Why Should You Attend:
The prevailing approach to process failure mode effects analysis (PFMEA) has some drawbacks including (1) the need to estimate the nonconforming fraction or defect rate to get the Occurrence rating and (2) the Risk Priority Number (RPN), which is the product of three ordinal numbers: The Severity, Occurrence, and Detection ratings .
As an example, suppose there are two failure modes. The first has a Severity of 10, an Occurrence of 3, and a Detection of 5. The second has a Severity of 3, an Occurrence of 5, and a Detection of 10. The RPN for both is 150. While the second will reach the customer more often than the first, it can at most annoy the customer as opposed to causing death or serious injury.
The AIAG/VDA approach is synergistic with AIAG's Effective Problem-Solving process (CQI-20) which cites three root causes for any problem. The Occurrence root cause, which is the traditional focus of corrective and preventive action (CAPA), is why the trouble happened. The Escape root cause is why the problem reached an internal or external customer (if it did escape), and the Systemic root cause relates to failures in the planning process, such as failure to apply lessons learned, that did not identify the problem ahead of time. The AIAG/VDA approach uses the nature of the prevention controls, as opposed to any estimate of the nonconforming fraction, to determine the Occurrence rating. The nature of the detection controls is used similarly to determine the Detection rating.
The AIAG/VDA approach also addresses not just quality, the traditional focus of FMEA, but also continuity of operations (e.g. could the problem idle an internal or external customer's production line?) and safety. The deliverable is an Action Priority of Low, Medium, or High as a function of the Severity, Occurrence, and Detection ratings in place of the Risk Priority Number. This takes care of the issue of the RPN as the product of three ordinal numbers.
The structure of the FMEA allows a control plan to be appended to create a dynamic control plan. The control plan identifies the prevention and detection controls whose respective purposes is to disable the occurrence root cause and to prevent poor quality from reaching a customer.
Areas Covered in the Webinar:
Who Will Benefit:
William A. Levinson, P.E., is the principal of Levinson Productivity Systems, P.C. He is an ASQ Fellow, Certified Quality Engineer, Quality Auditor, Quality Manager, Reliability Engineer, and Six Sigma Black Belt. He is also the author of several books on quality, productivity, and management.
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