PFMEA bending of steel tube

[mikeleighb]

I work for a steel tube manufacturer and we have a sister company that performs some bending of these tubes. I have been asked to help them develop pfmeas for the bending process(es). I will basically be starting from scratch and will have to train them on pfmeas in general as well. I was wondering if any of you great folks might have a basic pfmea for tube bending that I could use as a starting point and/or show as an example to get the ball rolling?

Thank you in advance for any support.

 

[malasuerte]

I work for a steel tube manufacturer and we have a sister company that performs some bending of these tubes. I have been asked to help them develop pfmeas for the bending process(es). I will basically be starting from scratch and will have to train them on pfmeas in general as well. I was wondering if any of you great folks might have a basic pfmea for tube bending that I could use as a starting point and/or show as an example to get the ball rolling?

Thank you in advance for any support.

Not to be too harsh, but that is not what an FMEA is about. You can show a generic example of any FMEA as part of your training. But the whole point is to go through the whole process SIPOC, C&E, FMEA so that the FMEA is meaningful and useable for the organization.

Or you can fill in the fields for a 'sample' FMEA - it shouldn't be that difficult.

 

[mikeleighb]

Not to be too harsh, but that is not what an FMEA is about. You can show a generic example of any FMEA as part of your training. But the whole point is to go through the whole process SIPOC, C&E, FMEA so that the FMEA is meaningful and useable for the organization.

Or you can fill in the fields for a 'sample' FMEA - it shouldn't be that difficult.

Awesome. Thank you.

 

[Ron Rompen]

Mike: I work for a company which produces bent steel tubing unfortunately I am not permitted to share our PFMEA publicly, however I would be happy to answer any specific questions that you may have. Feel free to message me directly, and I'll give you what assistance I can.

 

[Jim Wynne]

Not to be too harsh, but that is not what an FMEA is about. You can show a generic example of any FMEA as part of your training. But the whole point is to go through the whole process SIPOC, C&E, FMEA so that the FMEA is meaningful and useable for the organization.

Or you can fill in the fields for a 'sample' FMEA - it shouldn't be that difficult.

What is "C&E," and why is SIPOC necessary?

 

[Al Rosen]

What is "C&E," and why is SIPOC necessary?

C&E=Cause and Effect.

 

[Funboi]

Although it is tempting to simply generate a PFMEA for tube bending, it is important to first define the process Which needs control to assure a quality result. Only then can you look at potential failure modes. Thereafter, you can decide the plan to control the process. A “SIPOC” isn’t necessary, a process “flow” is. Cause and effect (of what?) is also not needed.
This thread and the mass-debate about “missing fields” amplifies how much misinformation there is about this tool.

 

[Miner]

What is "C&E," and why is SIPOC necessary?

C&E is a Cause and Effect Matrix
SIPOC is a macro level process map for Supplier, Inputs, Process, Outputs, Customer.

They are tools that are often taught as part of Six Sigma. C&E Matrix is used to narrow the search to those operations that are most likely to contain the Key process input variables (KPIVs) following by an PFMEA to further narrow the possibilities. The narrowed list is used as the basis for experiments to confirm the KPIV.

They are not typically used as a precursor for a PFMEA done for APQP.

 

[bbuss]

I will basically be starting from scratch and will have to train them on pfmeas in general as well.
Thank you in advance for any support.

Mike, do you have any FMEA training materials to get you started? Are you aware that AIAG publishes an FMEA manual which is widely accepted? Here is the link: aiag.org/store/publications/details?ProductCode=FMEA-4 The book covers Design FMEA, Process FMEA, and System FMEA.

One option for your training to "get the ball rolling" is to start with a simple process that all of your trainees have a common understanding of. Things like brewing a cup of coffee, baking a pizza, or driving your car around the block. But as the other posters mentioned, I'd suggest trainees first understand basics like flowcharting the process before moving into dividing up each process step to identify potential failure modes. Once a process flow chart and PFMEA is understood for these simpler examples, then you move on to bending tubes.

Please feel free to reach out to me on LinkedIn if you need training assistance.

Good luck!
Brian Buss, CQE, CQA

 

[mattador78]

Mike, do you have any FMEA training materials to get you started? Are you aware that AIAG publishes an FMEA manual which is widely accepted? Here is the link: aiag.org/store/publications/details?ProductCode=FMEA-4 The book covers Design FMEA, Process FMEA, and System FMEA.

One option for your training to "get the ball rolling" is to start with a simple process that all of your trainees have a common understanding of. Things like brewing a cup of coffee, baking a pizza, or driving your car around the block. But as the other posters mentioned, I'd suggest trainees first understand basics like flowcharting the process before moving into dividing up each process step to identify potential failure modes. Once a process flow chart and PFMEA is understood for these simpler examples, then you move on to bending tubes.

Please feel free to reach out to me on LinkedIn if you need training assistance.

Good luck!
Brian Buss, CQE, CQA

I did an example of the breakfast order for the staff here, it was amazing how easy it translated compared to the original example i had. When we then moved on to our processes here it was suprisingly easy and people had a lot more input than they orginally expected.