Advanced Powertrain Control Symposium 9 th July 2013

1. Advanced Powertrain Control Symposium 9th July 2013 Välkommen, welcome, huānyíng, welkom, Bienvenue, willkommen, fogadtatás, benvenuto, velkommen, powitanie, bem-vindo, croeso, bienvenido, vítejte www.fmea.co.uk

2. The Effective Application of FMEA • Who am I? • What is FMEA? • Why do FMEA? • Application of FMEA • A Structured Approach • Effective FMEA • Use Software for FMEA • Use an FMEA Facilitator www.fmea.co.uk

3. What is FMEA? Contrary to popular belief FMEA is actually an acronym for a risk analysis called Failure Modes & Effects Analysis, and not ‘Five Men Endlessly Arguing’. “Failure Modes & Effects Analysis is an activity that brings minds together in a collaborative and pre-emptive way in order to avoid failure of a system!” FMEA is a systematic procedure that focuses on a system(s) in order to uncover weaknesses, i.e. what can go wrong, what could possibly cause it and what are the potential effects. FMEA then focuses on these weaknesses with the objective of making them obsolete, or by reducing the likelihood of failure (or risk of failure) though the implementation of corrective methods, which in turn optimises the system. www.fmea.co.uk

4. What is FMEA? FMEA is a living document and if used correctly records: • intellectual property • weaknesses within the system • quantified risk of system failure • mistakes made • solutions to problems • responsibility for controls methods Failure are any potential errors or defects within a process, design, or part, especially ones that affect the ‘customer’, environment and law. www.fmea.co.uk

5. What is FMEA? • 1949 – US Military (MIL-P-1649) • 1963 – NASA • 1965 – Aerospace Industry • 1975 – Nuclear Industry • 1977 – Ford Motor Company • 1980 – DIN 25448 • 1986 – VDA Volume 4 • 1992 – Ford, Chrysler & GM • 2008 – AIAG Is universally accepted as an engineering tool www.fmea.co.uk

6. Why do FMEA? • Cost reduction and increased profits • Demand for higher quality • Extended warranty periods • Product liability • Quality standard demands • Retention of knowledge • Make processes more robust • Enhanced communication within the business, customer & suppliers • Shorter development times • Functional Safety & Reliability www.fmea.co.uk

7. Application of FMEA www.fmea.co.uk

8. Application of FMEA There are two main schools of thought about the methodology to use and which is most effective? • Rose with a different name • Procedure • Document formats • Adherence to ISO / TS 16949 • Basis for ISO / TS 26262 www.fmea.co.uk

9. Application of FMEA To get the best out of FMEA you should have: • Cross functional team • FMEA Moderator / Facilitator • Props and documentation • Structured approach • FMEA Software • Management Support! www.fmea.co.uk

10. A Structured Approach www.fmea.co.uk

11. Effective FMEA Step 1: Visual representation of the scope www.fmea.co.uk

12. Effective FMEA Step 2: Runs in line with other engineering techniques, such as Function Analysis System Technique (FAST) Mode How? Why? Causes Effects www.fmea.co.uk

13. Effective FMEA Focus on functions provide guidance for the analysis of failures, or step 3. • Short • Open • Signal stuck at ground • Signal stuck at specified voltage • Signal is corrupted • Loss of Voltage stimulus • Corrupted Voltage stimulus • Voltage stimulus when not required Mode Causes Effects www.fmea.co.uk

14. Effective FMEA Step 3: Efficient construction of effective possible failure scenarios Mode Effects Causes www.fmea.co.uk

15. Effective FMEA Step 4: Possible failure scenarios are displayed in a fashion that is consistent with previous steps www.fmea.co.uk

16. Effective FMEA AIAG form can be unintentionally misleading Mode Causes Effects www.fmea.co.uk

17. Effective FMEA E=MC2 VDA form is logical Mode Causes Effects www.fmea.co.uk

18. Effective FMEA Step 4: Ensuring that only the controls that are currently in fruition are considered when calculating the risk www.fmea.co.uk

19. Effective FMEA Step 4: Analysis of the data using RPN is not just 1-1000, there are 120 values that can result from SxOxD, which may not reflect criticality. www.fmea.co.uk

20. Effective FMEA Common sense shall prevail by looking at the risk assessment results in a different way e.g.: Automotive risk model www.fmea.co.uk

21. Effective FMEA Step 5: Reduction of the risk is displayed in a Chronological order www.fmea.co.uk

22. Effective FMEA Create your own descriptions of the risk factors of Severity (S), Occurrence (O) and Detection (D): • Reflect what you do as a business • Reflect the product you make • Is there a customer mandate? • Using ‘rule of thumb’ statements & benchmark examples • Use AIAG descriptions as guidance* www.fmea.co.uk

23. Use Software for FMEA Due to the complexities of modern products & processes, software is essential. Many companies use MS Excel, but dedicated software can provide a visual representation of: • the system analysed • interfaces between sub-systems, plus inputs and outputs • complex relationships between the failures www.fmea.co.uk

24. Use Software for FMEA In addition to this dedicated software allows the FMEA to: • be filtered or colour coded according to your own criteria • produce additional statistical data and additional quality documentation as a consequence • Switch easily between FMEA form layouts • handles variances • Supports delegation and tracking of corrective measures www.fmea.co.uk

25. Use an FMEA facilitator • Experienced FMEA facilitation will ultimately save time and make meetings more focused& constructive. • An experienced FMEA facilitation minimises digression into different types of FMEA. • An external FMEA facilitator may ask the ‘stupid questions’ that may have been overlooked as they may be thinking outside of the box • An effective FMEA records intellectual capital for the future developments (semantics) www.fmea.co.uk

26. tack, thanks, xièxie, dank u wel, merci, danke, köszönöm, grazie, tak, dziękuję, obrigado, diolch, gracias, děkuj, ďakujem 078 999 625 53 - 01785 711 296 gavin@fmea.co.uk Penkridge, Stafford, ST19 5TE. UK www.fmea.co.uk