Week 4 - Quality In Product And Process Design (FMEA) Flashcards
What is the Kano quality/design model? *NEEDS A PICTURE**
• Level of satisfaction against requirement fulfilment
• 3 quality curves: Exciting quality, Performance quality, basic quality
3 Examples of what can go wrong in product and process design
• Samsung exploding phones 2017 - product quality failure and customer safety failure
• Horsemeat scandal 2013 - supply chain ‘quality’ failure and customer expectation failure
• Fukushima Tsunami 2011 - Safety systems failure, nuclear/environmental disaster
What questions are asked in Failure mode and effects analysis (FMEA)? (5)
• What can go wrong?
• How serious could it be?
• How likely is that?
• Will we detect it?
• Can we control it?
What is Failure modes and effects analysis (FMEA)? (2)
• Is a process that’s systematically considers each component of a system
• The process involves identifying, analysing and documenting the possible failure within that system and the effects of each failure on the system
What are the benefits of failure modes and effects analysis (FMEA)? (5)
• Improved safety, quality, reliability of products
• Improvement of a company’s image and its competitiveness
• Increased satisfaction from a user standpoint
• Reduction in product development cost
• Record of actions taken to reduce a product risk
What do we look at with FMEA? (4)
• What is the nature of the failure
• Severity (scale from 1-9) - impact of consequences of failure
• Likelihood (scale from 1-9) how likely is the failure to occur
• Detection (scale from 1, will be detected, to 9, will not be detected,) how likely will we miss detection
How do you get risk priority number (RPN)?
RPN = Severity x likelihood x detection
Interpretations of a Risk priority number (RPN) (3)
• 1x1x1 = 1 is the best case and 9x9x9 = 729 is the worst case
• Highest scores are given the highest priority
• Can’t ignore high severity even if it is unlikely and not easily detected such as plane engine failure and operating on the wrong person
5 basic areas that FMEA can be applied
• Concept - analysis systems and sub systems in its conception of design
• Process - assembly and manufacturing processes
• Design - analysis if the product before it is produced in a mass quantity
• Service - Test industrial processes for any failures prior to release to customers
• Equipment - used to analyse equipment before you purchase it
What is the process of FMEA? (9)
1 - Give each component in the system a unique qualifier
2 - List all the functions each part of the systems performs - develop a block diagram for the design descriptions
3 - List one or two failure modes for each function from the second step
4 - Describe what affects each failure mode of the component - especially from customer or operator perspective
5 - Determine whether the failure will result in a potential hazard to personnel or the system
6 - Estimate the relative likelihood of the occurrence for each failure on a 10 point scale
7 - Estimate the ease with which the failure may be detected
8 - Use the estimates from steps 5,6 and 7 to identify the highest risk related to the system
9 - Decide what action will be taken to eliminate or reduce the highest risks in the system
Example FMEA Template NEEDS A PICTURE
Pic
What are 2 important ways of dealing with failures and potential failures
• Product traceability - being able to track down any faulty services or products before it gets to the customer
• Recall procedures - having an efficient system that helps to deal with any failure that impacts the customers final product or services such as refunds , repairs and replacements
What is the consumer product safety commission (CPSC)?
Protects consumer from any unnecessary risks of death or injury by making sure that companies have a system in place that allows them to trace products and be able to recall them
3 Reliability analysis tools
• FMEA
• Fault-tree analysis
• FMECA
What is fault-tree analysis?
Is an analytical tool that graphically renders the combinations of faults that lead to system failure
