Failure Mode Effects Analysis(FMEA) Abbr. Version DTQS-NPQ July 2000 Proprietary Material of Duracell Global Business Management Group 2 FAILURE What’s the failure Failure class Failure occurrence What’s the reason for failure Proprietary Material of Duracell Global Business Management Group 3 Questions? FAILURE Proprietary Material of Duracell Global Business Management Group 4 Failure Mode Effects Analysis FMEA A systematic group of activities intended to: Recognize the potential failure(s) of a product or process and the severity of effect of that failure(s). Identify critical characteristics. Rank order potential design and process deficiencies. Identify actions that can eliminate or reduce the chance of the potential failure from occurring and reaching the customer. Document the process. Proprietary Material of Duracell Global Business Management Group 5 FMEA Purpose To eliminate the cause of failure …if this is not possible reduce how often the failure occurs improve the ability to detect the failure before it reaches the customer Proprietary Material of Duracell Global Business Management Group 6 FMEA History and Types History 50’ Fighter Plane Design 60’ Apollo Plan 70’ Automobile/Medical Instrument 80’ Micro-electronic 90’ QS9000, ISO9000 Types DFMEA PFMEA Proprietary Material of Duracell Global Business Management Group 7 Process FMEA Form Proprietary Material of Duracell Global Business Management Group 8 Process FMEA Flow Proprietary Material of Duracell Global Business Management Group 9 Process FMEA Flow Team Selection Calculate Risk Numbers Define Process Detail Failure Mode Causes Effects Build Pareto Chart Develop Recommended Actions Proprietary Material of Duracell Global Business Management Group 10 Process FMEA Team Selection Cross Functional and Multilevel Operators, Mechanics, Engineers, Leaders Team Leader Designated Recommended to be Process Owner Must be Empowered to implement actions Functional experts can be pulled in as needed Smaller “Core” group may be useful initially to provide framework. Proprietary Material of Duracell Global Business Management Group 11 Process FMEA Flow Team Selection Calculate Risk Numbers Define Process Detail Failure Mode Causes Effects Build Pareto Chart Develop Recommended Actions