E6S-124 Score! - FMEA 10*10*10 Part 3

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Intro:  Welcome to the E6S-Methods podcast with Jacob and Aaron, your weekly dose of tips and tricks to achieve excellent performance in your business and career.  Join us as we explore deeper into the practical worlds of Lean, Six Sigma, Project Management and Design Thinking.  In this episode number 124, we Score! in this part 3 in our FMEA 10*10*10 series. If you like this episode, be sure to click the "like" link in the show notes.  It's easy.  Just tap our logo in the artwork, click and you're done. Tap-click-done!  Here we go. http://bit.ly/E6S-124 Leave a Review! http://bit.ly/E6S-iTunes


***FMEA 10-10-10 - Explodes Repeatedly Without Warning***                                                     

I            Failure Modes and Effects Analysis(FMEA) – Risk assessment technique to breakdown products, processes, services, etc. to detailed functional level to analyze potential points of failure.  Prioritizes where to focus.

II         Recall: PFMEA Procedure

a.       List process steps individually

b.      Brainstorm the potential failure modes and effects of those failures for each step (may be multiple)

c.       Score the Severity of the effects –

i.      High Severity (10) linked to safety issues, down to low severity (1), more of a “nuisant” loss or minor inconvenience

d.      Identify potential root causes (mechanisms) for the failure mode

e.       Score the Occurrence based on the probability of the root cause (if known) or the failure mode

i.      High Occurrence (10) means extreme probability of occurring.  Linked to process capability (yield or failure data), or similar designs. Low Occurrence (1).  Never happened and highly unlikely to happen (black swan?)

f.       Identify the controls in-place to detect or prevent the failure effects

g.      Score the Detection based on the quality of the control system to detect or prevent the problem

i.      Low Detection (10) indicates the error is likely to not be captured before the outcome severity is realized.     

h.      Multiplied together – Risk Priority Number (RPN = SEV*OCC*DET)

i.      (10*10*10) Explodes Repeatedly Without Warning - Highest possible risk (RPN = 1000)

1.      Extreme Severity – 10 (serious injury or death)

2.      High Occurrence – 10 (commonplace, everyday)

3.      Low Detectability – 10 (by surprise, without warning)         

III      Various Scoring Methods

a.       General

i.      Extremely subjective

b.      Ford (one of several Ford scoring rubrics)

i.      Very detailed

ii.      Automotive oriented

iii.      Different points of views for severity (Customer, and Manufacturing)

1.      High severity linked to Operator safety or serious machine (capital) damage, or product safety

c.       Society for Quality Engineers

i.      Not too detailed. Fairly straightforward.

ii.      Some Quality specific language (more difficult for front-line team)

iii.      Occurrence based on timeline, rather than only probability (more relatable scale)


d.      AIAG

i.      Very detailed

ii.      Quality specific language (occurrence based on Cpk)

iii.      Detection extremely precise in capturing failures (realistic?)

e.       CompanyStandard

i.      Pfizer - anecdotally, tried to standardize across several R&D groups in different geographies (after the fact); to cross-compare and combine separate FMEAs

1.      The idea of effectively standardizing seems unlikely, even if using the same rubric

a.       different contexts

b.      different group dynamics

c.       different scopes of work

d.      natural variation (attribute agreement)

f.       Customized to Project

i.      Solar wafer cutting - Modified from AIAG

1.      translated to product specific language, relatable to front line

ii.      Chemical Manufacturing

1.      Modified from AIAG

2.      Relatable to front line workers

3.      Severity extended to production schedule, not just product quality

Outro: Thanks for listening to episode 124 of the E6S-Methods podcast. Don't forget to click "like" or "dislike" for this episode in the show notes. Tap-click-done!  We love hearing from our listeners and learning about how you use Lean and Six Sigma.  Feel free to email us, aaron@e6s-methods.com, or contact us through our website, we reply to all messages.  Reviews on iTunes are always appreciated and keeps us higher in the ranks and allows us to reach more superstars like you.  Don't forget to you can find notes and graphics for all shows and more at www.E6S-Methods.com. "Journey Through Success. If you're not climbing up, you're falling down?    Leave a Review! http://bit.ly/E6S-iTunes

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