Product Failure - PFMEA/Control Plan actions

J

jkittle

#1
I have a supplier who supplies a brake component to me as a complete assembly.

We recently have had failures. The reason give for the failure were a sub-suppliers part failed.

The reason/root cause given for the individual part failure was an out of specification radius and low heat treat.

The radius was only slightly out of spec and the heat treat was 1 point (RC 35 min. actual RC 34) out of spec.

Since these two features seem to be very crucial and sensitive to the assemblies performance, should these two features severity be really high on the PFMEA and would it be advised to add these two features to the control plan as significant feature or at least some other special Char. class?
 
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Marc

Hunkered Down for the Duration with a Mask on...
Staff member
Admin
#2
Re: Product Failure - PFMEA/CP actions

You might have to 'bump' this thread on Monday if no one answers today. It's relatively slow here on weekends.
 

Kales Veggie

People: The Vital Few
#3
Re: Product Failure - PFMEA/CP actions

I have a supplier who supplies a brake component to me as a complete assembly.

We recently have had failures. The reason give for the failure were a sub-suppliers part failed.

The reason/root cause given for the individual part failure was an out of specification radius and low heat treat.

The radius was only slightly out of spec and the heat treat was 1 point (RC 35 min. actual RC 34) out of spec.

Since these two features seem to be very crucial and sensitive to the assemblies performance, should these two features severity be really high on the PFMEA and would it be advised to add these two features to the control plan as significant feature or at least some other special Char. class?
If you had not failure before, what changed? Any process changes at your facility? Any process changes at your supplier? What changed?

First has it be proven that this is the true root cause. If true, these should be in the PFMEA for sure and maybe on the control plan.

What does your design FMEA have about this failure mode? There may be a design issue as well.

Was the failure in the field or in your plant? Is that part casted, machined, stamped, powder metal?

Are you sure that radius and hardness are the root cause? It is hard for me to believe that a radius (slightly out) and 1 point hardness is causing the failure. How did the supplier proof that these two are the true root cause? What evidence do they have? (Are they hiding something?) (If true, then the design is not very robust either!)

Other potential causes:
On radius (machined or as casted) : burrs or sharp edges, stress risers?
On hardness: what about the structure, what about the chemistry, inclusions and other steel properties?

To make the correct analysis and judgment, more information is needed. I wish it was easy :)nope:)
 
G

gholland

#4
Unless the failure was more severe than your original analysis you don't adjust the severity ranking. In other words if you thought if the component failed there would be a minor problem but in fact it turned out to be major that is when you adjust the severity.

You should be looking at 'occurence' and 'detection'. Does the inspection process look at the radius? If so that tell you that your inspection method can't detect an out of specification condition. What is the gage R/R on the inspection method? If the supplier hasn't done a R/R then how did they/you arrive at your current detection ranking? Same questions for hardness. Your FMEA should now be looking harder at the way the hardness value is acheived, apparently something didn't happen properly and that failure was missed in the FMEA.

How does your 'occurence' ranking hold up? Is this 1 out of 1,000 parts that failed or 1 out of 1,000,000? This would also affect your final RPN number.

In my experience an unexpected failure means a FMEA failure as well, either the inspection method is assumed to be more effective or you under-estimated the occurence of the failure.

All of this is assuming the root cause analysis is correct. If during the FMEA process you can't come up with a logical path to the event that caused the failure you may push back on this as the root cause.

:2cents:
 
J

JaxQC

#5
I just wanted to point back to the item of root cause. “reason/root cause given for the individual part failure was an out of specification radius and low heat treat” In my thinking these are not root causes. They are results of root causes. OCCURANCE: What caused the low heat treat value (short time, incorrect heat etc)? What caused the out of spec radius (wrong cutting insert, work offset incorrect)? DETECTION: Why did the low heat treat & radius not get caught in the normal process? Method not sensitive enough to detect it, not checked, checked but results ignored?
 
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