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Section V, Projects, Tools

and Results

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Individually Given your sample of M&Ms, build a

Pareto diagram by color Before you destroy the evidence, be

sure you have an accurate count of each color and the total number of M&Ms.

Brown =Red =Yellow =Blue =Orange =Green =

------------------------ Total=

Exercise

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Pareto Chart Exercise

30 100%

2890%

26

24 80%

2270%

20

18 60%

1650%

14

12 40%

1030%

8

6 20%

410%

2

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Define (Key Milestones)

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Measure Analyze (Key Milestones)

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Improve Control

(Key Milestones)

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A finished document (i.e., unit) contains a total of 4 critical entries (i.e., a critical entry is an opportunity for a defect, mistake, or error). An inspection of 3,000 documents revealed a total of 195 errors, and 94% of the documents were good (i.e., defect free).

Calculate the following:

dpu =

dpm =

dpmo =

Total Number of Defective Documents =

Total Number of Defect-Free Documents =

FPY =

σ capability =

Yield exercise

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Failure Mode – The manner in which a part or process can fail to meet specification. It is usually associated with a defect or nonconformance.

Effect – The impact on a customer if a failure mode is not prevented or corrected. The customer can be an immediate one or one downstream.

Cause – A deficiency that results in a failure mode. Causes are sources of variability associated with key process input variables.

A FMEA is best when a team prepares it. The team should be made up of people from all areas impacted by the process. The FMEA is useful in a number of applications: in determining X’s, helping to define process improvements and controls, and others.

Reference◦ AIAG – Potential Failure Mode and Effects Analysis, FMEA◦ SAE J1739- Potential Failure Mode and Effects Analysis in

Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)

Failure Mode and Effects Analysis Terms

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System FMEA is used to analyze systems and subsystems in early concept and design stages. It focuses on potential failure modes associated with the functions of a system caused by design.

Design FMEA is used to analyze products before they are release to production.

Process FMEA is used to analyze manufacturing, assembly, and transactional processes.

Product FMEA is used to analyze failure modes that could occur to the product once it gets into the customers hands.

Types of FMEA’s

FMEA: Identify ways of eliminating or reducing the specific causes and document a plan to prevent the

failures.

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Preliminary Steps in the FMEA Process

Preparation A FMEA begins with a process map.

Identify the process and map its key steps.

List the key process outputs to satisfy customer requirements.

List the key process inputs for each process step.

Define a matrix relating product outputs to process inputs.

Rank inputs according to their importance.

The goal in your preparation is to have a complete understanding of the process you are analyzing. What are its steps? What are its inputs and outputs? How do they relate?

**Information for this section taken from: GE Six Sigma Playbook and the AIAG Reference Manual.**

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FMEA Process

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Start with the high level process map for an accounts receivable process:

FMEA Example

ReceivePayment

IdentifyCustomer

IdentifyInvoice

ApplyPayment to Invoice

Start

End

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For each Process Input Variable (PIV), determine the ways in which the input can go wrong (failure modes).

There is at least one way that each input can fail.

FMEA - Step 1

Process StepKey Process

InputPotential Failure

Mode

Potential Failure Effects

SEV

Potential Causes

OCC

Current Controls

DET

RPN

Receive Payment Checks Delay internal mail

Identify Customer Wire Transfer reference line

Information not supplied

Identify Invoice Checks Incorrect invoice supplied

Identify Invoice Checks Invoice number not supplied

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For each failure mode associated with the inputs, determine effects.

These effects are internal requirements for the next process as well as customer effects.

FMEA - Step 2

Process StepKey Process

InputPotential

Failure ModePotential

Failure Effects

SEV

Potential Causes

OCC

Current Controls

DET

RPN

Receive Payment Checks Delay internal mail

AR balance does not go down

Identify Customer Wire Transfer reference line

Information not supplied

AR balance is past due

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

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Identify potential causes of each failure mode.

In most cases, there will be more than one cause for a failure mode.

FMEA - Step 3

Process StepKey Process

InputPotential

Failure ModePotential Failure

Effects

SEV

Potential CausesOCC

Current ControlsDET

RPN

Receive Payment Checks Delay internal mail

AR balance does not go down

Inadequate staffing in mail room

Identify Customer Wire Transfer reference line

Information not supplied

AR balance is past due

Customer or bank did not include name and/or account info on wire transfer

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

Customer error

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

Customer error

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List the current controls for each cause.

For each cause, we list how we are either preventing or detecting it. List the document number for any SOP’s.

FMEA - Step 4

Process StepKey

Process Input

Potential Failure Mode

Potential Failure Effects

SEV

Potential CausesOCC

Current ControlsDET

RPN

Receive Payment Checks Delay internal mail

AR balance does not go down

Inadequate staffing in mail room

None

Identify Customer Wire Transfer reference line

Information not supplied

AR balance is past due

Customer or bank did not include name and/or account info on wire transfer

Acct identifies problem when trying to apply payment

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

Customer error Customer might catch it when reviewing the next statement

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

Customer error Acct identifies problem when trying to apply payment

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The risk priority number (RPN) is the product of the rankings for:◦ Severity (SEV)◦ Probability of Occurrence (OCC)◦ Difficulty to Detect (DET)

High RPN’s are flags to take effort to reduce the calculated risk

Regardless of RPN, high severity scores (9-10) must be given special attention

Risk Priority Numbers, RPN

RPN = SEV x OCC x DET

Effects Causes

Controls

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Generic FMEA Rating table Create a rating system that

makes sense for your project, the process, and the defects

you’re trying to prevent.

Create a rating system that makes sense for your project, the process, and the defects

you’re trying to prevent.

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Assign severity, occurrence and detection ratings to each cause.

We are now ready to assign appropriate criteria. The team then starts scoring each cause to compute a risk priority number (RPN).

FMEA - Step 5

Process StepKey Process

InputPotential Failure

ModePotential Failure

Effects

SEV

Potential CausesOCC

Current ControlsDET

RPN

Receive Payment Checks Delay internal mail

AR balance does not go down

7

Inadequate staffing in mail room

7

None

10 490

Identify Customer Wire Transfer reference line

Information not supplied

AR balance is past due

10

Customer or bank did not include name and/or account info on wire transfer

5

Acct identifies problem when trying to apply payment

5 250

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

5

Customer might catch it when reviewing the next statement 10 250

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

10

Acct identifies problem when trying to apply payment

5 250

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Calculate the RPN’s and determine recommended actions to reduce high RPN’s.

High severity scores (9-10) must be given special attention.

Which issues may we want to address first?

FMEA - Steps 6

Process StepKey Process

InputPotential Failure

ModePotential Failure

Effects

SEV

Potential CausesOCC

Current ControlsDET

RPN

Receive Payment Checks Delay internal mail

AR balance does not go down

7

Inadequate staffing in mail room

7

None

10 490

Identify Customer Wire Transfer reference line

Information not supplied

AR balance is past due

10

Customer or bank did not include name and/or account info on wire transfer

5

Acct identifies problem when trying to apply payment

5 250

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

5

Customer might catch it when reviewing the next statement 10 250

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

10

Acct identifies problem when trying to apply payment

5 250

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Determine recommended actions to reduce high RPN’s.

Now fill in recommended actions for high RPN’s.

Ease of Completion (EOC) for each action is optional.

FMEA - Step 7

Process StepKey

Process Input

Potential Failure Mode

Potential Failure Effects

SEV

Potential CausesOCC

Current ControlsDET

RPN

EOC

Actions Recommended

Receive Payment

Checks Delay internal mail

AR balance does not go down

7

Inadequate staffing in mail room 7

None

10 490

Investigate mail room staffing and associated processes

Identify Customer

Wire Transfer reference line

Information not supplied

AR balance is past due

10

Customer or bank did not include name and/or account info on wire transfer

5

Acct identifies problem when trying to apply payment

5 250

Poka-Yoke wire transer process

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

5

Customer might catch it when reviewing the next statement 10 250

Provide payment stub with statement for each invoice

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

10

Acct identifies problem when trying to apply payment 5 250

Provide payment stub with statement for each invoice

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Person or group responsible should take on the Actions Recommended and document those actions. Now recalculate your RPN’s.

FMEA - Steps 8 And 9

Process StepKey

Process Input

Potential Failure Mode

Potential Failure Effects

SEV

Potential CausesOCC

Current ControlsDET

RPN

EOC

Actions Recommended

Resp. Actions TakenSEV

OCC

DET

RPN

Receive Payment

Checks Delay internal mail

AR balance does not go down

7

Inadequate staffing in mail room 7

None

10 490

Investigate mail room staffing and associated processes

G. Lee Added another mail clerk. Adjusted dock schedule. 7 1 10 70

Identify Customer

Wire Transfer reference line

Information not supplied

AR balance is past due

10

Customer or bank did not include name and/or account info on wire transfer

5

Acct identifies problem when trying to apply payment

5 250

Poka-Yoke wire transer process

N. Peart Contacted banks and established wire transfer procedure (DI 2112) 10 1 3 30

Identify Invoice Checks Incorrect invoice supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

5

Customer might catch it when reviewing the next statement 10 250

Provide payment stub with statement for each invoice

A. Lifeson Revised statement to include payment stub with each invoice. 5 1 5 25

Identify Invoice Checks Invoice number not supplied

Invoice shows outstanding (AR balance does go down)

5

Customer error

10

Acct identifies problem when trying to apply payment 5 250

Provide payment stub with statement for each invoice

S. Hagar Revised statement to include payment stub with each invoice. 5 1 5 25

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Collaborative effort: Do not try alone, perform in a group.

Action items are required for completion.

Train team ahead of time by explaining scoring criteria.

Summarize often: FMEA is a living document.

FMEA Lessons Learned

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