FMEA
Services Contact
Improve product quality, increase productivity, capture engineering knowledge and
reduce waste with PlanTech FMEA services.
PlanTech FMEA Services
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Training Outline
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Sample eLearning
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DFMEA: PlanTech applies a specific methodology for DFMEA
with proven results. Our quality consultants will help you gain real benefit from
your risk analysis.
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PFMEA: PlanTech can help identify how your processes
can fail to meet the process intent. PFMEA is a tool to identify and prioritize
risk in your manufacturing processes.
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Process Control Plans: Define the methods for product
verification. PlanTech can help develop your Process Control Plans for prototype,
pre-launch, and production.
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Error Proofing/Mistake Proofing: PlanTech can help you
properly apply error proofing and mistake proofing ensuring low risk in your manufacturing
processes.
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MFMEA: Applies conventional FMEA methodology to equipment
and machinery design.
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DRBFM: (Design Review Based on Failure Modes), much
like a configuration control board, is the method used by engineers to ensure changes
made to proven engineering designs are properly evaluated. PlanTech consultants
are expert in the application of DRBFM.
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PlanTech offers Training, Facilitation & Implementation Services for each item
listed in this chart.
Would you like to see some of our sample FMEA eLearning modules?
Click Here!
DFMEA
DFMEA Risk Analysis Kit
$149.00 - Benefit from our Valuable Training, Tips & Examples
DFMEA is an analysis of risk that considers how a design can fail to meet the design
intent. When doing DFMEAs, design engineers need to understand the function(s) and
performance requirements of their design. Identifying functions and performance
requirements is key to understanding and subsequently identifying failure modes.
PlanTech's focused FMEA methodology will help scope your DFMEAs, ensuring emphasis
is placed where you receive the most benefit.
Some of the benefits resulting from the application of DFMEA are:
- Establish a priority system for design improvements
- Identify potential product Failure Modes early in the product development cycle,
when they are less expensive to correct
- Identify potential safety concerns / government regulation issues
- Capture engineering and organization knowledge and improve best practices
- DFMEAs become part of a company's quality system providing an audit trail for the
analysis
- Aid in identifying needs for special controls - error proofing by identifying Significant
and Critical Characteristics
And there are reasons why DFMEAs are ineffective at some companies:
- Lack of management support
- Failure to properly scope the DFMEA boundaries
- Misunderstand the goals of the DFMEA process
- Misunderstanding the mechanics of the process, including effective use of the tools
employed
- Doing a DFMEA too late in the design cycle to be able to employ the lessons learned
- Failure to execute the identified Recommended Actions
- Insufficient resources committed, e.g. the DFMEA completed by a single person
PFMEA
PFMEA Risk Analysis Kit
$149.00 - Benefit from our Valuable Training, Tips & Examples
PFMEAs look at how a process can fail to meet the process intent. PFMEAs are done
sequentially per a process flow diagram. The process flow diagram is the map Manufacturing
engineers use to determine the process steps. From the process steps teams can develop
their process requirements.
Just as the list of functions and performance requirements are key to identifying
design related failures, the process flow diagram and process requirements are key
to identifying process failures.
Some of the benefits resulting from the application of PFMEA are:
- Identifies potential product related process failure modes early in the process
development cycle, when they are less expensive to correct
- Assesses customer effect of failures
- Identifies process causes and identifies what process causes to focus on to reduce
occurrence
- Establishes a priority system for corrective actions
- Identifies critical and significant characteristics
- Communicates proposed design changes from manufacturing to design
And there are reasons why PFMEAs are ineffective at some companies:
- Lack of management support
- Insufficient scope or strategy
- Not doing a PFMEA when we should have - too late in the process development cycle
to be able to employ the lessons learned
- Failure to execute the identified Recommended Actions
- Insufficient resources committed, e.g. the PFMEA completed by a single person
Process Control Plans
Process Control Plans contain information such as specifications, tolerances, inspection
devices, sample sizes and frequencies, control methods and reaction plans necessary
to ensure products meet customer requirements. Control Plans provide the written
summary of the systems used to verify the quality of our products.
PlanTech has developed Process Control Plans for Prototype, Pre-launch, and Production
for our clients engaging in various manufacturing processes. Included are actual
examples on completing the Control Plans for a variety of conditions:
- Distinguishing between Product Characteristics and Process Characteristics
- Including multiple levels of detection
- Consideration for downstream error detection
Error proofing / Mistake proofing
Error proofing / Mistake proofing is a process of anticipating, preventing and detecting
errors which adversely affect the customer and result in waste.
Error Proofing: Error Proofing is a philosophy where the process / part is
designed such that an incorrect action or the omission of an action cannot occur.
The process CANNOT make a defective part.
Mistake Proofing: In the event the process allows the defect to occur, controls
are in place that prevents the error from PASSING to the next operation or controls
are in place that prevent the next operation from ACCEPTING the defect.
MFMEA
MFMEA Risk Analysis Kit
$149.00 - Benefit from our Valuable Training, Tips & Examples
MFMEAs apply conventional DFMEA methodology to equipment and machinery design. MFMEAs
differ from conventional DFMEAs because they focus on how Equipment / Machinery
/ Tooling fails to meet the design intent.
There are two approaches engineers use when conducting DFMEAs, the functional approach
and the hardware approach. When applying a functional approach, teams classify equipment
into functional subsystems and each subsystems functions are defined by statements
that are actionable and measurable. The functional approach is sometimes referred
to as the "Top Down" approach. In the hardware approach, teams focus on the
lowest functional level, i.e., belts, cabinets, gears, etc. This approach is commonly
referred to as the "Bottom Up" approach. The most common approach for MFMEA
is the functional approach.
MFMEA uses Mean Time Between Failure (MTBF) to determine Causes and Mean Time to
Repair (MTTR) to determine Effect(s) of Failure.
Benefits of MFMEAs:
- Early identification of spare part requirements
- Identification of potential failures before equipment build
- Prioritization of identified design improvements
- MFMEAs are an input to the preventive maintenance program
DRBFM
DRBFM Risk Analysis Kit
$149.00 - Benefit from our Valuable Training, Tips & Examples
DRBFM (Design Review Based on Failure Modes) is a tool developed on the philosophy
that problems are likely to occur when changes are made to proven, stable engineering
designs. If engineers want to ensure changes are made responsibly, proposed changes
must be closely scrutinized. To do this the designer must make the changes visible.
DRBFM is the means engineers use to ensure proposed changes are properly reviewed.
Steps required to complete a DRBFM:
- Determine the change points
- DRBFM Checklist
- Change Point Matrix
- Prepare the worksheet (Left Side)
- Gather the team
- Conduct the review (Right Side)
- Create Action Items
- Get sign off
- Follow through on the Action Items
DRBFM in the form of PRBFM (Process Review Based on Failure Modes) has been successfully
applied to manufacturing processes.
Additional Information:
We look forward to discussing our FMEA services with you.
Contact Us Today!