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  • Production Optimization With Process-FMEA

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    Mr. Black Jack
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    Process-FMEA should uncover any significant potential for mistakes by manufacturing of a specific product or sub-assembly. The individual error possibilities have to be clarified with regard to the impact to the end-user and the probability that the error is not discovered prior to delivery to the customer. The tool can be used to identify the "LEAN" potential to reduce waste and unnecessary work operations.

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    Process-FMEA should uncover any significant potential for mistakes by manufacturing of a specific product or sub-assembly. The individual error possibilities have to be clarified with regard to the impact to the end-user and the probability that the error is not discovered prior to delivery to the customer. The tool can be used to identify the "LEAN" potential to reduce waste and unnecessary work operations.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    35 views4 pages

    Production Optimization With Process-FMEA

    Uploaded by

    Mr. Black Jack
    Process-FMEA should uncover any significant potential for mistakes by manufacturing of a specific product or sub-assembly. The individual error possibilities have to be clarified with regard to the impact to the end-user and the probability that the error is not discovered prior to delivery to the customer. The tool can be used to identify the "LEAN" potential to reduce waste and unnecessary work operations.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 4

    Product-Quality ApS

    Products and Processes

    ProductionOptimizationwithProcessFMEA
    ForsomecompaniesProcessFMEAisimplementedasatooltoidentifypotential failuresinproduction,becausecustomersdemandit.Thetoolcanalsobeusedto identifythe"LEAN"potentialtoreducewasteandunnecessaryworkoperations. ThisarticledescribeshowtheProcessFMEAtoolisusefullybeingappliedtoredu ceproductioncostsbyoptimizingprocessesandmethods.
    TheprimarypurposeofProcessFMEA AsuccessfulProcessFMEAshoulduncoveranysignificantpotentialformistakesbymanufacturing ofaspecificproductorsubassembly.Theindividualerrorpossibilitieshavetobeclarifiedwith regardtotheimpacttotheenduserandtheprobabilitythattheerrorisnotdiscoveredpriorto deliverytothecustomer. ProcessFMEAshouldbeconductedearlyinthedesignphasetoallowproductiontoinfluence productdesigninordertoorganizeaflawlessandcosteffectivemanufacturing. WhatrevealsacompletedProcessFMEA? Basedonadetailedassessmentofeachpotentialfailureandtheirrelativeprioritization,the opportunitiestoreducetheimpacttotheenduserandincreasetheprobabilitythattheerroris discoveredpriortodeliverytothecustomer. Asabasisforidentifyingthevariouspossibleerrorsandtheirconsequencesandprobabilities,itis necessarytoanalyzethemanufacturingprocess,themethodsandtoolsusedinthemanufactu ringoftheproduct. Thedetailedreviewofthemanufacturingprocessoftenshowsthatdifferentemployeesuse slightlydifferentmethodsandtoolsincludingcriteriaforassessingthequalityoftheworkcarried out. Thisdiversityfrompersontopersonisaclearindicationthatthereisvariationintheproduction methodsandassessmentcriteriawithriskofvariationinthequalityandtheextraproduction costs. WhichtypesofwasteareidentifiedwithProcessFMEA? Theproductionmethodsandassessmentcriteriausedcanusuallybereducedtoonesetof methodsandassessmentcriteriainordertoreducepossibleerrorsandeliminateredundant operationsthatdonotaddvalue. Typicalwastetypesare: Partsorsubassembliesfromsubsuppliersarecheckedasecondtimetobesure

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    Product-Quality ApS
    Improperoperationsequence Usingthewrongtool Dirtyenvironmentspollutetheproduct Inadequatemaintenanceofprocessequipment We/Ihavealwaysdoneitthisway

    Products and Processes

    Howtoharvestthebenefits? Re.subcontractors: Inprinciple,deliveriesfromsubsuppliersshouldbeerrorfree.Ifthequalityfromsubsuppliersis notdeemedtobesufficientlystableatanacceptablelevelitshouldberequiredthatthesubsup pliertakesthenecessarymeasurestomeettherequirementsforthequalityofthedelivered items. InthiscontextitwillbeobvioustorequiresupplierstoimplementaprocessFMEAandthatthe customerbecomesawareofthecontentandtheconcreteactionstakenbythesubsupplierto ensureaconsistentandacceptablequality. Ifitisrequiredtocarryoutinspectionsandtestsofthesubsupplierdelivereditemsitshouldbein accordancewithwritteninstructionswithobjectiveacceptancecriteriaandshouldnotbebased oneachoperator'sassessmentasthiswillresultinvariationinqualityandcost. Re.OperationOrder: Itisimportantthattheoperationsequenceispreciselydefinedanddocumented.Duringthe selectionoftheoperationsequenceitmustbecarefullyevaluatedwhetherthereareseveral alternativeapproaches,sothemostappropriateandefficientsequencecanbedecidedupon. Itisessentialthatoperatorswithpracticalexperienceareinvolvedindeterminingtheoperational sequence,asthisalsosupportsthatworkiscarriedoutaccordingtothedefinedproceduresand methodsafterwards. Identificationanddeterminationofoperationsequenceandthemethodsusedisanessential prerequisitetoimplementanoptimumprocessFMEA. Re.Useofpropertools: Duringdeterminingoftheoperationsequence,itshouldalsobedeterminedwhattoolsand possibleassistivedevicesthatisrequired.Iftoolsincludingrequiredadjustmentsarenotprecisely defined,itislikelythatvariationwilloccurinboththequalityoftheproduceditemsandthe processingtimeconsumed. Identificationanddefinitionoftoolsisanessentialprerequisitetoimplementanoptimum processFMEA.

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    Product-Quality ApS
    Re.Cleanintheproductionenvironment:

    Products and Processes

    Itisimportantthatthemanufacturingenvironmentiskeptsufficientlycleansothatadditional cleaningoftheproduceditemsiskepttoaminimum.Theusageofcompressedairforcleaningisa goodexamplewherethereisamajorriskthatdirtismovedfromonesubassemblytoanother withextracleaningtofollow. Re.Maintenanceofprocessequipment: Mostprocessequipmentrequiresmaintenance,anditisimportantthattheseactivitiesare implementedaccordingtoaprescribedplan,soaccidentalstoparereducedtoaminimum. Breakdownofprocessequipmentoftenleadstodeviationfromtheplannedprocesssequence, andcouldresultintheusageofequipmentortoolsthatarenotapprovedinadvanceforthe manufacturingoftheapplicableassemblies. Adherencetostrictdeliverydeadlinesinconnectionwithdisruptionsinproductioncansometimes resultininsufficientqualityoftheproduceditemsandextramanufacturingcosts. Re."We/Ihavealwaysdoneitthisway: Inadditiontoallthetechnicalstuff,there'salsothehumanfactorsthatmustbehandledinan appropriatemanner. Hereistheinvolvement,commitment,motivationandownershipcrucialtoensureauniformcost optimalmanufacturingofconsistentlyhighqualityassemblieswithoutunnecessaryadditional operationsandrework. MeasurementandReporting Itisimportanttodefinetargetsforimprovementstosuchimportantissuesascost,qualityand delivery,anddefinethemeasurementsystemanditsreporting. Statusandprogressinrelationtotheobjectivesshouldbevisibletoallwhohaveresponsibilityfor andcaninfluenceontheresults.Reportingshouldincludeatleastthefollowingareasandbeheld upagainstthetargets: Deliveryperformance Manufacturingcostsasanindex Qualityintermofinternaldefectsandcustomercomplaints

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    Product-Quality ApS
    AgnerHansen Processconsultant ProductQualityApS www.productquality.dk agner@productquality.dk

    Products and Processes

    www.product-quality.dk

    Side 4 af 4

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