VDA FMEA Overview ASQ Section 1302
January 2020
Agenda
Why VDA FMEA was needed? Key Differences from AIAG FMEA 7-Step VDA FMEA Process Exercise Q&A
2
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 errorproofing process steps (risk reduction)
❑
–
–
Why was VDA FMEA needed? Business objectives that support VDA FMEA 1. Increas Increasing ing quali quality, ty, reli reliabi abilit lity, y, manuf manufactu acturab rabili ility ty and safe safety ty of Automotive products driverless vehicles –
2. Ensures Ensures the the linkage linkage,, interf interface ace and and alignme alignment nt of requir requireme ements nts to internal and external customers and suppliers 3. Bui Build ldin ing g a know knowle ledge dge ba base se in in the com compa pany ny Lessons Learned –
4. Ensures Ensures comp complia liance nce with with regu regulat lation ionss and cust custome omerr requir req uireme ements nts - IA IATF TF
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AIAG & VDA Combined Methodologies
13-Step Process
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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 4 th Edition 13-step approach
VDA FMEA 7-Step Process
Risk Communication
7 Results Documentation i s s y l a n A e r u l i a F 4
s i s y l a n A k s i R
n o i t a z i m i t p O
5
6
Failure Analysis & Risk Mitigation
3 Function Analysis 2 Structure Analysis 1 Planning & Preparation Preparation
System Analysis
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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
8
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 dat e
–
Tier 1 & 2 suppliers often list production/platform info
–
–
–
9
2nd Step: Structural Analysis ❑Identifies and breaks down
manufacturing Process Steps and Process work elements process into Process items,
❑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:
Process Item Control Factors
Inputs
Process
1) The next higher levels 2) Impact on product characteristics Noise Factors
Outputs
4th Step: Failure Analysis ❑
IdentifyModes), how theeffects focus element process can go wrong (Failure 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
with details action plans ❑Once
actions are complete complete re-assess the the Severity, Occurrence Occurrence and Detection ratings
risks
th
7
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 1. Process Item System,
2. Process Step Station
Subsystem, Part Element No. and Name of Focus or Name of Process
1. Function of the Process
3. Process Work Element
Item, Function of System,
4M Type
Subsystem, Part Element
Element
FAILURE ANALYSIS (Step 4)
FUNCTION ANALYSIS (Step 3)
STRUCTURE ANALYSIS (Step 2)
or Process
2. Function of the Process Step and Product
3. Function of the Process
Characteristic
Work Element and
(Quantitative value is
Process Characteristic
optional)
1. Failure Effects (FE) to the Next Higher Level Element and/or End User
f o ) S ( y E t i F r e v e S
2. Failure Mode (FM) Focus Element
3. Failure Cause (FC) of the Work Element
AIAG 4th Ed. FMEA Format Item
RISK ANALYSIS (Step 5)
Prevention Controls (PC) of FC
f o ) O ( e c E n F e r r u c c O
Detection Controls (DC) of FC of FM
OPTIMIZATION (Step 6) f o ) D ( n M F o / i t C e c F t e D
y t i r o i r P n t i o c A
s c i t s l i a i r c e e t p c a r S a h C
e ) d l o a C n o r i t e t p i l ( F O
Responsible Person's Name
Target Completion Status Date
Action Taken with Completion Pointer to Evidence
Date
Remarks
E F f o ) S ( y t i r e v e S
f o ) O ( e c E n F e r u c c O
f y o t ) i r D o ( i r n M F P o / i t C n c F i o e t t c e A D
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FMEA Overview
– Rate Rate the Severity most serious Failure Effect for a given Failure Mode Severity 9 or 10 Ranking is reserved for vehicle safety functions or
compliance
17
17
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
18
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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
RISK ANALYSIS (Step 5) ❑ Using the S, O, and D ratings the next
objective is the identify the Action Priority level
E F f o ) S ( y t i r e v e S
f o ) O ( e c E n F e r r u c c O
f o ) D ( n M F o / i t C c F e t e D
y t i r o i r P n o i t c A
❑
EX 1
7
2
6
M
❑ Going left to right S>O>D in the
EX 2
8
2
8
M
EX 3
3
3
2
L
EX 4
5
4
5
L
EX 5
8
4
7
H
VDA FMEA software can do this automatically
AP table on the next slide check for the appropriate AP level
❑See exercise values to the right
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EX5
EX1
EX3
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VDA FMEA Action Priority Rules -
(H) (H) Hi High ghe est Pr Priiorit orityy fo forr ac acti tion on
-
The team team must must either either identi identify fy an approp appropria riate te act action ion to improv improve e prevention and/or Detection controls or justify and document why the current controls are adequate
- (M) (M) Me Medi dium um pr prio iori rity ty fo forr ac acti tion on -
The team team shou should ld ident identify ify appr appropr opriat iate e act action ionss to impro improve ve preve preventi ntion on and/or detection controls, or, at company discretion, justify and document why controls are adequate
- (L) (L) LLow ow pr priiorit orityy ffor or ac acti tion on -
Team could could ident identify ify acti actions ons to to improv improve e preven preventio tion n and dete detecti ction on control
22
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, modification, all impacted impacted process steps are evaluated again
VDA FME VDA FMEA A 7-St 7-Step ep Ap Appr proa oach ch - Ex Exam ampl ple e SYSTEM ANALYSIS
FAILURE AN ANALYSIS & RISK MI MITIGATION
RISK CO COMMUNICATION
1st Step: PLANNING AND PREPARA PREPARATION TION ❑Project Identification ❑Project Planning: 5T’s – InTent, Timing, Team, Task and Tools ❑Boundaries:
What is included included and excluded from the process?
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PLANNING AND PREPARATION Example: A critical critical Automotive Automotive customer customer sent you you and RFQ to supply stainless 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 From Assy customer
STRUCTURE ANALYSIS (Step 2) 1. Process Item System, Subsystem, Part Element or
2. Process Step Station No. and Name of Focus Element
3. Process Work Element 4M Type
(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
Name of Process
Core & Heat Shield Assembly
...
From Process
From Process
Flow
Routing
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OEM Assembles Exhaust in Vehicle Exhaust pipe
VDA FMEA Structure Analysis Shipping
Assy and Test Assemble HS & Pressure Test Assemble Core STRUCTURE ANALYSIS (Step 2) 1. Process Item Weld & Test 2. Process Step Station
Visualizing processing steps is beneficial in assessing structure risks and necessary controls
Stamp & Shear Body & HS Coil Slitting
Cold Mill Hot Mill
System, Subsystem, 3. Process Work Element 4M No. and Name of Focus Part Element or Name Type Element of Process
Stamp Lower Body
(10)Setup coil guides (20) Set progression (30) Set draw
Machine: Mat’l: Lot to
depth (40) FAI
Measurement:
...
Casting LMF Scrap Loading
Method: Mat’l:
Edge Variation
Machine: Method: Man: Lot Formability
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Func ncti tion on Ana Analy lysi sis s - Pa Para rame mete ter r Diag Diagra ram m Fu ❑ Control Factors = System design parameters that engineering can change
Control Factors
Noise Factors ❑ 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
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Func ncti tion on Ana Analy lysi sis s - Pa Para rame mete ter r Diag Diagra ram m Fu ❑
Control FactorsFactors- Mechanical and Chemical>> Chemical>> Control Factors
Class exercise: List Noise Factors that could Noise Factors influence function ❑ Noise Factors –Performance Change Over Time, Extreme performance? Environments, Piece to Piece variation, Customer Usage, System Interactions
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Function Analysis ❑
Capture product and process functions for your processes ❑ A Function Analysis Structure Tree can help -one process focus element at a time 1. Function of the Process Item, Function of System, Subsystem, Part Element
2. Function of the Process Step and Product 3. Function of the Process Characteristic Work Element and Process (Quantitative value is Characteristic optional)
or Process
Assemble flanges, body, core elements. Weld for structural and gas flow function
(30) Position/align lower body and flanges for core assy procerss
Ensure proper alignment for welding process
Create structural and gas barrier seal to lower (50) Position core elements Place and align core for flow (no gases bypass) elements (40) Weld lower body to flanges
... (60) Weld upper body to Create structural and gas flanges and lower body to barrier seal between prevent gas bypass or upper body and lower escape
From Structure
From SA
Analysis Step
Routing step
CC Assembly Process Function: Assembly convertor core and weld
Op(60) Weld upper body to lower core assy.
Process Functions: Operator: Setup weld fixture, welder and tooling and parameters Operator: Place core sub-assy and upper body in weld fixture
Process Function: Create structural weld (to flanges and lower Weld Robot: Weld body assy) upper body to Welded gas barrier seal flanges
What does it do?
How?
Function Analysis Structure Tree
Weld Robot: Welds upper and lower flanges
OEM Assembles Exhaust in Vehicle Exhaust pipe
Function Analysis Shipping
Assy and Test Assemble HS & Pressure Test 2. Function of the Process 1. Function of the Process Assemble Core Step and Product 3. Function of the Process Item, Function of System, Characteristic Work Element and Process Weld & Test Subsystem, Part Element
Identifying Functions requires knowledge of transformative processes
(Quantitative value is optional)
Characteristic
Position/align lower body and flanges for core assy procerss
Ensure proper alignment for welding process
or Process
Stamp & Shear Body & HS
in your plant
Coil Slitting Cold Mill Hot Mill Casting LMF Scrap Loading
Cross functional teams identify internal process Functions
Assemble flanges, body, core elements. Weld for structural and gas flow function
Create structural and gas barrier seal to lower Position core elements for Place and align core flow (no gases bypass) elements
Weld lower body to flanges
... Weld upper body to flanges and lower body to prevent gas bypass or escape
Address any process characteristics (temp, pressures etc.)
Create and gas barrier structural seal between upper body and lower
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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) Function of the Process Item, 1)Process Item System, Process Step Station No. Process Work Element 4M Function of System, Subsystem, and Name of Focus Subsystem, Part Element Type Part Element or Process Element or Name of Process Rece Receiv ivin ing g mate materi rial al
(1 (10) 0) Re Rece ceiv ivin ing g In Insp spec ecti tion on
Ma Mate teri rial al:: (not (not me meet etin ing g spec)(damage)(assesss coil spec)(damage)(asses runability and surface)
Sli Sli tti tting ng co coii l
(20) (20)Sl Slii ttti ting ng Pr Pro o ces cesss Setu Setup p
Ma ach chii ne: ne: Sli Sli tte tterr
(20)Slitting Process Setup
Machine: Payoff
(20)Slitting Process Setup
Machine: Takeup
(20)Slitti (20)S litting ng Proce Process ss Setup
Man:
(30) Slit coil to width
Machine: Slitter
Ensure received material identification and adherence to specification (chemistry, mechanicals, dimensional, safety and appearance) Sli Sli t ful ful l wi widt dth h coi coi l to wi widt dth h specification
2) Function of the Process Step and Product Characteristic (Quantitative value is optional) Validate material is correct per requirements
Set payoff, guides slitting blades to achieve customer width and edge quality and meet efficient rate Position incoming coil and set loop/tension requirements for efficient slitter operation
3) Function of the Process Work Element and Process Characteristic Ensure only conforming material gets into production
Slitter: Edge guides set, blade quality/edge burr confirmed, no damage confirmed, Payoff: Supplied coil set, controls on-line with press controls, loop limit controls set (to ensure correct tension to slitter) Set slitter pit loop limits and take- Takeup: set take-up up parameters for efficient parameters and ensure operator controls are Set and confi confirm rm safet safety y rail railss /guards /guards Ensure operator is safe form are in place and functioning sharp edges and pinch points slit coil - maintaining dimensions, Through out run; Slit width edge quality and appearance are consistent and meets spec , met through out slitting run Edge quality consistent, appearance quality meets
(40) Complete slitter run/ band
Machine: Takeup
Ensure run finishes and coil is banded
customer requirements Banding to prevent lose of containment in shipment
Failure Analysis (Step 4) 1. 2.
Identify potential Failure Modes (FMs) Determine Failure Effects (FE)) )- at that (FE 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)
1. Failure Effects (FE) 3. Function of the Process Work to the Next Higher Element and Process Level Element Characteristic and/or End User Ensure only conforming material gets into production
Damage to machines, tooling, Shipping N/C
2
material to customer Slitter: Edge guides set, blade Excessive burr on coil quality/edge burr confirmed, no edges (safety of damage confirmed, operators) (potential to damage equipment Payoff: Supplied coil set, controls on- Downtime, frequent line with press controls, loop limit stops, inefficient slitter controls set (to ensure correct tension operation to slitter) Tak Takeup: eup: set take-up parameters and ensure controls are in auto Ensure operator is safe form sharp edges and pinch points Through out run; Slit width consistent and meets spec , Edge quality consistent, appearance quality meets
Unable to ship coil. Rework or scrap Operator (non-life threatening) injury Stamping customer unable to run product,
Opposites of the process function work elements
customer requirements Coil banding is placed and properly
become FMs.
Loss of coil containment
S ( y E t F i r f e o v e S 6
1 2. Failure Mode (FM) Focus Element
3. Failure Cause (FC) of the Work Element
Material incorrectly identified
Wrong material type or gauge gets to production
Dull ssllitter bl blade
Slitting bl blade us used be beyound epected PM
Slitter payoff not set-up properly
improper Payoff setup
8
3 3
5 9
Take Take Up ccoiler oiler - loosely Improper take-up parameters rapped Guarding Guardi ng not ccorrect orrectly ly se sett Guardin Guarding g not se sett and convimfed Slit width of coil varies Edge guide not properly set or (OOS) during run hydraulic cylinder fails
5
Banding fails to contain slit Incorrect placement or crimp
9
secured
coil
is not suffucient
Risk Analysis(Step 5) FAILURE ANALYSIS (Step 4) E F f o ) S ( y t i r e v e S
6
2. Failure Mode (FM) Focus Element
3. Failure Cause (FC) of the Work Element
Prevention Controls (PC) of FC
Material incorrectly
Wrong material type or Lot information
identified
gauge gets to production
1
barcoded
3
f o ) O ( e c E n F e r r u c c O
Dull slitter b la lad e
Slitting blade u se sed beyond expected PM
Blade PMs, Blade force monitoring and alarm
2
properly
5
Tak Take e Up coiler - loosely rapped
Improper take-up parameters
8
Guarding not correctly set
Guarding not set and convimfed
of
2
from suppliers, Barcodes/ scanners used by Material handlers to select material from stock End-of-coil inspection
2
Slitter payoff not set-up Improper Payoff setup 3
Detection Controls (DC) FC of FM
Certificates of Analysis
4
8
RISK ANALYSIS (Step 5) f o ) D ( n M F o / i t C c F e t e D
6
y t i r o i r P n o i t c A
L
5
6
8
M
Verification inspection by Work Instructions, Checklists Tak Take-up e-up parameters saved - automatically loaded Training, sensor linked to controller (auto-off)
3
2nd setup op erator erator,, checklist
2
L
4
Checklist, First article, periodic check
5
L
4
Visual, 2nd operator verifiction
7
H
s c i s l t i a r i e c t e c p a S r a h C
e ) d l a o n C o r i e t p t l i ( O F
Risk Analysis (Step 5) RISK ANALYSIS (Step 5)
FAILURE ANALYSIS (Step 4) 1. Failure Effects (FE) to the Next Higher Level Element and/or End User Damage to machines, tooling(7) Shipping N/C material to customer(5)
Excessive burr on coil edges (safety of operators)(8), damage equipment(7)
E F f o ) S ( y t i r e v e S
2. Failure Mode (FM) Focus Element
Material incorrectly identified
Wrong material type or gauge gets to production
Prevention Controls (PC) of FC
Lot information barcoded
D u l l s l i t t er b l a d e 8 Slitter payoff not set-up
stops(3), inefficient slitter o per atio n(2)
3
properly
Unable to ship coil-delay shipment (5). Rework or scrap(4)
5
8
4
2
7
Downtime(3), frequent
Operator (non-life th rea ten ing) in jur y
3. Failure Cause (FC) of the Work Element
f o ) O ( e c E n F e r r u c c O
Slittin g b lad e u s ed beyon d expected PM time
Blade PMs, Blade force monitoring(analytics)
Take Up coiler - loosely rapped
Improper take-up parameters
Guarding Guar ding not correct correctly ly set
Guar Guarding ding not set and confirmed
Take-up parameters saved - automatically loaded Training, sensor linked to controller (auto-off)
Certificates of Analysis from suppliers, Barcodes/ scanners used by Material handlers to select material from stock End-of-coil inspection
2
Improper Payoff setup
N on e
Detection Controls (DC) of FC of FM
3
Verification inspection by 2nd setup operator, checklist
f o ) D ( n M F o / i t C c F e t e D
y t i r o i r P n o i t c A
5
6
6
L
8
M
2
L
4
Checklist, First article, p er i o d i c c h ec k
5
L
4
Visual, 2nd operator verifiction
7
H
s c i t s l i a i r c e e t p c S a r a h C
e ) d l a o C n o i r t e p t l i O F (
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7 Step Approach
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FMEA – MSR (VDA FMEA-Section 4)
Not directly applicable for base materials
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Questions?
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