Effective FMEAs

CARL S. CARLSON is a consultant and instructor in the areas of FMEA, reliability program planning, and other reliability engineering disciplines. He also currently supports clients of ReliaSoft Corporation. He has thirty years' experience in reliability testing, engineering, and management positions, including manager of product reliability at General Motors. He co-chaired the cross-industry team that developed the commercial FMEA standard (SAE J1739, 2002 version) and was a past member of the Reliability and Maintainability Symposium (RAMS) Advisory Board. He holds a BS in mechanical engineering from the University of Michigan and is a Certified Reliability Engineer.

• Series Editor’s Foreword xviiCopyrights and Permissions xixAcknowledgments xxiIntroduction xxiiiChapter 1 The Case for Failure Mode and Effects Analysis 1In This Chapter 11.1 The Need for Effective FMEAs 11.2 FMEA Application by Industry 41.3 The Factor of 10 Rule 51.4 FMEA Successes 61.5 Brief History of FMEA 81.6 FMEA Standards and Guidelines 81.7 How to Use This Book 91.8 Web Companion to Effective FMEAs 101.9 End of Chapter Problems 10References 11Chapter 2 The Philosophy and Guiding Principles for Effective FMEAs 12In This Chapter 122.1 What Is Philosophy and Why Does It Matter to FMEAs? 122.2 Guiding Principles for Effective FMEAs 132.3 The Role of FMEA in Design for Reliability 172.4 You Can’t Anticipate Everything 182.5 End of Chapter Problems 19References 20Chapter 3 Understanding the Fundamental Definitions and Concepts of FMEAs 21In This Chapter 213.1 Definition of FMEA 213.2 Primary Objective of FMEA 223.3 Definition of Failure Mode Effects and Criticality Analysis 223.4 Types of FMEAs 233.5 FMEA Definitions and Examples 253.6 Is It a Failure Mode, Effect, or Cause? 483.7 FMEA Glossary 493.8 Web Companion to Effective FMEAs 513.9 End of Chapter Problems 51References 55Chapter 4 Selection and Timing of FMEA Projects 56In This Chapter 564.1 Guidelines for When to Do FMEAs 564.2 FMEA Project Selection Criteria 584.3 Preliminary Risk Assessment 594.4 When to Do Different Types of FMEAs 604.5 Responsibility for FMEAs between OEMs and Suppliers 624.6 Introducing the All-Terrain Bicycle Case Study 634.7 End of Chapter Problems 64Chapter 5 How to Perform an FMEA Project: Preparation 66In This Chapter 66Use of the Bicycle Examples in the Chapter 665.1 The Subject of FMEA Preparation 675.2 Preparation Tasks Done Once for All FMEA Projects 675.3 Preparation Tasks for Each New FMEA Project 785.4 End of Chapter Problems 103References 106Chapter 6 How to Perform an FMEA Project: Procedure 107In This Chapter 107Use of the Bicycle Examples in the Chapter 1076.1 FMEA Procedure Sequence of Steps 1086.2 Basic FMEA Procedure 1096.3 FMEA Linkages 1526.4 End of Chapter Problems 158References 161Chapter 7 How to Develop and Execute Effective Risk Reduction Actions 162In This Chapter 162Use of the Bicycle Examples in the Chapter 1627.1 Prioritize Issues for Corrective Action 1637.2 Develop Effective Recommended Actions 1657.3 Action Strategies to Reduce Risk 1667.4 Examples of Recommended Actions 1767.5 FMEA Execution Enablers 1767.6 The Essence of Execution 1827.7 Documenting Actions Taken 1827.8 Ensuring Risk Is Reduced to an Acceptable Level 1837.9 End of Chapter Problems 183References 186Chapter 8 Case Studies 187In This Chapter 1878.1 Case Study: Shock Absorber Assembly 1888.2 Case Study: Strudel Pastry Manufacturing 1908.3 Case Study: Motorola Solutions “Press-to-Talk” Feature 1938.4 Case Study: Flashlight 2008.5 Case Study: DC-10 Cargo Door Failure 2008.6 Case Study: Space Shuttle Challenger O-Ring Failure 2048.7 Case Study: Projector Lamp 2068.8 Case Study: All-Terrain Bicycle 2068.9 Case Study: Resin Lever 2138.10 Case Study: Power Steering 2178.11 Other Case Studies and Examples 2178.12 Web Companion to Effective FMEAs 2218.13 End of Chapter Problems 221References 224Chapter 9 Lessons Learned for Effective FMEAs 226In This Chapter 2269.1 The Most Common FMEA Mistakes: How to Avoid Them and Audit Them 2269.2 Summary of FMEA Quality Objectives 2359.3 FMEA Quality Audit Procedure 2359.4 End of Chapter Problems 236Chapter 10 How to Facilitate Successful FMEA Projects 241In This Chapter 24110.1 FMEA Facilitation 24110.2 Effective Meetings 24210.3 Primary FMEA Facilitation Skills 24310.4 Unleashing Team Creativity 25210.5 FMEA Facilitation Roles and Responsibilities 25510.6 How to Reduce FMEA In-Meeting Time 26110.7 Difficulty Getting Consensus on Competing Ideas 26110.8 End of Chapter Problems 263References 265Chapter 11 Implementing an Effective Company-Wide FMEA Process 266In This Chapter 26611.1 What is a Company-Wide FMEA Process and Why is it Important? 26611.2 Management Roles and Responsibilities 26711.3 Effective FMEA Process 26811.4 Lessons Learned in Implementing a Company-Wide FMEA Process 27911.5 Company Climate for Sharing Failure Information 28111.6 End of Chapter Problems 282Chapter 12 Failure Mode Effects and Criticality Analysis (FMECA) 285In This Chapter 28512.1 Introduction to FMECA 28512.2 When to Use FMECA 28612.3 Brief History of FMECA 28612.4 Types of FMECA 28712.5 Quantitative Criticality Analysis 28712.6 Qualitative Criticality Analysis 28912.7 FMECA Criticality Matrix 29212.8 FMECA Worksheet 29212.9 Summary Output of FMECA 29212.10 End of Chapter Problems 294References 296Chapter 13 Introduction to Design Review Based on Failure Mode (DRBFM) 297In This Chapter 29713.1 What Is DRBFM? 29713.2 Change Point Analysis 30013.3 Conducting DRBFM Projects 30213.4 How DRBFM Integrates with FMEA 30413.5 DRBFM Worksheet 30413.6 DRBFM Examples and Case Studies 30413.7 Design Review Based on Test Results 30913.8 DRBFM Glossary 31113.9 DRBFM Resources for Further Study 31213.10 End of Chapter Problems 313References 315Chapter 14 Introduction to Fault Tree Analysis (FTA) 316In This Chapter 31614.1 What Is Fault Tree Analysis? 31614.2 FTA and FMEA 31714.3 Brief History of FTA 31814.4 Models 31814.5 Events and Gates 31814.6 FTA Example 31914.7 FTA Glossary 32014.8 FTA Procedure 32314.9 FTA Handbooks and Standards 32414.10 Use of FTA on Software 32414.11 FTA Benefits and Limitations 32414.12 End of Chapter Problems 326References 327Chapter 15 Other FMEA Applications 328In This Chapter 32815.1 Reliability-Centered Maintenance 32815.2 Hazard Analysis 34015.3 Concept FMEA 34715.4 Software FMEA 34815.5 Failure Modes, Mechanisms, and Effects Analysis 35615.6 Failure Modes, Effects, and Diagnostic Analysis 35815.7 End of Chapter Problems 361References 363Chapter 16 Selecting the Right FMEA Software 365In This Chapter 36516.1 Characteristics of Excellent FMEA Software 36516.2 Why Not Just Use Spreadsheet Software? 36816.3 Advantages of Relational Database 36816.4 Using the Criteria for Selecting Relational Database Software 36916.5 End of Chapter Problems 369Reference 370Appendices 371Appendix A FMEA Scales 371Appendix B FMEA Worksheet Forms 376B.1 Design FMEA Worksheet Forms 377B.2 Process FMEA Worksheet Forms 382Appendix C All-Terrain Bicycle Documents 388Appendix D Lists and Checklists 392D.1 FMEA Preparation Checklists 392Checklist 393D.2 Lists of Failure Mechanisms (excerpts from book) 396D.3 FMEA Quality Objectives 399D.4 FMEA Facilitation Checklists 400D.5 FMEA Action Strategy Checklist 405D.6 FMEA Quality Audit Procedure 409D.7 FMEA Quality Survey Form 413Appendix E FMEA Glossary 414References 418Index 419