1. Process Failure Mode Effect Analysis Northrop Grumman Corporation Integrated Systems CA/PA-RCA : Advanced Tool

4. Agenda Why does it always seem we have plenty of time to fix our problems, but never enough time to prevent the problems by doing it right the first time?

6. What is FMEA ? Cause & effect, Root Cause Analysis, Fishbone Diagram Etc Failure Mode Effect Analysis

8. What is FMEA ? What it can do for you! 1.) Identifies Design or process related Failure Modes before they happen. 2.) Determines the Effect & Severity of these failure modes. 3.) Identifies the Causes and probability of Occurrence of the Failure Modes. 4.) Identifies the Controls and their Effectiveness . 5.) Quantifies and prioritizes the Risks associated with the Failure Modes. 6.) Develops & documents Action Plans that will occur to reduce risk.

9. Types of FMEAs ? System/Concept “S/CFMEA”- (Driven by System functions) A system is a organized set of parts or subsystems to accomplish one or more functions. System FMEAs are typically very early, before specific hardware has been determined. Design “DFMEA”- (Driven by part or component functions) A Design / Part is a unit of physical hardware that is considered a single replaceable part with respect to repair. Design FMEAs are typically done later in the development process when specific hardware has been determined. Process “PFMEA”- (Driven by process functions & part characteristics) A Process is a sequence of tasks that is organized to produce a product or provide a service. A Process FMEA can involve fabrication, assembly, transactions or services.

10. Types of FMEAs ? System/Concept “S/CFMEA”- (Driven by System functions) A system is a organized set of parts or subsystems to accomplish one or more functions. System FMEAs are typically very early, before specific hardware has been determined. Design “DFMEA”- (Driven by part or component functions) A Design / Part is a unit of physical hardware that is considered a single replaceable part with respect to repair. Design FMEAs are typically done later in the development process when specific hardware has been determined. Process “PFMEA”- (Driven by process functions & part characteristics) A Process is a sequence of tasks that is organized to produce a product or provide a service. A Process FMEA can involve fabrication, assembly, transactions or services.

11. The FMEA Team Roles FMEA Core Team 4 – 6 Members Expertise in Product / Process Cross functional Honest Communication Active participation Positive attitude Respects other opinions Participates in team decisions Champion / Sponsor Provides resources & support Attends some meetings Promotes team efforts Shares authority / power with team Kicks off team Implements recommendations Recorder Keeps documentation of teams efforts FMEA chart keeper Coordinates meeting rooms/time Distributes meeting rooms & agendas Facilitator “ Watchdog“ of the process Keeps team on track FMEA Process expertise Encourages / develops team dynamics Communicates assertively Ensures everyone participates Team Leader “ Watchdog” of the project Good leadership skills Respected & relaxed Leads but doesn’t dominate Maintains full team participation Typically lead engineer

15. Getting Started on FMEA Determine “ Controls” Detection Rating Determine “ Effects” of The Failure Mode Severity Rating What Must be done before FMEA Begins! Determine “ Causes” of The Failure Mode Occurrence Rating Determine Product or Process Functions Determine Failure Modes of Function Understand your Customer Needs Develop & Evaluate Product/Process Concepts Create an Effective FMEA Team Develop and Drive Action Plan 1 3 2 4 6 =QFD =Brain Storming =4 to 6 Consensus Based Multi Level Experts = What we are and are not working Define the FMEA Scope 5 Calculate & Assess Risk 6 7 Ready?

16. The FMEA Worksheet If an FMEA was created during the Design Phase of the Program, USE IT! Create an Action Plan for YOUR ROOT CAUSE and Re-Evaluate the RPN Accordingly 1 6 2 3 4 5 7 Determine Product or Process Functions Determine Failure Modes of Function Determine “ Effects” of The Failure Mode Severity Rating Determine “ Causes” of The Failure Mode Occurrence Rating Determine “ Controls” Detection Rating Calculate & Assess Risk Develop and Drive Action Plan

17. FMEA Scoring Severity Severity of Effect Rating May endanger machine or operator. Hazardous without warning 10 May endanger machine or operator. Hazardous with warning 9 Major disruption to production line. Loss of primary function, 100% scrap. Possible jig lock and Major loss of Takt Time 8 Reduced primary function performance. Product requires repair or Major Variance. Noticeable loss of Takt Time 7 Medium disruption of production. Possible scrap. Noticeable loss of takt time. Loss of secondary function performance. Requires repair or Minor Variance 6 Minor disruption to production. Product must be repaired. Reduced secondary function performance. 5 Minor defect, product repaired or "Use-As-Is" disposition. 4 Fit & Finish item. Minor defect, may be reprocessed on-line. 3 Minor Nonconformance, may be reprocessed on-line. 2 None No effect 1 Extreme High Moderate Low

18. FMEA Scoring Occurrence Likelihood of Occurrence Failure Rate Capability (Cpk) Rating 1 in 2 < .33 10 1 in 3 > .33 9 1 in 8 > .51 8 1 in 20 > .67 7 1 in 80 > .83 6 1 in 400 > 1.00 5 1 in 2000 > 1.17 4 Process is in statistical control. 1 in 15k > 1.33 3 Low Process is in statistical control. Only isolated failures associated with almost identical processes. 1 in 150k > 1.50 2 Remote Failure is unlikely. No known failures associated with almost identical processes. 1 in 1.5M > 1.67 1 Failure is almost inevitable Process is not in statistical control. Similar processes have experienced problems. Process is in statistical control but with isolated failures. Previous processes have experienced occasional failures or out-of-control conditions. Very High High Moderate

19. FMEA Scoring Detection Likelihood that control will detect failure Rating Very Low No known control(s) available to detect failure mode. 10 9 8 7 6 5 4 3 2 1 The process automatically detects failure. Controls will almost certainly detect the existence of a failure. Controls have a good chance of detecting the existence of a failure Low Moderate High Very High Controls have a remote chance of detecting the failure. Controls may detect the existence of a failure

20. FMEA Scoring RPN or Risk Priority Number S everity x O ccurrence x D etection= RPN The Calculation !

22. Failure Modes & Effect Analysis Questions? Call or e-mail: Kevin M. Treanor Bob Ollerton 310-863-4182 310-332-1972/310-350-9121 [email_address] [email_address]