vda fmea overview - asq-1302 · 2020-01-21 · vda fmea action priority rules 22 - (h) highest...

VDA FMEA Overview

ASQ Section 1302 January 2020

2

Agenda

Why VDA FMEA was needed?Key Differences from AIAG FMEA7-Step VDA FMEA ProcessExerciseQ&A

Failure Modes and Effects Analysis

❑What is FMEA? A tool for proactively identifying how a product, process or system can fail (Risks) – then prioritize actions to reduce risks

❑Developed by NASA – adopted by the Automotive Ind.

❑Proactive > to be used early in the product or process development > design out or control potential failure causes

❑Living > should be reviewed regularly – drive continuous improvement

❑ PFMEA – Process FMEA – emphasizes lowering risk by error-proofing process steps (risk reduction)

Gengenbach Quality Consulting © 2019

Why was VDA FMEA needed?Business objectives that support VDA FMEA

1. Increasing quality, reliability, manufacturability and safety of Automotive products – driverless vehicles

2. Ensures the linkage, interface and alignment of requirements to internal and external customers and suppliers

3. Building a knowledge base in the company – Lessons Learned

4. Ensures compliance with regulations and customer requirements - IATF


AIAG & VDA Combined Methodologies

13-Step Process

Changes with VDA FMEA (compared to AIAG)

❑ RPN is replaced with Action Priority level (High, Medium or Low) for prioritizing risk reduction/improvement actions

❑ Greater emphasis on understanding function, and effect on critical characteristics at each process

❑ Focus on prevention controls (error proofing)

❑ Columns in former FMEA format are moved to new locations for greater emphasis

❑ 7-Step approach replaces FMEA 4th Edition 13-step approach


VDA FMEA 7-Step Process

1 Planning & Preparation

2 Structure Analysis

3 Function Analysis

4 F

ailu

re A

nal

ysis

5 R

isk

An

alys

is

6 O

pti

miz

atio

n

7 Results Documentation

System Analysis

Failure Analysis & Risk Mitigation

Risk Communication

8

VDA PFMEA Expectations

❑Clearly described potential failure modes in technically precise specific terms (use x-functional team with SMEs)

❑Consequences of failure modes are accurately described

❑Failure causes are realistic and reasonable

❑Not Considered:

❑Extreme events are not considered

❑Failures resulting from intended misuse

❑Completeness:❑Foreseeable potential failures are not concealed

9

VDA FMEA Overview

Step 1 – Planning and Preparation

– Process identification or product/process name

– Document number

– Individual and/or team responsibility for the FMEA update

– Revision level & date and original FMEA date

– Tier 1 & 2 suppliers often list production/platform info

2nd Step: Structural Analysis❑Identifies and breaks down manufacturing process into Process items,

Process Steps and Process work elements

❑Tools include tree diagram (below) or block diagram

❑Use 4Ms to determine work element (Man, Machine, Material, Method)

3rd Step: Function Analysis❑Describes what the process item or process step is intended to do

❑Identify all the functions performed at the process step and how this function relates to:

1) The next higher levels

2) Impact on product characteristics

ProcessInputs Outputs

Control Factors

Noise Factors

Process Item

4th Step: Failure Analysis❑ Identify how the focus element process can go wrong

(Failure Modes), effects on product and process (failure effects), severity of the effects and causes impacting:

1. End-product performance (Product Effect)

2. Downstream process quality/efficiency

3. Product Characteristics

5th Step: Risk Analysis

❑ Describe/rate Severity(S) of Effects, the effectiveness of current process prevention and detection controls, identified in step 4, and calculates the Action Priority number

❑Highlight Special Characteristics – Customer req. or from D/PFMEA

6th Step: Optimization❑ Prioritize high risk failure modes and define corrective actions to reduce risks

with details action plans

❑Once actions are complete re-assess the the Severity, Occurrence and Detection ratings

7th Step: Results Documentation

❑Confirm effectiveness and document tasks completed and summarize the results of actions identified based on PFMEA analysis

❑Management of the improvement actions

❑Communicate results and conclusions from analysis within organization, customers and suppliers


FMEA 4th Edition Method vs VDA FMEA

AIAG 4th Ed. FMEA Format

2. Process Step Station

No. and Name of Focus

Element

3. Process Work Element

4M Type

STRUCTURE ANALYSIS (Step 2)

1. Process Item System,

Subsystem, Part Element

or Name of Process

2. Function of the Process

Step and Product

Characteristic

(Quantitative value is

optional)


Work Element and

Process Characteristic


Item, Function of System,


or Process

FUNCTION ANALYSIS (Step 3)

Item

1. Failure Effects

(FE) to the Next

Higher Level

Element and/or

End User Se

ve

rit

y (

S)

of

FE 2. Failure Mode (FM)

Focus Element

3. Failure Cause (FC) of

the Work Element

FAILURE ANALYSIS (Step 4)

Prevention Controls

(PC) of FC

Occ

urr

en

ce (

O)

of

FE

Detection Controls (DC)

of FC of FM

De

tect

ion

(D

) o

f

FC/F

M

Act

ion

Pri

ori

ty

Spe

cia

l

Ch

ara

cte

rist

ics

Filt

er

Co

de

(Op

tio

na

l)

RISK ANALYSIS (Step 5)

Responsible

Person's Name

Target

Completion

Date

StatusAction Taken with

Pointer to Evidence

Completion

DateRemarks

Se

ve

rit

y (

S) o

f F

E

Occu

rre

nce

(O

) o

f

FE

De

te

ctio

n (

D) o

f

FC

/F

M

Actio

n P

rio

rit

y

OPTIMIZATION (Step 6)

17

FMEA Overview

Rate Severity –Rate the most serious Failure Effect for a given Failure Mode

Severity 9 or 10 Ranking is reserved

for vehicle safety functions or

compliance


PFMEA Occurrence Rating Guidelines

•Based on history (customer complaints, internal scrap, or rework)

•Be conservative and consistent in rating selections Copied from FMEA manual 3rd Ed.

•One table is used throughout local plant

•Supporting rational are documented

•Changes have been approved by local customer management office

VDA FMEA Detection Rankings

Review each column and to determine best fit related to controls ability to detect either:

1) Failure Cause (FC)

2) Failure Mode (FM)

Column on the right can be used for plant examples –helps to drive consistency



Seve

rity

(S)

of

FE

Occ

urr

en

ce (

O)

of

FE

De

tect

ion

(D

) o

f FC

/FM

Act

ion

Pri

ori

ty

EX 1 7 2 6 M

EX 2 8 2 8 M

EX 3 3 3 2 L

EX 4 5 4 5 L

EX 5 8 4 7 H

❑ Using the S, O, and D ratings the next objective is the identify the Action Priority level

❑ VDA FMEA software can do this automatically

❑ Going left to right S>O>D in the AP table on the next slide check for the appropriate AP level

❑See exercise values to the right


EX1

EX5EX3

VDA FMEA Action Priority Rules

22

- (H) Highest Priority for action

- The team must either identify an appropriate action to improve prevention and/or Detection controls or justify and document why the current controls are adequate

- (M) Medium priority for action

- The team should identify appropriate actions to improve prevention and/or detection controls, or, at company discretion, justify and document why controls are adequate

- (L) Low priority for action

- Team could identify actions to improve prevention and detection control

Optimization (Step 6)

❑ Action Status Options:

❑ Action order of effectiveness:

❑ Process modifications to eliminate or mitigate Failure Effect (FE)

❑ Process modifications to reduce the Occurrence of Failure Cause (FC)

❑ Increase the Detection ability for the Failure Cause (FC) or Failure Mode (FM)

Note: With any process modification, all impacted process steps are evaluated again


VDA FMEA 7-Step Approach - ExampleSYSTEM ANALYSIS FAILURE ANALYSIS & RISK MITIGATION RISK COMMUNICATION

1st Step: PLANNING AND PREPARATION

❑Project Identification

❑Project Planning: 5T’s – InTent, Timing, Team, Task and Tools

❑Boundaries: What is included and excluded from the process?

PLANNING AND PREPARATIONExample: A critical Automotive customer sent you and RFQ to supply stainless steel for a new catalytic converter -details below:

❑Two components: 1) Heat Shield (2-piece) and 2) Body (2 piece Upper & Lower)

❑Heat Shield: .6mm thick 409 stainless steel

❑Body: .8 mm thick 409 stainless steel

❑ Stamped (deep draw) shape and shear to shape > assemble > resistance welded

*Assume stainless steel is a common product for your plant, but this is a new grade (never before produced)


Boundary Diagram

STRUCTURE ANALYSIS (Step 2)

1. Process Item System, Subsystem, Part Element or Name of Process

2. Process Step Station No. and Name of Focus Element

3. Process Work Element 4M Type

Core & Heat Shield Assembly

(Op10)Place lower body and flanges in weld fixture Operator: Fixture: Materials

(Op20) Weld lower body to flanges Operator: Machine: Method

(Op40) Assemble core elements Operator: Method:

(Op60) Weld upper body to flanges and lower body Operator: Machine: Method

. . .

From Assy customer

From Process Flow

From Process Routing


VDA FMEA Structure Analysis

Visualizing processing steps is beneficial in assessing structure risks and necessary controls

Scrap Loading

LMF

Casting

Hot Mill

Cold Mill

Shipping

Coil Slitting

Stamp & Shear Body & HS

Assemble Core Weld & Test

Assemble HS & Pressure Test

Exhaust pipe Assy and Test

OEM Assembles Exhaust in Vehicle

STRUCTURE ANALYSIS (Step 2)1. Process Item System, Subsystem, Part Element or Name of Process

2. Process Step Station No. and Name of Focus

Element

3. Process Work Element 4M Type

Stamp Lower Body

(10)Setup coil guides

Method:Mat’l: Edge Variation

(20) Set progression

Machine: Method: Man:

(30) Set draw depth

Machine: Mat’l: Lot to Lot Formability

(40) FAI Measurement:

. . .


Function Analysis - Parameter Diagram

Control Factors

Noise Factors

❑ Control Factors = System design parameters that engineering can change

❑ Noise Factors = things that can influence the design that are not under direct control of the engineer

❑Error States are any kind of inherent loss of energy transfer or other undesirable system outputs


Function Analysis - Parameter Diagram

Control Factors

Noise Factors

❑ Control Factors- Mechanical and Chemical>>

❑ Noise Factors –Performance Change Over Time, Extreme Environments, Piece to Piece variation, Customer Usage, System Interactions

Class exercise: List Noise Factors that could influence function performance?

Function Analysis❑Capture product and process functions for your processes

❑A Function Analysis Structure Tree can help -one process focus element at a time

CC Assembly

Process Function:Assembly convertor core and weld

Op(60) Weld upper body to

lower core assy.

Process Function:Create structural weld (to flanges and lower body assy) Welded gas barrier seal

Process Functions:Operator: Setup weld fixture, welder and tooling and parameters

Operator:Place core sub-assyand upper body in weld fixture

Weld Robot: Weld upper body to flanges

Weld Robot:Welds upper and lower flangesFunction Analysis Structure Tree

What does it do? How?


Step and Product

Characteristic


optional)


Work Element and Process

Characteristic

(30) Position/align lower

body and flanges for core

assy procerss

Ensure proper alignment

for welding process

(40) Weld lower body to

flanges

Create structural and gas

barrier seal to lower

(50) Position core elements

for flow (no gases bypass)

Place and align core

elements. . .

(60) Weld upper body to

flanges and lower body to

prevent gas bypass or

escape


barrier seal between

upper body and lower




or Process

Assemble flanges,

body, core

elements. Weld

for structural and

gas flow function

From Structure Analysis Step

From SA Routing step


Function Analysis

Identifying Functions requires knowledge of transformative processes in your plant

Scrap Loading

LMF

Casting

Hot Mill

Cold Mill

Shipping

Coil Slitting

Stamp & Shear Body & HS

Assemble Core Weld & Test

Assemble HS & Pressure Test

Exhaust pipe Assy and Test

OEM Assembles Exhaust in Vehicle


Step and Product

Characteristic


optional)


Work Element and Process

Characteristic

Position/align lower body

and flanges for core assy

procerss

Ensure proper alignment

for welding process

Weld lower body to flangesCreate structural and gas

barrier seal to lower

Position core elements for

flow (no gases bypass)

Place and align core

elements. . .

Weld upper body to flanges

and lower body to prevent

gas bypass or escape


barrier seal between

upper body and lower




or Process

Assemble flanges,

body, core

elements. Weld

for structural and

gas flow function

Cross functional teams identify internal process Functions

Address any process

characteristics (temp, pressures

etc.)

Function Analysis❑ Function of Process identified in Structure Analysis is described in Process Function column

❑ The function or transforming action from the focus element is describe in the function of process step column

❑ The function of the process work element is described in the function of the Process work column

STRUCTURE ANALYSIS (Step 2) FUNCTION ANALYSIS (Step 3)1)Process Item System, Subsystem, Part Element or Name of Process

Process Step Station No. and Name of Focus

Element

Process Work Element 4M Type

1) Function of the Process Item, Function of System, Subsystem, Part Element or Process

2) Function of the Process Step and Product Characteristic

(Quantitative value is optional)

3) Function of the Process Work Element and Process

Characteristic

Receiving material (10) Receiving Inspection Material: (not meeting spec)(damage)(assess coil runability and surface)

Ensure received material identification and adherence to specification (chemistry, mechanicals, dimensional, safety and appearance)

Validate material is correct per requirements

Ensure only conforming material gets into production

Slitting coil (20)Slitting Process Setup Machine: Slitter Slit full width coil to width specification

Set payoff, guides slitting blades to achieve customer width and edge quality and meet efficient rate

Slitter: Edge guides set, blade quality/edge burr confirmed, no damage confirmed,

(20)Slitting Process Setup Machine: Payoff Position incoming coil and set loop/tension requirements for efficient slitter operation

Payoff: Supplied coil set, controls on-line with press controls, loop limit controls set (to ensure correct tension to slitter)

(20)Slitting Process Setup Machine: Takeup Set slitter pit loop limits and take-up parameters for efficient operator

Takeup: set take-up parameters and ensure controls are

(20)Slitting Process Setup Man: Set and confirm safety rails /guards are in place and functioning

Ensure operator is safe form sharp edges and pinch points

(30) Slit coil to width Machine: Slitter slit coil - maintaining dimensions, edge quality and appearance are met through out slitting run

Through out run; Slit width consistent and meets spec , Edge quality consistent, appearance quality meets customer requirements

(40) Complete slitter run/ band

Machine: Takeup Ensure run finishes and coil is banded

Banding to prevent lose of containment in shipment

Failure Analysis (Step 4)1. Identify

potential Failure Modes (FMs)

2. Determine Failure Effects (FE) )- at that process step, next hire level and/or end user

3. Brainstorm Failure Causes (FC)

Rank Severity (S) during Risk Analysis

FUNCTION ANALYSIS (Step 3) FAILURE ANALYSIS (Step 4)

3. Function of the Process Work Element and Process

Characteristic

1. Failure Effects (FE) to the Next Higher Level Element and/or End User Se

veri

ty (

S)

of

FE 2. Failure Mode (FM) Focus Element

3. Failure Cause (FC) of the Work Element

Ensure only conforming material gets into production

Damage to machines, tooling, Shipping N/C material to customer

6Material incorrectly identified

Wrong material type or gauge gets to production

Slitter: Edge guides set, blade quality/edge burr confirmed, no damage confirmed,

Excessive burr on coil edges (safety of operators) (potential to damage equipment

8

Dull slitter blade Slitting blade used beyound epected PM

Payoff: Supplied coil set, controls on-line with press controls, loop limit controls set (to ensure correct tension to slitter)

Downtime, frequent stops, inefficient slitter operation 3

Slitter payoff not set-up properly

improper Payoff setup

Takeup: set take-up parameters and ensure controls are in auto

Unable to ship coil. Rework or scrap

5Take Up coiler - loosely rapped

Improper take-up parameters

Ensure operator is safe form sharp edges and pinch points

Operator (non-life threatening) injury

9Guarding not correctly set Guarding not set and

convimfedThrough out run; Slit width consistent and meets spec , Edge quality consistent, appearance quality meets customer requirements

Stamping customer unable to run product,

5

Slit width of coil varies (OOS) during run

Edge guide not properly set or hydraulic cylinder fails

Coil banding is placed and properly secured

Loss of coil containment9

Banding fails to contain slit coil

Incorrect placement or crimp is not suffucient

1

2

3

Opposites of the process function work elements become FMs.

Risk Analysis(Step 5)FAILURE ANALYSIS (Step 4) RISK ANALYSIS (Step 5)

Seve

rity

(S)

of

FE

2. Failure Mode (FM) Focus Element

3. Failure Cause (FC) of the Work Element

Prevention Controls (PC) of FC

Occ

urr

en

ce (O

) o

f FE

Detection Controls (DC) of FC of FM

De

tect

ion

(D

) o

f FC

/FM

Act

ion

Pri

ori

ty

Spe

cial

C

har

acte

rist

ics

Filt

er

Co

de

(O

pti

on

al)

6

Material incorrectly identified

Wrong material type or gauge gets to production

Lot information barcoded

2

Certificates of Analysis from suppliers, Barcodes/ scanners used by Material handlers to select material from stock

6 L

8

Dull slitter blade Slitting blade used beyond expected PM

Blade PMs, Blade force monitoring and alarm 2

End-of-coil inspection

8 M

3

Slitter payoff not set-up properly

Improper Payoff setupWork Instructions,

Checklists3

Verification inspection by 2nd setup operator, checklist

2 L

5Take Up coiler - loosely rapped

Improper take-up parameters

Take-up parameters saved - automatically loaded

4Checklist, First article, periodic check 5 L

8Guarding not correctly set

Guarding not set and convimfed

Training, sensor linked to controller (auto-off) 4

Visual, 2nd operator verifiction 7 H

1 2

3 4 5 6


Risk Analysis (Step 5)

FAILURE ANALYSIS (Step 4)

1. Failure Effects (FE) to

the Next Higher Level

Element and/or End

UserSe

veri

ty (S

) of F

E

2. Failure Mode (FM)

Focus Element

3. Failure Cause (FC) of

the Work Element

Prevention Controls

(PC) of FC

Occ

urre

nce

(O) o

f

FE

Detection Controls (DC)

of FC of FM

Det

ecti

on (D

) of

FC/F

M

Act

ion

Prio

rity

Spec

ial

Char

acte

rist

ics

Filt

er C

ode

(Opt

iona

l)

Damage to machines,

tooling(7) Shipping N/C

material to customer(5)7

Material incorrectly

identified

Wrong material type or

gauge gets to productionLot information

barcoded

2

Certificates of Analysis

from suppliers, Barcodes/

scanners used by Material

handlers to select material

from stock

6 L

Excessive burr on coil edges

(safety of operators)(8),

damage equipment(7)8

Dull slitter blade Slitting blade used beyond

expected PM timeBlade PMs, Blade force

monitoring(analytics) 2

End-of-coil inspection

8 M

Downtime(3), frequent

stops(3), inefficient slitter

operation(2) 3

Slitter payoff not set-up

properly

Improper Payoff setup

None 3

Verification inspection by

2nd setup operator,

checklist2 L

Unable to ship coil-delay

shipment (5). Rework or

scrap(4)5

Take Up coiler - loosely

rapped

Improper take-up

parametersTake-up parameters

saved - automatically

loaded

4

Checklist, First article,

periodic check 5 L

Operator (non-life

threatening) injury 8

Guarding not correctly set Guarding not set and

confirmedTraining, sensor linked

to controller (auto-off) 4Visual, 2nd operator

verifiction 7 H


4 5 6


7 Step Approach


FMEA – MSR (VDA FMEA-Section 4)

Not directly applicable for base materials


Questions?


Contact Info

[email protected](402)405-4980

mailto:[email protected]

vda fmea overview - asq-1302 · 2020-01-21 · vda fmea action priority rules 22 - (h) highest...

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