Use of Design and Process FMEA tools - Kitchen Cabinets Manufacturing

R

Rahulkanety

#1
Our plant manufactures kitchen cabinets, mostly using designs from customers and also making changes to the current ones. We have no documentation particularly when we come up with new products. I would like to know if we can use FMEA both for risk analysis and also for ISO documentaion purposes.
Should we use design FMEA also along with process FMEA? Most of the concepts and drawings are proposed by customers we only make minor modifications and request for approval.
 
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Jim Wynne

Staff member
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#2
Re: Use of FMEA tool

Our plant manufactures kitchen cabinets, mostly using designs from customers and also making changes to the current ones. We have no documentation particularly when we come up with new products. I would like to know if we can use FMEA both for risk analysis and also for ISO documentaion purposes.
Should we use design FMEA also along with process FMEA? Most of the concepts and drawings are proposed by customers we only make minor modifications and request for approval.
Welcome to the Cove. :D

You didn't say if your company is already ISO-certified or if you're pursuing certification, or if you just want to be compliant with the standard without certification. In any case, it's difficult to say from here whether your company might be considered design-responsible, but it appears that you're not.

If there are no external FMEA requirements (i.e., from customers), you can use those tools as you see fit. It might be helpful to do a flowchart of your basic processes, starting with receipt of specifications from customers and ending with packaging and shipment of products. This will give you a clearer picture of what needs to be controlled, and where risks might lie. If there is some manipulation going on at the front end--where your company takes customer specifications and "translates" them into production requirements--a DFMEA might be helpful, but a "top level" PFMEA would probably suffice.
 
R

Rahulkanety

#3
Re: Use of FMEA tool

Welcome to the Cove. :D

You didn't say if your company is already ISO-certified or if you're pursuing certification, or if you just want to be compliant with the standard without certification. In any case, it's difficult to say from here whether your company might be considered design-responsible, but it appears that you're not.

If there are no external FMEA requirements (i.e., from customers), you can use those tools as you see fit. It might be helpful to do a flowchart of your basic processes, starting with receipt of specifications from customers and ending with packaging and shipment of products. This will give you a clearer picture of what needs to be controlled, and where risks might lie. If there is some manipulation going on at the front end--where your company takes customer specifications and "translates" them into production requirements--a DFMEA might be helpful, but a "top level" PFMEA would probably suffice.
Thanks for the reply. Right now we are looking to be compliant with the standards. ISO certification is our longterm goal.
 
D

DrM2u

#4
Our plant manufactures kitchen cabinets, mostly using designs from customers and also making changes to the current ones. We have no documentation particularly when we come up with new products. I would like to know if we can use FMEA both for risk analysis and also for ISO documentaion purposes.
Should we use design FMEA also along with process FMEA? Most of the concepts and drawings are proposed by customers we only make minor modifications and request for approval.
Using FMEA is always good practice, at least IMHO.:applause:

The use of DFMEA is suitable only if you are designing the product and it can help identify and prevent design flaws that can lead to product failures, manufacturing and assembly difficulties, etc. From what you wrote it seems like the product is designed by your customers.

The use of PFMEA is applicable when developing the controls for the processes employed. Like Jim suggested, start with a process flow diagram of the product realization process. This is the starting point for any FMEA activities and it helps identify the processes involved, where they start and where they end. From there you can develop the PFMEA for all processes or for each process individually. If you have a number of common processes (i.e. receiving, storage, shipping, etc) then I suggest generating PFMEA for each process and creating customized PFMEAs only for the changing processes (based on product variation). Keep in mind that one of the primary inputs to the PFMEA is the DFMEA if available.

After you are done with the PFMEAs then you can develop the control plans and implement them. Once you have everything in place you can evaluate the effectiveness of your processes and controls to identify improvement opportunities. And, just like that, you have covered most of the requirements for clauses 7 & 8. A little more work on the management side and other requirements and you'll be ready for the registration audit.:agree1:
 
R

Rahulkanety

#5
My superiors liked the idea of implementing FMEA. But the problem is they are not in a position to quantify the FMEA implementation costs and savings from implementation. Since FMEA requires time and people they are not able to decide. Can any one suggest me any idea inorder to simplyfy FMEA process. Our company manufactures lot of products which are mostly grouped under few product families. There is variation in every product and every product has a lot of processes involved in manufacturing. So what would be the best way to do a pilot FMEA? Thanks
 
#6
My superiors liked the idea of implementing FMEA. But the problem is they are not in a position to quantify the FMEA implementation costs and savings from implementation. Since FMEA requires time and people they are not able to decide. Can any one suggest me any idea inorder to simplyfy FMEA process. Our company manufactures lot of products which are mostly grouped under few product families. There is variation in every product and every product has a lot of processes involved in manufacturing. So what would be the best way to do a pilot FMEA? Thanks
One of the best ways to quantify the (cost) benefit and swing them to making a decision is to take a look at some of the failures you get with product in the field, i.e. customer and what that costs, or internally in processing - waste, scrap, reworked or down graded product (lower revenue). If you look at the (potentially) $Thousands, it's not hard to see that a) these issues could have been avoided through controls and b) they are a relatively large cost compared to having a few people meet for a training session. Most of you 'family' design and process FMEAs could be done in a day of training. I've done such with past clients.
 
R

Rahulkanety

#7
Re: New product Development- Kitchen Cabinets Manufacturing

Hello Everyone,

I would like to share my companies NPD process flow and would like to know any suggestions for a better process.

Problems faced:
  1. Usually after step 6 customer never asks for a prototype instead he wants a quote from us. If they like it they order it straight away, if not we never get any thing back from them
  2. And inorder to give a good quote we need to do all the 2d/3d drawings which is a time consuming process
  3. So if they like quote they ask for a prototype, and if they dont like they never get back to us sometimes
  4. I am looking for a sample document which i would like to send it with prototype so that we can acess ourselves
The document attached is the way we intend to do but usually after step 6 we jump to step 14 and then once customer approves it we go to step 7.
 

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