How Six Sigma and Failure Mode and Effects Analysis Create A More Productive Business Environment

While it isn't possible to prevent every problem from occurring, it is possible to put a damper on many of them in order to eliminate the presence of unwanted issues that could potentially slow down your business' productivity. Six Sigma provides many very useful tools for doing just that. One that is frequently used in various aspects of an organization is failure mode and effects analysis otherwise known as FMEA.

FMEA is used to diagnose potential problems and find solutions before they really have an opportunity to develop. This saves organizational leaders a lot of time and money in the long run and translates into more time for normal business operations that will increase the overall level of productivity. This, in turn will increase profits which is the true aim of any corporation.

Six Sigma and FMEA are used in large organizations throughout the world and have become value tools on many levels of business. Results have shown these tools to be very successful and companies have reported their productivity levels are on the rise as a result of utilizing them.

A well documented FMEA that contains robust action plans will help companies gain a better foothold on various issues in all aspects of the company. The Implementation of these plans is what helps organizations avoid the reworking of various projects. This saves a considerable amount of time and money because the information is there that enables them to be successful the first time around.

FMEA can also be used to minimize risks. It can be applied in various services to help companies avoid certain actions that could pose problems later on in a particular project. This is one of the greatest advantages of using FMEA and Six Sigma together. There is always risk involved in every business, so the more organizations are able to eliminate these risks, the more successful they will be all around. This, of course, will spell out larger profits due to a more productive atmosphere in the end.

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Process Failure Modes and Effects Analysis (PFMEA) From the Process Flow to Production

PFMEA is a tried and tested approach to critique risk. Its purpose is simple, to identify potential failures, their consequences, the seriousness of the consequences and the reasons why they happen. Control methods are considered in two ways:

The first being activities in place which reduce the likelihood of the reasons for failure happening. The second being activities which tell you when a failure has occurred and thus enabling you to do something about it.

The overall purpose is to establish where the high risk areas are based on the current situation and then take action to reduce the risks. The approach taken and the timing of the task are instrumental to achieve maximum payback. When used correctly it is one of the singly most powerful quality tools available to companies. Process FMEA used in isolation like this is very thorough, but a missed opportunity to reap the full intended benefits of the document.

PFMEA strategy

Process Flow Diagram

The starting point is not the PFMEA but defining the process in the process flow diagram. Care must be taken here to select the correct wording and level of resolution. The output of process flow diagram must then be synchronised with the input to the PFMEA so that you critique the correct aspects of the process for risk.

PFMEA

You now compile your PFMEA in terms of failure modes, effects, severity of effects, causes of failure, prevention controls, occurrence, detection controls and their ranking followed by priority. At this stage it is still important to have recommended actions to reduce risk. However you now need to bring the PFMEA to life through the practical deployment of the content of the PFMEA to production. Primary data being the prevention controls to avoid failure and the detection controls to detect failure at the various stages of the process as defined in the process flow.

Production documents

It is essential that the primary data contained within the PFMEA is displayed at the point of use in plain view to the person who needs to know and act on the data. Failure to do this simple but necessary task will result in a company being exposed to the latent risk of a loss of process control, often resulting in customer complaints. Deployment typically is through the use of visual instructions located where the task takes place, sometimes the data flow is via the control plan (automotive sector), although this does depend of sector specific requirements.

Key points for consideration are:

Sufficient resolution of the process steps in the process flow diagram. The data contained in the process flow diagram is synchronised to the functional requirements column on the PFMEA. PFMEA is a true reflection of the current situation, as a living document. The prevention and detection controls defined in the PFMEA are communicated to the person carrying out that particular step of the process at the location where the task is undertaken. Appropriate reaction planning is identified at the process step location to clearly identify what to do if a failure is identified.
Summary

This article is intended to provide an overview of the necessary linkage of the PFMEA to achieve maximum benefit to a business who are considering the utilisation of PFMEA for the first time or are existing practitioners but don't believe they are reaping the true benefits that PFMEA can deliver.

Roger Thorpe has been an FMEA facilitator and consultant for 13 years. Many of his customers being tier 1 automotive manufacturers. For more information on PFMEA construction from an expert visit his website: http://www.fmea.org.uk

Manufacturing Insights: Failure Mode Effects Analysis (FMEA) [VHS]

This video was produced in cooperation with Robert Bosch Corporation in Farmington Hills, Michigan. The program is an introduction to the quality methodology Failure Mode Effects Analysis (FMEA). As every new product is being designed, most manufacturing companies are developing FMEA documents to reduce the risk of product failures. In addition, quality standards like ISO9000 and QS9000 require an FMEA on all new products. To shorten development cycles, many different experts are involved in the design and testing phases of new products. After viewing this tape, every person on your design team will have a good understanding of the importance of risk reduction and how the FMEA will keep track of these responsibilities. This video was design to quickly bring all the team members up to speed on how the FMEA methods and procedures will impact them. Learning Objectives: A general understanding of why companies do FMEAs; What is the difference between a product and a! process risk?; What can companies do to minimize risks?; See how FMEA documents track responsibilities to reduce risks; How an FMEA is used within Robert Bosch Corporation.

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Battery Failure Mode and Effects Analysis Part 3

In part 1 and 2 of the article series Battery Failure Mode and Effects Analysis we identified that a battery mode and effects analysis is a procedure for identifying and understanding potential failure modes in a battery system. We found that a battery mode and effects analysis contains four main steps or phases including:

Battery Mode Pre-work - explained in part 1

Battery Failure Severity - explained in part 2

Battery Failure Occurrence - explained in part 2

Battery Failure Detection

Now in part 3 of Battery Failure Mode and Effects Analysis I will address Battery Failure Detection and wrap with a summary of the article series.

Battery Failure Detection

Battery failure detection is method of inspection that is used when examining failure modes within a battery system. The method of detecting a battery failure begins with a review of existing system controls that are designed to prevent failure modes. Next comes testing, analysis, and monitoring failures. The purpose of which is to understand why a particular mode is failing. When a failure mode occurs, a detection number that represents the likelihood of detecting a failure mode, is subsequently assigned, and after a series of detections the total number of detection numbers are collected and added together to give a total score of battery failure modes; the lower the detection number is the better the overall battery system design schema.

Remember as in all of the three previous articles it has been noted that the purpose of a battery failure mode and effects analysis is to identify and understand potential failure modes in a battery system. The reason why this is so important is that customers, who provide cash-flow (the lifeblood of a company), must be satisfied. Satisfaction as it relates to batteries is the lowest possible cost while still maintaining the best possible battery product. Thus insuring the lowest possible detection number is critically important to insuring the maximum potential of a company involved in battery design, manufacturing and sales.

Battery Failure Mode and Effects Analysis Summary

Over the last three articles we looked a battery failure mode and effects analysis and learned how helpful this procedure is for analyzing potential failure modes in a battery system. Discovering potential defects in a battery design or manufacturing process is extremely helpful in controlling business expenses and losses as well helping to make more efficient the overall battery development project. A battery failure mode and effects analysis is also closely associated with six sigma methodologies and is a proactive tool for reducing errors, reducing expenses, and increasing profits. Now you could probably find a failure mode and analysis software online or you can build a custom template (that would be my preference) to suit your individual needs. Regardless, simply integrating a battery failure mode and effects analysis into your battery design process, battery manufacturing process, and battery sales process is a valuable tool in helping providing the best possible product to customers.

? Dan Hagopian
You have permission to publish this article electronically or in print, free of charge, as long as the bylines are included with link. Dan Hagopian of http://www.batteryship.com is a known electronics author that specializes in battery power technology, portable power, and handheld electronic gadgets. His work can be found on the BatteryShip blog at http://www.batteryeducation.com. Dan frequently writes about battery development, battery failures, battery usage, and battery news and information from inside the battery industry. For further information please visit BatteryShip for all battery products or BatteryEducation for more battery articles.