FMEASAE J1739.docx
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FMEASAE J1739.docx
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FMEASAEJ1739
SURFACEVEHICLERECOMMENDEDPRACTICE
POTENTIALFAILUREMODEANDEFFECTSANALYSISINDESIGN(DESIGNFMEA),POTENTIALFAILUREMODEANDEFFECTSANALYSISINMANUFACTURINGANDASSEMBLYPROCESSES(PROCESSFMEA),ANDPOTENTIALFAILUREMODEANDEFFECTSANALYISFORMACHINERY(MACHINERYFMEA).
Draft
ProposalfromtheSAEJ1739MainWorkingCommittee
WilliamCarlson-DaimlerChrysler
CarlCarlson-GeneralMotors
GlenVallanceandCynthiaTaaffee-Ford
WithMachineryWorkingSub-Committee
DavidJanas-DaimlerChrysler
AdhiKersala-GeneralMotors
GaryGivens-Ford
NOTE:
FormatofthisReviewDocument:
ChangestotheOriginalSAEJ1739documentintheIntroductionandDesignandProcessFMEAsectionshavebeenhighlightedforeaseofcomparison.Textthatisboldanditalicizeisneworrevised.
TheMachineryFMEAsectioniscompletelynewandhasnotbeenboldedoritalicizedforpurposesofreadability.
FinalFormatoftheStandardispendingapprovalofcontent.Thisdocumentisbeingprovidedfor‘content’relatedcommentsonly.
1.Scope—GeneralInformation
1.1Overview—ThisSAERecommendedPracticewasjointlydevelopedbyDaimlerChrysler,Ford,andGeneralMotors.
ThisdocumentintroducesthetopicofpotentialFailureModeandEffectsAnalysis(FMEA)andgivesgeneralguidanceintheapplicationofthetechnique.
AllFMEA’sfocusonthedesign,whetheritbeoftheproduct,theprocessorthemachineryusedtobuildtheproduct.AnApplicationsSection(seeSection5)hasbeenaddedtoprovideinformationonapplyingtheFMEAtechniquetoplantmachineryandequipmentusingtheMachineryFMEA(MFMEA).
1.2RecommendedPracticeFormat—Foreaseofuse,thisreferencedocumentpresentsthetwobasictypesofFMEA(DesignFMEAandProcessFMEA)intheirownseparatesections.ThisdocumentalsocontainsanApplicationsSection(Section5)whichdiscussesinsomedetailhowanFMEAisappliedtoPlantMachineryandEquipment(MachineryFMEA).
TheMachineryFMEA(MFMEA)informationhasbeenprovidedduetotheimportanceofPlantMachineryandEquipmentfunctioningasintendedinmanufacturingandassemblyplants.TheuseoftheMFMEA,onPlantMachineryandEquipment,willassistwiththeidentificationofpotentialfailuremodes,sothatdesignandprocessingalternativescanbeconsidered,priortofinalizingthePlantMachineryandEquipmentDesigns.
Itshouldbenotedthatthisdocumentisarecommendedpractice,andassuch,eachTeamisfreetousetheguidelineslistedhereininthemannerwhichwillbemosteffectiveforagivensituation.Section5.2.17.1containsatableof"SuggestedDetectionEvaluationCriteria"forMFMEAwhichhasrankingsof10,7,5,3,and1(doesnotcontainrankingsof9,8,6,4,and2).ThisApplicationsSectionDetectionTableillustratesthattheTeamcanmakemodificationstothestandardformatof10-1rankings,ifthiswillbemosteffectivefortheTeam'ssituationandapplication.
Figure1illustratesanapproximatetimelinewheretheDesignFMEA(DFMEA)fortheproductisstartedsomewhatbeforetheProcessFMEA(PFMEA)forproducingtheproduct.Figure1showsthattheMachineryFMEA(MFMEA)shouldbestartedataboutthesametimeasthePFMEA.The"OEMProductDevelopmentTimeLine"referstothe"OriginalEquipmentManufacturer'sTimeLine"whichisusedforthedesign,development,andproductionoftheproduct.Insomesituations,allthreeFMEAs(i.e.,DFMEA,PFMEA,andMFMEA)mightbestartedatthesametime.Ingeneral,theearlierthatFMEAsarestarted,thebetterthechancesofoptimizingthevariousactivities/designs/processesinacostandtimeeffectivemanner.
FIGURE1
1.3WhatisanFMEA?
-AnFMEAcanbedescribedasasystemizedgroupofactivitiesintendedto:
(a)recognizeandevaluatethepotentialfailureofaproduct/processanditseffects,(b)identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring,and(c)documenttheprocess.Itiscomplementarytotheprocessofdefiningwhatadesignorprocessmustdotosatisfythecustomer.
1.4FMEAImplementation—Becauseofthegeneralindustrytrendtocontinuallyimproveproductsandprocesseswheneverpossible,theneedforusingtheFMEAasadisciplinedtechniquetoidentifyandhelpminimizepotentialconcernisasimportantasever.StudiesofvehiclecampaignshaveshownthatfullyimplementedFMEAprogramscouldhavepreventedmanyofthecampaigns.
OneofthemostimportantfactorsforthesuccessfulimplementationofanFMEAprogramistimeliness.Itismeanttobea"before-the-event"action,notan"after-the-fact"exercise.Toachievethegreatestvalue,theFMEAmustbedonebeforeaproductorprocessfailuremodehasbeenincorporatedintoaproductorprocess.UpfronttimespentproperlycompletinganFMEA,whenproduct/processchangescanbemosteasilyandinexpensivelyimplemented,willminimizelatechangecrises.AnFMEAcanreduceoreliminatethechanceofimplementingapreventive/correctivechangewhichwouldcreateanevenlargerconcern.CommunicationandcoordinationshouldoccurbetweenalltypesofFMEAs(i.e.Design-DFMEA,Process-FMEA,andMachinery-MFMEA).(SeeFigure1).
Figure2
FMEAProcessSequence
Figure2depictsthesequenceinwhichanFMEAshouldbeperformed.Itisnotsimplyacaseoffillingoutthecolumn,butratherunderstandingtheprocessandhowtoeliminateriskandplantheappropriatecontrolstoprotectcustomersatisfaction.
TherearethreebasiccasesforwhichFMEA’saregenerated,eachwithadifferentscopeorfocus:
Case1:
Newdesigns,newtechnology,ornewprocess.
ThescopeoftheFMEAisthecompletedesign,technologyorprocess.
Case2:
Modificationstoexistingdesignorprocess(assumesthereisaFMEAforthe
existingdesignorprocess).
ThescopeoftheFMEAshouldfocusonthemodificationtodesignor
process,possibleinteractionsduetothemodification,andfieldhistory.
Case3:
Useofexistingdesignorprocessinanewenvironment,location
orapplication(assumesthereisanFMEAfortheexistingdesignor
process).ThescopeoftheFMEAistheimpactofthenewenvironmentor
locationontheexistingdesignorprocess.
AlthoughresponsibilityforthepreparationoftheFMEAisusuallyassignedtoanindividual,FMEAinputshouldbeateameffort.Ateamofknowledgeableindividualsshouldbeassembled(e.g.,engineerswithexpertiseinDesign,Analysis/Testing,Manufacturing,Assembly,Service,Recycling,Quality,andReliability).TheFMEAisinitiatedbytheengineerfromtheresponsibleactivity,whichcanbetheOriginalEquipmentManufacturer(i.e.,producesthefinalproduct),supplierorasubcontractor.
Itisnotappropriatetocomparetheratingsofoneteam'sFMEAwiththeratingsofanotherteam'sFMEA,eveniftheproduct/processappeartobeidentical,sinceeachteamenvironmentisuniqueandthustheirrespectiveindividualratingswillbeunique(i.e.,theratingsaresubjective).
ReviewoftheFMEAdocumentagainstFMEAqualityobjectives(seeAppendixAandAppendixB)isrecommendedincludingamanagementreview.
1.5FOLLOW-UP—Theneedfortakingspecific,preventive/correctiveactionswithquantifiablebenefits,recommendingactionstootheractivitiesandfollowing-upallrecommendationscannotbeoveremphasized.AthoroughlythoughtoutandwelldevelopedFMEAwillbeoflimitedvaluewithoutpositiveandeffectivepreventive/correctiveactions.
Theresponsibleengineerisinchargeofassuringthatallrecommendedactionshavebeenimplementedoradequatelyaddressed.TheFMEAisalivingdocumentandshouldalwaysreflectthelatestlevel,aswellasthelatestrelevantactions,includingthoseoccurringafterthestartofproduction.
Theresponsibleengineerhasseveralmeansofassuringthatrecommendedactionsareimplemented.Theyinclude,butarenotlimitedtothefollowing:
a.Assuringdesign/process/machinerequirementsareachieved
b.Reviewofengineeringdrawings,processesandspecifications
c.Confirmationofincorporationofchangesto
design/assembly/manufacturingdocumentation
d.ReviewofDesign/ProcessFMEAs,specialFMEAapplicationssuchas
MachineryFMEAandControlPlans
2.References—Therearenoreferencedpublicationsspecifiedherein.
FIGURE3scannedimage,figuretobeupdated
3.PotentialFailureModeandEffectsAnalysisinDesign(DesignFMEA)
3.1Introduction—ADesignpotentialFMEAisananalyticaltechniqueutilizedprimarilybyaDesignResponsibleEngineer/Teamasameanstoassurethat,totheextentpossible,potentialfailuremodesandtheirassociatedcauses/mechanismshavebeenconsideredandaddressed.Enditems,alongwitheveryrelatedsystem,subassemblyandcomponent,shouldbeevaluated.Initsmostrigorousform,anFMEAisasummaryoftheteam'sthoughts(includingananalysisofitemsthatcouldgowrongbasedonexperience)asacomponent,subsystem,orsystemisdesigned.Thissystematicapproachparallels,formalizes,anddocumentsthementaldisciplinesthatanengineernormallygoesthroughinanydesignprocess.
TheDesignpotentialFMEAsupportsthedesignprocessinreducingtheriskoffailures(includingunintendedoutcomes)by:
a.Aidingintheobjectiveevaluationofdesign,includingfunctionalrequirementsanddesignalternatives.
b.Evaluatingtheinitialdesignformanufacturing,assembly,service,andrecyclingrequirements.
c.Increasingtheprobabilitythatpotentialfailuremodesandtheireffectsonsystemandvehicleoperationhavebeenconsideredinthedesign/developmentprocess.
d.Providingadditionalinformationtoaidintheplanningofthoroughandefficientdesign,developm
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