In your company, you might have seen disappointments with a lot of expenses. With the innovation of new methods daily, identification of failure is as significant as ever. These new methods habitually assurance raised competence through decreased headcount. This happens in scenarios such as:
- A new method or system
- A new application design
- The component in the industrial space
- Robotic systems
Suppose these items failed then what impact will occur? Introducing FMEA will help in calculating the probability and seriousness of any failure. Process engineering, quality, and regular enhancement these are the few examples where FMEA analyses are widely used. They have also entered their foot to Information Technology in automation applications. They are created in such a way that to offer engineers, in association with Experts, the prospect to make a quantitative analysis of how one mode of disaster can impact on the whole system.
Suggested read: What is lean six sigma and levels of six sigma belts
When to do FMEA (Failure Mode and Effects Analysis)?
A very common question always asked before starting the continuous development process is when FMEA is needed? FMEA is used for new development to test bugs, prospects, and difficulties to the product related to that particular item. FMEA is also implemented to achieve specific productivity or quality KPI. This is the place where an FMEA must be very effective. It is also an effective method for providing a cultural tool for continuous improvement in your department or team.
An important factor of a successful FMEA execution is to get the process owner from another department before analysis. Also, it is necessary to consider the inputs and suggestions from these participants during the process of analysis. Moreover, it is very obvious to do an FMEA regularly throughout the process cycle. It is required to observe and schedule based on modifications in the company over time. It is very crucial in the case where services have a high severity and risk to the business if it flops.
While implementing an FMEA identifies the function in question and what it is an inclined purpose. For instance, give friction with rubbing to an element to polish out inadequacies to its surface is the basic function of polishing wheel. Next, assume possible Failure Modes for the process.
When the expected results not matched with the associated requirements after the operation or process then failure mode occurred. Failure modes occur because of the incapability to produce a result in the defined limits, or improper execution, unsatisfied performance.
Causes for failure modes in the above polishing example might be battery supply (low or dead), improperly lubricated machine components to rotate the wheel. With the reason described, now you are able to evaluate its impact and give a Severity to the affected failure mode – the very first step is the calculation of the Risk Priority Number (RPN).
Risk Priority Number (RPN)
Calculation of RPN is one of the essential factors for the successful implementation of FMEA. There are different methods to calculate RPN, and the old-style way is one. The old way contains allocating an arbitrary number to every activity stage within an assigned system.
And the factors are:
- SEV: The weights of severity
- OCC: Occurrence
- DET: Detection
These factors calculate the RPN number and must be measured for any healthy design or process connected to FMEA. The formula for RPN is
Also read: Success factors of lean six sigma
RPN = Severity x occurrence x detection
For the figure of Severity, discuss with your Kaizen team what the cost to the customer is because of this defect? Lean six sigma principle is to always try to bring your hard work back to the customer. It might be because of not achieving the production rate or time given by the customer.
It may consist of legal risk, safety regulations, or damage to organization reputation. Does this disaster discontinue a production line altogether? If the answer is yes, then it might be taken a 10 on your severity metric, but only if the part is an only one point of failure. Observe if this failure impacts the whole production or only part of the production.