation and loading and unloading at receiving stage for transit damages as failure mode and to analyse the current process controls of transportation and loading and unloading is sufficient or not then only you need to add these processes, i.e, loading and unloading and transportation at receiving stage.
 
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