Failure Mode and Effect Analysis

D.H. Stamatis

Description

Author D. H. Stamatis has updated his comprehensive reference book on failure mode and effect analysis (FMEA). This is one of the most comprehensive guides to FMEA and is excellent for professionals with any level of understanding.!--nl--This book explains the process of conducting system, design, process, service, and machine FMEAs, and provides the rationale for doing so. Readers will understand what FMEA is, the different types of FMEA, how to construct an FMEA, and the linkages between FMEA and other tools. Stamatis offer a summary of tools/methodologies used in FMEA along with a glossary to explain key terms and principles. The updated edition includes information about the new ISO 9000:2000 standard, the Six Sigma approach to FMEA, a special section on automotive requirements related to ISO/TS 16949, the “robustness” concept, and TE 9000 and the requirements for reliability and maintainability. Also includes FMEA forms and samples, design review checklist, criteria for evaluation, basic reliability formulae and conversion failure factors, guidelines for RPN calculations and designing a reasonable safe product, and diagrams, and examples of FMEAs with linkages to robustness.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Total Quality Management
• Quality Control
• Gestion et management
• Quality control (disambiguation)
• Reliability
• Statistics
• Measurement
• Economics

Informations

• Publié par: ASQ Quality Press
• Date de parution: 07 mai 2003
• Nombre de lectures: 0
• EAN13: 9780873895743
• Langue: English
• Poids de l'ouvrage: 2 Mo

Extrait

Failure Mode and Effect Analysis
FMEA from Theory to Execution
Second Edition
Revised and Expanded
D. H. Stamatis
ASQ Quality Press
Milwaukee, Wisconsin
American Society for Quality, Quality Press, Milwaukee 53203
2003 by ASQ
All rights reserved. Published 2003
Library of Congress Cataloging-in-Publication Data
Stamatis, D. H., 1947-
Failure mode and effect analysis : FMEA from theory to execution / D.H. Stamatis.-2nd ed.
p. cm.
Includes bibliographical references and index.
ISBN 0-87389-598-3
1. Reliability (Engineering) 2. Quality control. I. Title.
TS176.S7517 2003
620'.00452-dc21 2003005126
No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.
Publisher: William A. Tony
Acquisitions Editor: Annemieke Koudstaal
Project Editor: Paul O Mara
Production Administrator: Gretchen Trautman
Special Marketing Representative: Robin Barry
ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange.
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To my wonderful wife Carla Jeanne, daughter Christine, and sons Cary, Stephen, and Timothy
Table of Contents
List of FMEA Samples Found in Appendix D
List of Figures
List of Tables
Preface
Acknowledgements
Introduction
Chapter 1. Legal Approach to Liability
A Legal Approach to Liability
What Is Product Liability?
What Is a Product?
The Defect Requirement
The Legal Process
Legal References
References
Chapter 2. FMEA: A General Overview
Critical or Significant Characteristics or Key Indicators
The Four Types of FMEAs
Relationships of FMEA and Other Tools
Who Is Responsible and Controls the FMEA?
Quantitative Techniques
Qualitative Techniques
References
Chapter 3. The Language of the FMEA
Vocabulary of the FMEA
References
Chapter 4. Teams and Team Mechanics of FMEA
What Is a Team?
Why Use a Team?
About Consensus
Team Process Check
Handling of Difficult Individuals
Problem Solving
Planning the Meeting
In-Process Meeting Management
Avoiding Common Meeting Pitfalls
Utilizing the Meeting-Management Guidelines
References
Chapter 5. System FMEA
Step-by-Step System FMEA Analysis
Recommended Team
References
Chapter 6. Design FMEA
Step-by-Step Design FMEA Analysis
Recommended Team
References
Chapter 7. Process FMEA
Step-by-Step Process FMEA Analysis
Recommended Team
References
Chapter 8. Service FMEA
Step-by-Step Service FMEA Analysis
Recommended Team
References
Chapter 9. Machine FMEA
Summary Steps of Conducting the FMEA
References
Chapter 10. FMEA and the Electromechanical Industry
Uses of FMEA
Limitations of FMEA
The Principles of FMEA
Information Necessary to Perform the FMEA
References
Chapter 11. FMEA and Computers: Hardware and Software
A System Approach to Implementation
References
Chapter 12. FMEA and the Semiconductor Industry
References
Chapter 13. FMEA and the Medical Device Industry
References
Chapter 14. FMEA and the Automotive Industry
Definition of FMEA
The FMEA Form
Special Automotive Characteristics
Driving the Action Plan
Getting the Most from FMEA
After the FMEA
References
Chapter 15. FMEA and ISO 9000
References
Chapter 16. Six Sigma and FMEA-Design Review
General
Quality System Assessment (QSA)-Product Development (PD)
Applicability and Scope
Design Review Fundamentals
Design Review Operation
QSA Scoring Guidelines
References
Chapter 17. FMEA and Robustness
References
Chapter 18. An Overview of Some Typical Tools Used in FMEA 391
Tools/Methodologies
Forecasting Rules of Thumb
Epilogue
Glossary
Selected Bibliography
Appendix A. Formulae
Appendix B. Sample Checklist for Design Review
Appendix C. Active Verbs and Nouns Used for Function
Appendix D. FMEA Samples
Appendix E. FMEA Forms
Appendix F. Guidelines for RPN Calculations and Different Scales
Appendix G. Guidelines for Designing the Reasonably Safe Product
Appendix H. Linkages of FMEA
Appendix I. Example of a Concern Resolution, a Block (Boundary) Diagram, a Function Tree, and a P-Diagram for a Spark Plug
List of FMEA Samples Found in Appendix D
All samples are real and represent a variety of different industries. Due to their proprietary nature, changes were made to eliminate company identification. Some of the FMEAs are still being developed and do not have all the columns filled or are only partly presented.
System FMEA
Example 1. Sample of a generic system FMEA
Example 2. Fidd Quad LSD
Design FMEA
Example 3. Throttle body machine
Example 4. Package/layout
Example 5. Armature
Product Design and Development FMEA
Example 6. Cooling fan assembly
Process FMEA
Example 7. Nitride etch
Example 8. Slit base laminate
Example 9. GDS assembly
Service FMEA
Example 10. Complaint diagnosis
FTA Development
Example 11. FTA development of an air pumping system
Machine FMEA
Example 12. Machine FMEA: modular oven
List of Figures
I.1 . Loss control sequence
I.2 . Pressures leading to overall perception of risks
2.1 . FMEA interrelationships
2.2 . The road map of product engineering and FMEA
2.3 . Evolution of design
2.4 . An alternate FMEA construction
2.5 . Different distributions
2.6 . Types of FMEAs
2.7 . Fault tree gate symbols
2.8 . Fault tree event symbols
2.9 . FTA and FMEA (possible specific failures)
2.10 . FTA for engine (incomplete)
2.11 . Block diagrams and logic diagrams
2.12 . Schematic diagram
2.13 . Reliability functional diagram
2.14 . Sketch layout diagram
2.15 . An example of a typical control plan
2.16 . A different format of a control plan
2.17 . QFD-the impetus for planning
2.18 . The four phases of QFD
2.19 . The production planning matrix
2.20 . Cowboy after OSHA
3.1 . Levels of failure modes
4.1 . Teams and great expectations
5.1 . Relationship of system, design, and process FMEA
5.2 . Relationship of system, assembly, and part FMEA
5.3 . Relationship of system, design, and service FMEA
5.4 . A form for system FMEA
5.5 . Reliability bathtub curve
5.6 . Cases of no-failure performance
5.7 . Catastrophic and degradation failures and their effects on output
6.1 . A form for design FMEA
6.2 . Function evaluation worksheet
6.3 . Part deployment
6.4 . Cost effectiveness
7.1 . Relationship of a process FMEA in an iteration mode of failure identification
7.2 . A form for process FMEA
8.1 . The relationship of a service FMEA in an iteration mode of failure identification
8.2 . A form for service FMEA
9.1 . An example of a machinery FMEA
10.1 . Criteria for a product
10.2 . Cause-and-effect diagram
11.1 . Software failures
11.2 . IBM s 12 biggest PC blunders
11.3 . Software structure overview for FMEA application
14.1 . Early planning through FMEA and quality lever
14.2 . The Kano model
14.3 . Scope for DFMEA-braking system
14.4 . Scope for PFMEA-printed circuit board screen printing process
14.5 . A typical FMEA header
14.6 . A typical FMEA body
14.7 . Function tree process
14.8 . Function tree for a ball point pen
14.9 . A typical format for the failure mode analysis
14.10 . Failure modes in the FMEA form
14.11 . Effects positioned in FMEA form
14.12 . Causes and their ratings placed on the FMEA form
14.13 . Current controls and their rating placed on the FMEA form
14.14 . RPN placed on the FMEA form
14.15 . Action plans and results analysis
14.16 . Record final outcomes in the action plan and action results
14.17 . FMEA to control plan
14.18 . The learning stages
14.19 . Example: pen assembly process
17.1 . A typical boundary structure
17.2 . A typical interface matrix
17.3 . A typical P -diagram format
17.4 . A typical characteristic matrix
A.1 . Reliability block diagrams
A.2 . Development of block diagrams from system to units
B.1 . Typical process flow diagram of system development process
B.2 . Process flow diagram of typical considerations of a new product to be produced
B.3 . Design FMEA procedure
B.4 . Process FMEA interrelationships
B.5 . Reliability growth in terms of contract milestones
E.1 . A generic FMEA form
E.2 . A generic FMEA form
E.3 . A generic FMEA form
E.4 . A design FMEA form
E.5 . A design FMEA form
E.6 . A process FMEA form
E.7 . A design FMEA form
E.8 . A process FMEA form
E.9 . A process FMEA form
E.10 . The recommended standard design form for the automotive industry
E.11 . The recommended standard process form for the automotive industry
E.12 . A design FMECA form
E.13 . A process FMECA form
E.14 . An FMEA and causal analysis form
E.15 . An FMEA and value engineering analysis form
H.1 . Process flow diagram for a coffee chopper
H.2 . A basic control system
H.3 . Boundary diagram of the mounted enclosure assembly
H.4 . Wall mounted enclosure P -diagram
H.5 . Wall mounted enclosure interface matrix
H.6 . Wall mounted enclosure-design
H.7 . Example of a process FMEA
I.1 . Block diagram
I.2 . Function tree
I.