Looking for resistance welding FMEA examples

L

lovingquality

#1
Hello everyone,

We are starting to take the FEMA more seriously... ( about time). My team and I have be tasked with creating a Golden FMEA for our organization. We currently Stamp, Weld (resistance and Spot) and lite assemble. I was looking for help in finding a resistance weld FMEA that could help us start our brains going. I know every process is different but, I am looking for a genralized FMEA. We use H frame tip to tip welders, with weld controllers. We weld all different size weld studs and nuts, on sheet metal stamping (thickness 2.mm-5.mm). Most of our welders are single hit.


P.S. I just love this site!!!!!!!
 
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Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#2
Welcome to The Cove! :bigwave:

A golden FMEA? Hmmmm. Do you have a copy of the FMEA Manual by the automotive group?

The problem with examples is that it can be so tempting to use the example's information instead of making the FMEA reflect your processes. Templates can be made with documents or spreadsheets, but the information should be entered into some type of blank form.

The Manual is made for automotive, so interpreting it can be tricky. I found a sample FMEA for machinery here. I am not affiliated with Reliasoft.

I wanted to include that example because I thought it did a good job of defining the criteria for assigning severity, occurence and detection ratings. I have seen people struggle to apply automotive manual definitions to their own industries.

This forum also has training for FMEA. Since FMEAs are supposed to be a multifunctional effort, there will need to be some awareness development to get this thing done right.

I hope this helps!
 
Q

Quality-Geek

#3
WOW, your facility sounds just like mine, except for the location... I'm in Nebraska. Are you in the automotive industry?

While I do have FMEA's that would probably suit your needs, they are so bad that I hesitate to let anyone see them. I inherited an old format that doesn't work very well and doesn't define the criteria well enough to be useful. (We finally got new forms from our parent company, and they are much better. Now if I only had the time to review every FMEA...)

Get onto AIAG's website. They have books and training classes for a ton of stuff, including FMEA's. Also, check out Quality Press - I've gotten a couple useful books there for other subjects. I hope this helps!!

After I posted this, I got an e-mail from ASQ about a virtual FMEA course. I haven't checked into it at all, but I thought the timing was perfect.
 
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L

lovingquality

#4
Well thank you for the replies.

I knew that people would feel that we would use the example as our FMEA. I don't want to do this. We do not have a great deal of Welding experience outside of our walls. We have a few weld tech's, but they are home grown. We are looking for outside experience to glean understanding off of.

Quality-Geek,
I to have inherited a very derelict FMEA system. I have worked for two years to convince everyone if you use the FMEA correctly it will be our saving grace in:
APQP
Root cause
Lessons learned


We have done a great job on our Receiving and Prog. press FMEA's I would be willing to share. I feel if a company is going to borrow a FMEA and just use it as is, then they will suffer in the long run. I will not let that happen to us.

Thanks,
Mike
 
Last edited by a moderator:

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#5
I did a Google search and didn't come up with any samples for a welding process. I do also like referring to samples. :agree:

When I did a search on this site, using the Search tool (yellow font in the blue tool bar above) and key words "welding fmea", I came up with this list of threads. A couple of the threads have attachments in them. Maybe they will help.

Another hint: When reading a post, scroll to the bottom of the page and see a list of suggested similar links.
 

Miner

Forum Moderator
Staff member
Admin
#6
You are unlikely to get a weld-specific FMEA. Most companies have strong policies against giving out intellectual property such as this. Are there specific areas that we can help with such as weld-specific failure modes?
 

Stijloor

Staff member
Super Moderator
#7
Hello everyone,

We are starting to take the FEMA more seriously... (about time). My team and I have be tasked with creating a Golden FMEA for our organization. We currently Stamp, Weld (resistance and Spot) and lite assemble. I was looking for help in finding a resistance weld FMEA that could help us start our brains going. I know every process is different but, I am looking for a generalized FMEA. We use H frame tip to tip welders, with weld controllers. We weld all different size weld studs and nuts, on sheet metal stamping (thickness 2.mm-5.mm). Most of our welders are single hit.


P.S. I just love this site!!!!!!!
How do you define a "Golden FMEA?"

You may want to start developing a draft FMEA (record) and then post it here for review. Examples may help to see how others do it, but the "best" ones are the FMEA's you do yourself.

Stijloor.
 
L

lovingquality

#8
A "Golden FMEA" is = a FMEA with a collection of Failure modes and assoc. Causes.
We will use this during our APQP process to save time we will add or delete as needed to address our product. We will also use it for our lessons learned updating new Failure modes and causes along with our corrections.


Anyhow If I could ask the forum to list possible failure modes and related causes (related to Spot or resistance welding). I don't need to know how to correct them. We have a very good team to put in place Poka-yokes and process to correct.

Just to give you some in-sight or examples of what I am up against:

When we started reviewing our FMEA's we had let's take the receiving failure modes:

Then
Improper Gage and Coil Width
Chemical Condition
Rust

Now
Improper ID
Improper Gage and Coil Width
Chemical Condition
Physical and Surface Condition
Rust
Foreign Material
lamination
Scoring

And I could go on.... it was the same for the Failures and causes we went from around 5 to 14 or more.
 

CarolX

Super Moderator
Super Moderator
#9
I have a really silly question to start - what is the difference between resistance and spot? In my book they are one in the same - RSW - resistance spot welding.

OK - so here is my list of what can go wrong

Weld Quality
Weld Location
Number of Welds

Now that is a pretty generic list, but it really covers it all - I am sure you can get real specific about different aspects of weld quality such as nugget size, deformation, etc. but this may get you started.

Hope this helps a bit.
 
M

Matt Swartwood

#10
First, you must identify all current and possible ways the process can fail. Then you identify all of the possible causes for each failure and what failsafes you have in place to prevent each cause of failure. Finally, determine RPN's based on how severe the issue would be, how often it could occur, and how easily the defect would be noticed) Hint: the more fixturing/error-proofing you put in place, the lower the detection number will be.

Potential failure modes for spot weld (metal to metal) might include:

Weld in wrong location
Not enough or too many welds
Weld shear
Poor penetration
Cold welds
Undersized weld nugget
Weld does not meet peel test requirements
Weld porosity
Burn through
Weld flash (sharp burrs)
Part deformation or damage

Potential failure modes for spot weld (metal to nuts/bolts/other hardware) might include:

Hardware fails torque test
Hardware fails pushout test
Threads damaged
Flash in threads
Flash in hole
Hardware off center
Hardware not flush
Hardware not square/perpendicular
Wrong hardware used
Hardware in wrong position (GD&Tpositional callout)
Hardware in wrong location (wrong hole)

Hope this helps.
 
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