Failure Mode & Effect Analysis (FMEA) in Half the Time Howard C Cooper, MS, DFSS-BB

1. INCOSE Michigan – May Dinner Meeting Failure Mode & Effect Analysis (FMEA) in Half the Time Howard C Cooper, MS, DFSS-BB May 13th, 2014

2. Introduction • Failure Mode & Effects Analysis (FMEA) is an analytical tool and structured method to: • Recognize and evaluate the potential failure of a product/process and its effects • Identify and prioritize actions which could eliminate or reduce the chance of a potential failure • Document the process Before they are “baked” into a product Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

3. Common Types of FMEA • Design FMEA • Identify and mitigate potential design problems early in the design cycle • Process / Manufacturing FMEA • Improve quality and reliability, during set-up of initial manufacturing process • Problem Solving / Six Sigma FMEA • Understand failure modes and effects to identify and solve quality or reliability issues Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

4. Where FMEA is Used Common FMEA Usage Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

5. Prioritize Failure Modes by Risk Priority Number SEV X OCC X DET = (RPN) Example Design FMEA Failure Mode Item Severity FM & Effects of each failure mode Relative Occurrence Root Cause Items within the system being analyzed Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

6. Example Process FMEA Steps within the process being analyzed Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

7. Typical FMEA Process • Assemble team of people with diverse knowledge of process & product • Bound the problem • Identify functions • Identify potential failure modes • Populate FMEA details • Prioritize failure modes based on RPN • Mitigate failure modes Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

8. Mission to Improve FMEA Development • Challenge Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

9. Improved FMEA Process • In 2012, GDLS developed process to prepare ‘efficient’ and ‘effective’ FMEA at greatly reduced time and cost • Process involves four primary tools: Major innovation: Decomposition Table identifies and prioritizes Failure Modes (FMs) into FMEA. Focuses analysis on critical failure modes Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

10. Step 1: Bound the System Boundary Diagram / Process Flow What • Identifies and verifies: • System functions: lines crossing the dotted boundary • “Items” within the dotted line system boundary Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

11. Step 2: Characterize the Process What (From Boundary Diagram) P-Diagram Why Green blocks, identify functions of the system (or process) Yellow blocks ~ Noise Factors, Blue block, Control Factors,Pink blocks ~ Error States Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

12. Outstanding Problem & Opportunity • Boundary or Process Flow Diagram • Identifies “Items” for the FMEA, but not the Failure Modes (FM) of those “items” • P-Diagram • Identifies system functions or requirements (even noise factors) but not the function or FMs of the “items” • Opportunity • Develop a table that will identify and link “items” to their functions, and to their functional FMs Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

13. Step 3: Map Functions to Failure Modes System Functions P-Diagram Boundary / Process Diagram Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

14. Step 3: Map Functions to Failure Modes System Functions P-Diagram Need to Identify Item / HW Functions Boundary / Process Diagram Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

15. Step 3: Map Functions to Failure Modes System Functions P-Diagram Identify Functions Boundary / Process Diagram Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

16. Step 3: Map Functions to Failure Modes System Functions P-Diagram Identify Functions Boundary / Process Diagram Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

17. Step 3: Map Functions to Failure Modes System Functions P-Diagram Identify Functions Boundary / Process Diagram Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

18. Decomposition Table Structures FMEA System Functions functions translate to FMs 3-4 FMs per Function From B-Diagram or Pr-Flow Chart “X” indicates a Function (and 4 FMs in the FMEA) Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

19. 3 Purposes of the Decomposition Table • Ensures all items are captured into the FMEA • Ensures multiple function items and their potential failure modes are identified into the FMEA • Provides opportunity to identify and prioritize by criticality of hardware or process functions before populating failure modes into the FMEA Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

20. Decomposition Table Prioritizes Functions System Criticality # rather than “X” Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

21. Preparation Flow into Decomp Table System 1. P-Diagram Ideal Functions – to Design Functions in F-H Decomp. 3. Identify all ‘Item’ Functions needed to accomplish each System Function 4. Mark with an “X” or with a “Criticality #” 2. B-Diagram or Process Flow inner blocks go to Decomp. Table Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

22. Step 4: Use Decomp Table to Fill FMEA 1 System 1 3 3 1 4 2 2 1 4 2 3 FMEA filled in from F-H Decomp Table Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

23. Benefits of Improved FMEA Development Four Step FMEA Process: • Organizes and speeds FMEA failure mode identification • Ensures all hardware-functions and FMs are identified • Prioritizes critical hardware-functions for FMEA analysis • Provides power of 80/20 Rule on FMs for best Reliability Growth • Focuses attention and time on mitigation of “significant few” (the most critical failure modes (FMs) Pareto Chart (80/20 Rule) F-H Decomp Table now being used on multiple GDLS Contracts: for DFR, to facilitate earlier diagnostics planning, to meet Weight and Testability Requirements Addressing most critical FMs yields greatest reliability growth. Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

24. Cost Savings Attributed to New Process Before vs, After Facilitator Cost Savings on Facilitator Cost Facilitator Savings X 3 for FMEA Team, X 3 Programs in 2013 = Total Savings Approved for Public Release, Distribution Unlimited, LogNo. 2014-07, 26 FEB 14

25. Questions? Presenters: • Howard C Cooper, MS, DFSS-BB • DFR Reliability Engineer • cooperh@gdls.com Mark Petrotta, MS, DFSS-MBB Engineering Process Excellence • petrotta@gdls.com