What should be included in a Machining Process FMEA?

H

haueyman

#1
Good morning Gents and ladies,

I recently had an issue with a machine that lost a Key in the tool holder in the magazine and the tool feel, the machine ran for a few hours with out anyone realizing that it happened. After looking up the FMEA, this is not covered at all. Our FMEA's only cover the actual machining process.

My question is should this be covered? Love to hear your thoughts.
 
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howste

Thaumaturge
Super Moderator
#2
Re: What should be included in machining process FMEA?

It's not completely clear to me from your description what the failure and the effect of the failure were. Was the NC machine running without a tool?

Anyway, now that you've identified it as a failure mode, I would add it to the FMEA if I were you. Generally any time you do a corrective action you should look to any related FMEAs and see if they should be updated.
 
H

haueyman

#3
Re: What should be included in machining process FMEA?

Yes the machine ran with out a tool thus a feature was not machined. Thankfully we were able contain all parts.

That is my thought as well. By adding it, I would have to add it to every feature that is cut, since this could happen to each and every tool that we use.
 
M

Markaich

#4
Re: What should be included in machining process FMEA?

Anything that could adversely affect the process output should be included, remembering that crystal balls tend not to work and that you may not get everything, hence the need to review as stated earlier.

I wouldn't however include an entry for each of the machined features, particularly as you are likely to find they all bear a remarkable similarity with one another. You should however have a generic entry to address the issue hillighted by the missing tool.

Hope it helps
M
 
H

haueyman

#5
Re: What should be included in machining process FMEA?

My FEMA whould be too long if I entered it for each tool. Here is my other problem. Not really sure of how to implement a corrective action. This can happen at any time during machining, my company will not spend any money for a detection process so not really sure how to fix.
 
Last edited by a moderator:

howste

Thaumaturge
Super Moderator
#6
Re: What should be included in machining process FMEA?

This can happen at any time during machining, my company will not spend any money for a detection process so not really sure how to fix.
How much did the problem already cost the company? Running parts with missing features for several hours was probably quite expensive. This will be a recurring cost if no corrective action is taken.
 
H

haueyman

#7
Re: What should be included in machining process FMEA?

So far the cost to the company will not exceed the cost of putting some sort of detection sensor into each machine which is 25 CNC machines. I am not sure of any other ways to limit this type of "dropped tool" to happen again.
 

howste

Thaumaturge
Super Moderator
#8
Re: What should be included in machining process FMEA?

The options are to do nothing, do a corrective action, or implement a detection activity. Your organization needs to decide what's most appropriate.

If you add this to your FMEA, what kind of Severity, Occurrence, and Detection rankings would you have with your current situation? Use that information to decide what you should do.
 

Ron Rompen

Trusted Information Resource
#9
To address the first question, absolutely this should be included in your PFMEA. It is a failure mode that, if not detected, could lead to unmachined features being shipped to your customer.

Rather than add it as a separate line item for each tool, add it as a general failure for the NC machine, there should be a whole group of 'generic' failures which can occur in the machining process, followed by ones which are part-specific.

As for how to address it, that depends on what your current detection is, the probability of recurrence, and the potential cost of failure. If this happened because an operator neglected to visually check that the key was in place, that is one thing; if the key fell out during operation (can't visualize this but I'm not a specialist in CNC machining) that is another. You have to assess the risk to you, your customer, the end user of the product, and your operators.
 
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