Process FMEA—Key Exercises

IMPORTANT
It is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site.

Basic Data Setup

Entering Classification Criteria

Purpose: The purpose of this exercise is to show how to set up classification criteria required for creating FMEAs.

Menu Path: Failure Modes and Effects Analysis/FMEA Basic Data/Basic Data for FMEA

  1. Open the Basic Data for FMEA window and click the Classification Criteria tab.
  2. Select a line and create a new record.
  3. Enter a value in the Class Criteria field and a description in the Class Description field (for example, Critical, Major, Key, or Minor).
  4. Enter three or four additional criteria and descriptions.
  5. Save the information.

Note: Values on the Severity Criteria, Occurrence Criteria, and Detection Criteria tabs are entered automatically, in accordance with QS-9000, when IFS Applications is installed.

General Exercise for Entering Classification Criteria

Entering Checklist Templates

Purpose: The purpose of this exercise is to show how to set up a checklist template required for creating FMEAs. Note: There is one template for process FMEAs and one for design FMEAs, as indicated by the FMEA Type field on the Checklist Templates tab. For the exercises in this lesson, you need to set up a process FMEA checklist template.

Menu Path: Failure Modes and Effects Analysis/FMEA Basic Data/Basic Data for FMEA

  1. Open the Basic Data for FMEA window and click the Checklist Templates tab.
  2. Select a line and create a new record.
  3. Enter a sequence number, checklist question, and a checklist comment.
  4. Enter additional sequence numbers, checklist questions, and checklist comments, as appropriate.
  5. Save the information.

General Exercise for Entering Checklist Templates

Required Data

Viewing Parts

Purpose: The purpose of this exercise is to view the parts that have been created for the Quality Management course and could be included in a process FMEA. If you are using the Racing TM database, all the data is already installed. Note: The exercises of this lesson only use part no. 29-321, Camshaft.

Part Name Part No. Operation   Areas of Concern
Camshaft 29-321 CNC Outer Diameter Grinding Consistent outer diameters (ODs) of bearing journals—Each camshaft has five bearing journals. The bearing journal ODs must be consistent for each camshaft and among the different camshafts, as they are being finish-ground.
Rocker Arm 29-523 CNC Milling/Boring Correct mounting hole diameters—The rocker arm must correctly actuate the valves and swivel freely when the valves open and close. If the clearance is too tight, the arm will not allow the valve to function properly, and it will generate excessive heat.
Intake Valve and Exhaust Valve 29-521 and 29-522 Compression Testing for Valve Seat Leakage Proper valve seating—Loose fit will allow compression to escape past the valve seat.

Main Exercise

Creating a Process FMEA

Purpose: The purpose of this exercise is to show how to create a process FMEA header.

Menu Path: Manufacturing Standards/Routings/Routing

  1. Open the Routing window
  2. Query part no. 29-321, Camshaft.
  3. Click the Process FMEAs tab and create a new record. 
  4. In the Alternate field, select a routing alternate from the List of Values.
  5. In the FMEA Level list, select Component.
  6. Save the information. 
  7. Verify that the FMEA status shown in the Status field has been changed to Created.

Adding a Checklist to a Process FMEA

Purpose: The purpose of this exercise is to show how to enter a checklist for a process FMEA header.

Menu Path: Manufacturing Standards/Routings/Routing

  1. Open the Routing window and query for part no. 29-321, Camshaft.
  2. Click the Process FMEAs tab.
  3. Select a line. Then right-click and click Process FMEA Checklist. The Process FMEA Checklist window appears.
  4. Enter at least one new checklist line. You can also delete checklist lines.
  5. Select the Item Approved check boxes to approve the respective checklist items. Then save the information and close the window. 
  6. In the Routing window, verify that the checklist status has changed to Approved.
  7. Query for part no. 29-321, Camshaft, in the Routing window. Verify that the checklist status has changed to Approved.

Adding Functions

Purpose: The purpose of this exercise is to show how to enter a function for a process FMEA.

Menu Path: Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Graphic

  1. Open the Process FMEA Graphic window and query for part no. 29-321, Camshaft.
  2. Expand the graphic structure shown on the left and select the routing alternate. A window appears on the right.
  3. Select a line and create a new record. Enter a function (for example, Grinding) and a function description (for example, Maintain Consistent Diameters).
  4. Save the information. The function now appears in the graphic structure on the left.

Note: You can also add a function in Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Functions.  The same window can be reached from Manufacturing Standards/Routings/Routing/Process FMEAs by right-clicking and then clicking Process FMEA Function.

Entering Failure Modes

Purpose: The purpose of this exercise is to show how to enter failure modes for a process FMEA.

Menu Path: Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Graphic

  1. Open the Process FMEA Graphic window and query for part no. 29-321, Camshaft.
  2. Select the Grinding function you just created in the graphic structure on the left.
  3. A window appears on the right.
  4. Select a line and create a new record.
  5. Enter a failure and a failure description (for example, Diameter Oversize).
  6. In the Occurrence field, select a value from the List of Values (for example, 7– High – Repeated Failures).
  7. Save the information.

Note: You can also add failure modes in Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Failures.

Entering Causes of Failure

Purpose: The purpose of this exercise is to show how to enter causes of failures for a process FMEA.

Menu Path: Manufacturing Standards/Failure Modes and Effects Analysis/Process FMEA Graphic 

  1. Open the Process FMEA Graphic window and query for part no. 29-321, Camshaft.
  2. Click the Causes tab.
  3. Select a line and create a new record.
  4. Enter a cause and a cause description (for example, Machined Incorrectly).
  5. Save the information.

Note: You can also add failure causes in Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Failures.

Entering Effects of Failure

Purpose: The purpose of this exercise is to show how to enter effects of failures for a process FMEA.

Menu Path: Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Graphic

  1. Open the Process FMEA Graphic window and query for part no. 29-321, Camshaft.
  2. Click the Effects tab.
  3. Select a line and create a new record.
  4. Enter an effect and an effect description (for example, Improper Bearing Clearance).
  5. Select a severity from the List of Values (for example, 8 – Very High).
  6. Select a classification criterion from the List of Values. 
  7. Save the information.

  8. Expand the graphic structure on the left and verify that the causes and effects have been added.

Note: You can also add failure effects in Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Failures.

Entering Controls and Recommendations 

Purpose: The purpose of this exercise is to show how to enter controls and recommendations for effects of failure.

Menu Path: Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Graphic

  1. Open the Process FMEA Graphic window and query for part no. 29-321, Camshaft.
  2. Select an effect in the graphic structure on the left (the lowest accessible level). A window appears on the right.
  3. On the Controls tab, select a line and then create a new record.
  4. Enter a control and a control description (for example, Inspection).
  5. In the Detection field, enter a value from the List of Values (for example, 2 – Very High).
  6. Save the information.
  7. Verify that a risk priority number (RPN) is shown in the RPN field. If you have used the examples in this exercise, the RPN should be 112 (8*7*2). (Severity = 8, Occurrence = 7, and Detection = 2).
  8. On the Recommendations tab, select a line and then create a new record.
  9. Enter a recommendation and a recommendation description (for example, SPC).
  10. Enter a responsible person and a target completion date.
  11. Save the information.  
  12. Expand the graphic structure on the left and verify that the controls and recommendations have been added.

Viewing a Graphic Analysis

Purpose: The purpose of this exercise is to show how to view a graphic FMEA effects analysis for a part.

Menu Path: Manufacturing Standards/Process Failure Modes and Effects Analysis/Process FMEA Effects Analysis Graph

  1. Open the Process FMEA Effects Analysis Graph window and query for part no. 29-321, Camshaft. A graph appears displaying severity and occurrence. 
  2. View the graph. The effects in the upper right corner are the most serious ones.