R.

HARIHARAN, LECT / EEE

It is an analytical technique to identify foreseeable failures in a product or a process and to eliminate it. It is also defined as a group of activities intended to understand and evaluate the potential failure of a product or process and to eliminate it. FMEA is a Before-the-event action that requires a team effort to easily and inexpensively, improves changes in design and production.

DESIGN FMEA PROCESS FMEA Other types are

Equipment FMEA (modified version of process FMEA) Maintenance FMEA Concept FMEA Service FMEA (modified version of process FMEA) System FMEA ( combination of both design & process) Environmental FMEA (modified version of process FMEA)

It is the design process by identifying the failures. It will rank the failures according to their relative impact on product. It helps to establish priorities based on expected failures and helps to uncover oversights, misjudgments and errors that may have been made. It helps to reduce development time and cost of manufacturing. It also specifies the appropriate tests to check the designed product.

It is to identify potential process failure by ranking the failures. It priorities the failures according to the impact on external and internal customer. It helps to identify manufacturing and assembly failures in order to establish controls for failure reduction.

It is the probability that the product will perform as per the expectations for a certain period of time. The factors to be considered are long life, safety of the product.

DEBUG FAILURE
Failure at initial stages because of inappropriate use or flaws in design.

CHANCE FAILURE
Failure occur in the product due to accidents, poor maintenance or limitations of design.

WEAR OUT FAILURE

It occur in a product after the product has performed as expected for at least the amount of time given by the manufacturer as the product life.

It attempts to find out potential productrelated failures. FMEA is an debugging and preventing problems that may occur in the manufacturing process. FMEA evaluation should be carried out immediately after the design phase of the product certainly before purchasing and setting up any machinery.

Helps in determining the impact of any failure on other items in the product. Helps to calculate the possibilities of failure in assemblies, sub-assemblies, product. Helps to establish test programs to determine failures. Helps to establish test programs to determine failure.

Specifying possibilities Quantifying risk Correcting high risk causes Re-evaluation of risk

Function involved are identified. Possible failure modes are determined. Root causes for the failures are found out. Effects of failures on other components of the system is found out. Steps involved in detection of failures are found out.

Probability of cause is determined. Severity of the failure and its effect is determined. Effectiveness of control system to prevent cause is checked. The risk is prioritized.

The work is prioritized. Action is explained in a detail manner. Now the action is assigned to the necessary people. Go in for check points to check the completion level.

It is the process of determining who is the very best, who sets the standard and what that standard is. It answers to the questions of WHAT can be achieved and HOW can be achieved. The process of identifying, understanding and adapting outstanding practices and processes from organizations anywhere in the world to an organization to improve its performance.

WHAT IS OUR PRESENT PERFORMANCE LEVEL? HOW DO WE DO IT?

WHAT ARE THE OTHERS PERFORMANCE LEVELS? HOW DID THEY GET THERE?

CREATIVE ADAPTION

BREAK THROUGH PERFORMANCE

Reasons to benchmark:
It aims at goal setting process to facilitate comparison with the best. It aims at motivating and stimulating employees towards the goal of continuous quality improvement. It aims at external orientation of the company. It aims at identifying a technological breakthrough. It aims at searching for industry best practices.

Product benchmarking Performance benchmarking Process benchmarking Strategic benchmarking

Planning
What can be benchmarked? To whom or what shall we compare? (partners) Determine data collection method and collect data

Analysis
Determine the current performance gap. Project future performance levels

Integration
Communicate benchmark findings and gain acceptance Establish functional goals

Action
Develop action plans Implement specific actions and monitor the progress Recalibrate benchmarks

Maturity
Attain the leadership position Integrate practices into process

It is the activity to ensure the physical assets to continue to do what their users wanted to do. Types:
Corrective or breakdown maintenance Scheduled or routine maintenance Preventive maintenance Predictive maintenance

TPM is the systematic execution of maintenance by all employees through small group activities. Goals zero breakdown and defects It improves equipment efficiency rate and reduces cost. Implementation of TPM can generate cost saving through increased productivity of the machinery.

To improve equipment effectiveness To achieve autonomous maintenance To plan maintenance To train all staff in relevant maintenance skills To achieve early equipment management

Breakdowns long interruption, expensive repairs Setup and changeover- taking much longer than needed Idling and minor stoppages hard to quantify Reduced speed equipment cycle times have gradually deteriorated Defects and rework quality loss Start up losses to get steady state after a change

Preparation stage
Announce top management about the decision to introduce TPM Launch education and campaign to introduce TPM Create organization to promote teams Establish basic TPM policies and goals Formulate basic TPM policies and goals

Preliminary implementation stage

Hold TPM kick-off

TPM implementation stage

Improve effectiveness of each piece of equipment Develop an autonomous maintenance program Develop a scheduled maintenance program for the maintenance department Conduct training to improve operation and maintenance skills. Develop early equipment management program

Stabilization stage
Perfect TPM implementation and raise TPM levels

Increased equipment productivity Improved equipment reliability Reduced equipment downtime Increased plant capacity Extended machine line Improved return on investment improved safety

It is a systematic and organized approach of taking customer needs and demands into consideration while designing new products and services. It focus on the voice of the customer or it is called as customer driven engineering.

To identify the true voice of the customer and to use this knowledge to develop products which satisfy customers. To help in the organization and analysis of all the pertinent information associated with the project.

List customer requirements (what) List technical descriptors(how) Develop a relationship matrix Develop an interrelationship matrix Competitive assessments Develop prioritized customer requirements Develop prioritized technical descriptors

Phase I QFD methodology Phase-II- part development

Phase-III- process planning

Deploy QFD process down to sub-components level both in terms of requirements and characteristics. Deploy the component deployment chart. Relate the critical sub-component control characteristics Develop the relationship between the critical characteristics and process used to create the characteristics Develop the control plan relating critical to critical processes.

Phase-IV- Product planning

Tabulate the final product to the market Develop prototype product to the market Launch the final product to the market.