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Out Side of the Box for FMEAs

Out Side of the Box for FMEAs. Peter Sterndale Sr. Supplier Quality Engineer QinetiQ-North America. Summary. The “Pre-Control” FMEA Requirements review Drawing Review (internal & external –Supplier) The “ROD” FMEA Remedy or Die If more factors than S, O & D are required

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Out Side of the Box for FMEAs

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  1. Out Side of the Box for FMEAs Peter Sterndale Sr. Supplier Quality Engineer QinetiQ-North America

  2. Summary • The “Pre-Control” FMEA • Requirements review • Drawing Review (internal & external –Supplier) • The “ROD” FMEA • Remedy or Die • If more factors than S, O & D are required • The Dollarization FMEA • Translating RPN to Dollars? • The use 0 to Infinity

  3. The “Pre-Control” FMEA • Required equipment: • Red (pink), Yellow and Green Highlighters • Applicable to Requirements, Specifications, Purchase Orders, Drawings, etc. • The Technique • Highlight all Safety items in Red (Pink) • Highlight all items that are a “Slam dunk” in Green. • Highlight all items that require consderation – additional review, mistake-proofing, training , etc. in Yellow • Highlight all items requiring change in Red (Pink) • All items will be colored • Make action plan for Reds and Yellows • Works great when you have only a couple of hours to perform an FMEA. Examples of Drawing and Spec review will be supplied

  4. The “ROD” FMEA • Remedy or Die • Add additional Factors and Weights to the RPN equation to fit your business need. • Consider • Cost to implement ($) • Time to implement (T) • Man Hours to implement (M) • Upper Management Directives (U) • ROD = 2S * 3O * D * 5$ * 0T * M * 4U • This is a great priority tool.

  5. The “Dollarization” FMEA • Gain Upper Management Attention with the use of $ vs. RPN. • Everything becomes a Cost Savings! • Engage Finance • Who really understands the Severity Index? • A $10,000 piece of equipment gets scrapped • S = 6 • S = $10,000! • I Defect Rate for the $10,000 equipment is 10% for the 1000 units/year • O = 4 • O = 0.1! • I can detect and avoid 70% of the issues above • D = 2 • D = 0.7 • $RPN = ($10,000) * (1000/yr) * (0.1*(1-0.7)) = $300,000/yr • What is easier to understand: RPN = 48 or $300,000/yr? / / /

  6. Any Questions?

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