Welcome -- Day 1

1. Welcome -- Day 1 Failure Mode and Effects Analysis

2. FTEP Modules Quick QFD Systems Engineering Fundamentals Global 8D Ford Technical Education Program FMEA Process Control Methods ExperimentalDesign Reliability Parameter Design ToleranceDesign

3. Warm-Up -- Day 1 Place Self Others Team Purpose Agenda

4. Course Purpose These three days are designed to... help you function effectively as an FMEA team member, but not to leave as an FMEA team leader or an FMEA expert

5. Participant Materials Questionnaire • Only one correct answer is possible • Do NOT guess if unsure of answer

6. Day 1 Introduction FMEA -- An Introduction • Why Do FMEAs? • Definition, Purpose, Types, Benefits • FMEA Working Model • Generating / Managing • Team Approach

7. Nimble Through Process Leadership Lead in Customer Satisfaction Ford 2000 Strategies EmpoweredPeople Achieve Worldwide Growth Ford The World’s Leading Automotive Company Achieve Worldwide Product Excellence The Low CostProducer Lead in Corporate Citizenship

9. Why Do FMEAs? • Appropriate recommended actions may not have been taken • Significant savings in engineering time -- reduction in changes immediately before and after Job 1

10. 2-2 FMEA -- Definition Structured group of activities which ... • Recognize and evaluate the potential failure of a product or process and its effects • Identify actions which could eliminate or reduce the chance of the potential failure occurring • Document the process

11. Origin of Failures Elimination of Failures FMEA JOB 1 FMEA Purposes Failures Time

12. Unreliable Products Excellent Products Customer Orientation QFD Reliable Products Customer Doesn't Want Disaster Design and Process Orientation FMEA FMEA Purposes

13. 2-2 FMEA -- Purposes FMEAs are intended to ... • Identify potential failure modes and rate severity of effects • Identify critical and significant characteristics • Help engineers prioritize and focus on eliminating product and process concerns and helps prevent problems from occurring • Test adequacy of controls from DCP process

14. System Design FMEA Sub-System Component System Assembly Sub-System Process FMEA Component System Manufacturing Sub-System Component 2-4 FMEA -- Types Concept FMEA

15. 2-5 Benefits -- Concept FMEAs Design • Helps select optimum concept • Identifies potential failure modes • Considers potential effects • Helps generate occurrence ratings • Identifies testing requirements • Helps determine if hardware system redundancy is required Concept Process

16. 2-5 Benefits -- Design FMEAs Design • Aids in evaluating requirements and alternatives • Aids in initial design for DFM • Increases probability of detecting failure modes and their effects • Provides additional information for testing requirements • Helps identify critical and significant characteristics • Helps validate DVPs and SDSs Concept Process

17. 2-6 Benefits -- Process FMEAs Design • Identifies potential product related failure modes • Assesses effects on all customers • Identifies potential Manufacturing and Assembly causes to focus controls on reducing occurrence and/or increasing detection • Establishes a priority system for considering corrective actions • Identifies confirmed critical and significant characteristics Concept Process

18. Potential Failure Mode and Effects Analysis ___ System FMEA Number: Design Responsibility: ___ Subsystem Page 1 of 1 Key Date: ___ Component Prepared by: Model Year / Vehicle(s): FMEA Date ( Orig): (Rev) Core Team: Action Results Potential Potential S C Potential O Current D R Responsibility & O R S D Item e c e P Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions v c t N Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken s Failure u e Function s r c FMEA Working Model

19. 2-9 Generating FMEAs Who initiates? Who prepares? Who updates? Who is FMEA customer? When to discard? Failure Mode and Effects Analysis FMEAs When started and updated? How is FMEA documented? Relationshipto FPDS? When is FMEA complete?

20. Managing FMEAs FMEAs are living documents, and are updated when ... • Modification to a component, process or system is planned • Component is to be used in new environment • Customer concern arises: Global 8D

21. 2-13 KO SC PA PR J1 SI FMEAs and Systems Engineering Customer Customer Customer Focus Musts / Wants Satisfaction Customer Experience & Feedback CFMEA Vehicle Level Inputs Customer Purchase, Operate • Purchaser / owner / operator Disposal & Maintain Requirements • Regulatory (FMVSS, EPA, ...) • Corporate (WCR, ABS, Manuf, ...) Feasibility Requirements Feedback Cascade Vehicle Level Requirements Vehicle DVM / DVP • Vehicle Attributes Production Verification • Vehicle System Specification - VDS Feasibility Requirements Feedback Cascade DFMEA System / Subsystem Level PFMEA DVM / DVP System • System & Verification • Subsystem Design Specifications - SDS Feasibility Requirements Feedback Cascade Part / Part/ Component Fabrication / Verification Component Design • Component Design Specification - CDS

22. Core Team Support Team 3-5 Team Approach -- FMEA

23. Day 1 Introduction Section Summary • Why Do FMEAs? • Definition, Purpose, Types, Benefits • FMEA Working Model • Generating / Managing • Team Approach

24. Break

25. Day 1 Design FMEA Introduction Design FMEA -- An Introduction • Identify FMEA Team • Establish Scope • Describe Function • Brainstorming • Function Trees • Practice Exercise 1

26. Potential Failure Mode and Effects Analysis ___ System FMEA Number: Design Responsibility: ___ Subsystem Page 1 of 1 Key Date: ___ Component Prepared by: Model Year / Vehicle(s): FMEA Date ( Orig): (Rev) Core Team: Action Results Potential Potential S C Potential O Current D R Responsibility & O R S D Item e c e P Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions v c t N Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken s Failure u e Function s r c Design FMEA Scope Team Team

27. Facilitator or Application Engineer Technical Affairs • Representatives from: • Customer Service • Suppliers • Global Test Operations • Corporate Quality SupportTeam Design Engineer Manufacturing / Process Engineer CORETeam 3-5 Design FMEA -- Team

28. 3-8 Design FMEA -- Scope Once core teamis established... • Create a block diagram • Identify the boundary for analysis • Confirm composition of the support team

29. Assembly Service Part X Part Y Screw Weld User Part Z OtherSystems Adhesive 3-10 Constructing Block Diagrams Component/Assembly

30. Block Diagram -- Example Headlamp Assembly

31. Block Diagram -- Example Vertical Trimmer Assembly

32. Hood(Clearance) AdjusterSocket User Block Diagram -- Example Lateral Location Screw Clips 2 Vehicle BodyUpper CrossMember Reflector VerticalTrimmerAssembly

33. Potential Failure Mode and Effects Analysis ___ System FMEA Number: Design Responsibility: ___ Subsystem Page 1 of 1 Key Date: ___ Component Prepared by: Model Year / Vehicle(s): FMEA Date ( Orig): (Rev) Core Team: Action Results Potential Potential S C Potential O Current D R Responsibility & O R S D Item e c e P Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions v c t N Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken s Failure u e Function s r c Determine Function Scope Team

34. 5-6 What is Function ? • Design intent or engineering requirement • Must be measurable or set at an actionable level • Representation of all wants, needs and requirements, both spoken and unspoken

35. Verb Noun Indicates action, occurrence, being Indicates what the action relates to 5-7 Describe Function Generate Control Dispense Retain Prevent Light Speed Fuel Seat Track Rust

36. Describe Function Thought Starters ... • Satisfy user • Attract user • Assure convenience • Assure dependability • Governmental requirements • Safety requirements

37. Brainstorming Exercise in creative thinking Method to generate ideas

38. Brainstorming -- Guidelines • Warm up • Suspend judgment • Anything goes • Quantity counts • Springboard • Persevere • Warm down

39. Brainstorming -- Pitfalls • Low team trust • Broad task definition • Criticism, competition, defensiveness • Silliness, lack of focus • Questions and explanations • Organizing ideas during creative stage

40. Brainstorming -- Agreement • Everyone explains view(s) • Identify needs of individuals • If you can’t meet a need, say so • Check out feelings -- yours / others • Don’t compromise, average, or ‘split the difference’

41. Function Trees • Provide an organized approach to identify the essential features of a product (or process sometimes) • Help ensure that ‘unspoken’ and ‘spoken’ requirements are defined • Provide a graphical representation of functions to ensure clear, total team understanding

42. HOW ? WHY ? SecondaryLevel TertiaryLevel Primary Level Constructing Function Trees

43. HOW ? WHY ? Adjust Light Beam X° Both Directions Permit / Maintain HorizontalAdjustment Locate Headlamp Laterally 10 Years, 150,000 Miles Retain Setting10 Years, 150,000 Miles Adjust Light Beam X° Both Directions Permit / Maintain Vertical Adjustment Locate Headlamp Vertically 10 Years, 150,000 Miles Retain Setting10 Years, 150,000 Miles Vertical Trimmer Function Tree Adjust Headlamp

44. Guidelines • Brainstorm all functions (VERB - NOUN) • Document individual functions by asking “HOW is function achieved?” • Repeat left to right, until actionable level • Use worksheet to check that actionable level is measurable • Work right to left and check structure by asking “WHY is function included?”

45. Practice Exercise 1 Block diagram Brainstorming Function Tree

47. Presentation -- Practice 1 Team Debrief Technical Debrief

48. Potential Failure Mode and Effects Analysis ___ System FMEA Number: Design Responsibility: ___ Subsystem Page 1 of 1 Key Date: ___ Component Prepared by: Model Year / Vehicle(s): FMEA Date ( Orig): (Rev) Core Team: Action Results Potential Potential S C Potential O Current D R Responsibility & O R S D Item e c e P Failure Effect(s) e l Cause(s)/ c Design e P Recommended Target Actions v c t N Mode of Failure v a Mechanisms c Controls t N Action(s) Completion Date Taken s Failure u e Function s r c Function 1 Function 2 Function 3 Sub-Sub-Function Sub-Function Function n Sub-Sub-Function Sub-Function Function Sub-Sub-Function Sub-Function Design FMEA Functions

49. Day 1 Design FMEA Introduction Section Summary • Identify FMEA Team • Establish Scope • Describe Function • Brainstorming • Function Trees • Practice Exercise 1

50. Day 1 DFMEA -- Path 1 Design FMEA Path 1 • Failure Modes • Effects -- Severity • Recommended Actions • Potential Special Characteristics • Practice Exercise 2