FMECA

FMECA stands for Failure Mode, Effects & Criticality Analysis. It is a method which involves quantitative failure analysis. Moreover, it involves creating series of linkages between potential failures, impact on the mission and the failure cause.

FMECA or FMEA

Firstly, FMEA is a bottom-up, inductive analytical method which may be performed at either the functional or piece-part level. And, FMECA extends FMEA by including a criticality analysis to chart the probability of failure modes . Most importantly, FMECA is in more trend than FMEA in space and North Atlantic Treaty Organization (NATO) military applications, while various forms of FMEA predominate in other industries.

Logical Steps- FMECA

By RAC CRTA–FMECA, the FMECA analysis procedure consists of the following logical steps

• Define the system
• Define ground rules and assumptions in order to help drive the design
• Construct system block diagrams
• Identify failure modes (piece part level or functional)
• Analyze failure effects/causes
• Feed results back into design process
• Classify the failure effects by severity
• Perform criticality calculations

Functional and Piece Part

Functional FMECA considers the effects of failure at the functional block level which includes power supply or an amplifier. Whereas, piece part considers the effects of individual component failures, such as resistors, transistors, microcircuits, or valves. Moreover, piece part FMECA requires more effort, but provides the benefit of better estimates of probabilities of occurrence. However, Functional FMEAs can be performed much earlier, may help to better structure the complete risk assessment and provide other type of insight in mitigation options.

FMECA  involves the following steps :

• Firstly, selecting process to evaluate with FMECA.
• Then, recruiting multidisciplinary team.
• After that, having the team meet together to list all of the steps in the process.
• Having team list failure modes and causes.
• For each failure mode, have the team with a numeric value which include likelihood of occurrence, likelihood of detection, and severity.
• Lastly, evaluating the results

Most importantly, use RPNs to plan improvement efforts. As, failure modes with high RPNs are probably the most important parts of the process on which to focus improvement efforts. And, failure modes with very low RPNs are not likely to affect the overall process very much.

 

DFMECA

This is basically used to analyze designs before releasing it to production. Moreover, in the DFSS algorithm, a DFMECA should always be done in advance of a prototype build. It includes outputs which are,

• Firstly, list of actions for preventing causes or detecting failure modes
• Lastly, history of actions taken and future activity.

DFMECA helps the DFSS team in

• Estimating the effects on all customer segments
• Assessing and selecting design alternatives
• Identifying the potential special design parameters (DPs) in terms of failure
• Documenting the findings for future reference

PFMECA

This is used to analyze manufacturing, assembly, or any other processes such as transactional DFSS projects. Moreover, the focus is on process inputs. Above all, it is a valuable tool available to the concurrent DFSS team to help them in,

• Identifying potential manufacturing/assembly or production process
• Prioritizing the list of corrective actions using strategies such as mitigation, transferring, ignoring, etc
• Documenting the results of their processes.

Moments of truth

Moments of truth (MoT) is a same concept as FMEA. Moreover, it is the moment in time when a customer first comes into contact with an organization, leading to a judgement about quality. Above all, Moments of Truth happens when they are not thought to occur in odd interfaces with staff and moments with products.

Uses

• Exploring the customer surface of your organization, looking for problem and issues that need resolution.
• Understanding the overall customer experience and hence understanding your real brand.
• Focus in and identify specific aspects of the customer experience that need improving.
• Understand experiences of people other than customers.

Process

• Identifying the customer surface – Customers interface with companies in many different ways and places, both formally and informally.
• Selecting the critical areas – Investigating the whole surface is impossible in a single project or session, so it is necessary to find a way to focus on areas where you can make a difference.
• Slowing down time and watch every moment – Play through the customer experience during this time in ‘slow motion’, watching for any moments in which impressions may be formed.

Learn and enhance your knowledge in FMECA related topics by applying for Certified TQM Professional exam Now!