Effective FMEAs: achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis
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Hoboken, NJ
Wiley
2012
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| Series: | Wiley series in quality & reliability engineering
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| Subjects: | |
| Online Access: | Inhaltsverzeichnis Buchcover |
| Item Description: | Literaturangaben |
| Physical Description: | XXV, 435 S. Ill., graph. Darst. |
| ISBN: | 9781118007433 |
Staff View
MARC
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| 245 | 1 | 0 | |a Effective FMEAs |b achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis |c Carl S. Carlson |
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Record in the Search Index
| _version_ | 1804149599536939008 |
|---|---|
| adam_text | Titel: Effective FMEAs
Autor: Carlson, Carl S
Jahr: 2012
Contents
Series Editor s Foreword xvii
Copyrights and Permissions xix
Acknowledgments xxi
Introduction xxiii
Chapter 1. The Case for Failure Mode and Effects Analysis 1
In This Chapter / 1
1.1 The Need for Effective FMEAs / 1
1.2 FMEA Application by Industry / 4
1.3 The Factor of 10 Rule / 5
1.4 FME A Successes / 6
1.5 Brief History of FME A / 8
1.6 FME A Standards and Guidelines / 8
1.7 How to Use This Book / 9
1.8 Web Companion to Effective FMEAs I 10
1.9 End of Chapter Problems / 10
References /Il
Chapter 2. The Philosophy and Guiding Principles for Effective FMEAs 12
In This Chapter / 12
2.1 What Is Philosophy and Why Does It Matter to
FMEAs? / 12
2.2 Guiding Principles for Effective FMEAs / 13
2.2.1 Having the Right Objectives / 13
2.2.2 Having the Right Resources / 14
2.2.3 Having the Right Procedures / 16
2.3 The Role of FMEA in Design for Reliability / 17
2.4 You Can t Anticipate Everything / 18
2.5 End of Chapter Problems / 19
References / 20
Chapter 3. Understanding the Fundamental Definitions and Concepts
of FMEAs 21
In This Chapter / 21
3.1 Definition of FMEA / 21
3.2 Primary Objective of FMEA / 22
3.3 Definition of Failure Mode Effects and Criticality
Analysis / 22
3.4 Types of FMEAs / 23
3.5 FMEA Definitions and Examples / 25
3.5.1 Item / 26
3.5.2 Function / 27
3.5.3 Failure Mode / 28
3.5.3.1 Failure Modes at System/Subsystem
Level versus Component Level / 30
3.5.4 Effect / 32
3.5.5 Severity / 34
3.5.6 Cause / 36
3.5.7 Occurrence / 38
3.5.8 Controls / 38
3.5.9 Detection / 43
3.5.10 Risk Priority Number / 44
3.5.11 Recommended Actions / 45
3.6 Is It a Failure Mode, Effect, or Cause? / 48
3.7 FMEA Glossary / 49
3.8 Web Companion to Effective FMEAs I 51
3.9 End of Chapter Problems / 51
References / 55
Chapter 4. Selection and Timing of FMEA Projects 56
In This Chapter / 56
4.1 Guidelines for When to Do FMEAs / 56
4.2 FMEA Project Selection Criteria / 58
4.3 Preliminary Risk Assessment / 59
4.4 When to Do Different Types of FMEAs / 60
4.5 Responsibility for FMEAs between OEMs and
Suppliers / 62
4.6 Introducing the All-Terrain Bicycle Case Study / 63
4.7 End of Chapter Problems / 64
Chapter 5. How to Perforai an FMEA Project: Preparation 66
In This Chapter / 66
Use of the Bicycle Examples in the Chapter / 66
5.1 The Subject of FMEA Preparation / 67
5.2 Preparation Tasks Done Once for Ali FMEA
Projects / 67
5.2.1 FMEA Software Selection / 67
5.2.2 Selecting or Modifying FMEA Worksheets
and Scales / 68
5.2.3 Identifying Roles and Responsibilities / 70
5.2.4 FMEA Team Training / 72
5.2.5 Legai Guidelines for Doing FMEAs / 72
5.2.6 Meeting Logistics / 73
5.2.7 Defining the System Hierarchy
(For System and Design FMEAs) / 73
5.2.8 Defining the Process Steps
(for Process FMEAs) / 75
5.2.9 Access to Failure Information / 76
5.3 Preparation Tasks for Each New FMEA Project / 78
5.3.1 Determine the Scope of the Analysis / 79
5.3.2 Make the Scope Visible
(for System and Design FMEAs) / 82
5.3.2.1 FMEA Block Diagram / 82
5.3.2.2 FMEA Interface Matrix / 84
5.3.2.3 Parameter Diagram (P-Diagram) / 85
5.3.2.4 Functional Block Diagram / 87
5.3.3 Make the Scope Visible
(for Process FMEAs) / 88
5.3.3.1 Process Flow Diagram (PFD) / 88
5.3.3.2 PFD Worksheet / 91
5.3.4 Assemble the Correct Team / 93
5.3.5 Establish the Ground Rules and
Assumptions / 96
5.3.6 Establish the Role of Suppliers / 98
5.3.7 Gather and Review Relevant Information / 98
5.3.7.1 Gather Information Checklist (for System
and Design FMEAs) / 100
5.3.7.2 Gather Information Checklist (for
Process FMEAs) / 101
5.3.8 Prepare FMEA Software for First Team Meeting / 102
5.3.9 Ready-for-First-Meeting Checklist / 103
5.4 End of Chapter Problems / 103
References / 106
Chapter 6. How to Perforai an FMEA Project: Procedure 107
In This Chapter / 107
Use of the Bicycle Examples in the Chapter / 107
6.1 FMEA Procedure Sequence of Steps / 108
6.2 Basic FMEA Procedure / 109
6.2.1 Items / 109
6.2.2 Functions /111
6.2.2.1 Requirements / 113
6.2.2.2 Checklist of Function Types / 114
6.2.3 Failure Modes / 119
6.2.4 Effects / 121
6.2.5 Severity Ranking / 125
6.2.6 Classification (Optional) / 127
6.2.7 Causes and Failure Mechanisms / 129
6.2.7.1 Failure Mechanisms (for System and Design
FMEAs) / 131
6.2.7.2 Five Whys / 136
6.2.8 Occurrence Ranking / 138
6.2.9 Controls / 140
6.2.9.1 Design Controls for System or Design
FMEAs / 140
6.2.9.2 Process Controls for Process FMEAs / 141
6.2.9.3 Use of Early Warning Devices and
Mitigating Controls / 142
6.2.10 Detection Ranking / 145
6.2.10.1 Detection Scale for Assessing Risk Related
to In-Service Detection Systems / 146
6.2.10.2 Limitations and Alternatives to Using
Detection Ranking / 147
6.2.11 Risk Priority Number (RPN) / 148
6.2.11.1 Limitations and Alternatives to Using
RPN / 150
6.3 FMEA Linkages / 152
6.3.1 System or Design FMEA Linkage to Design
Verification Pian / 152
6.3.2 Process FMEA Linkage to Process Control
Plans / 153
6.3.3 Design FMEA Linkage to Process FMEA / 155
6.3.4 Relationship between System, Subsystem, and
Component FMEAs / 157
6.4 End of Chapter Problems / 158
References / 161
Chapter 7. How to Develop and Execute Effective Risk Reduction
Actions 162
In This Chapter / 162
Use of the Bicycle Examples in the Chapter / 162
7.1 Prioritize Issues for Corrective Action / 163
7.1.1 Is Action Always Required on High Severity
Issues? / 164
7.2 Develop Effective Recommended Actions / 165
7.2.1 Quality and Reliability Resources to Help
Formulate FMEA Recommended Actions / 166
7.3 Action Strategies to Reduce Risk / 166
7.3.1 Action Strategies to Reduce
Severity Risk / 167
7.3.2 Action Strategies to Reduce
Occurrence Risk / 168
7.3.3 Action Strategies to Reduce
Detection Risk / 172
7.3.4 Common Action Strategy Mistakes to Avoid / 174
7.4 Examples of Recommended Actions / 176
7.5 FMEA Execution Enablers / 176
7.6 The Essence of Execution / 182
7.7 Documenting Actions Taken / 182
7.8 Ensuring Risk Is Reduced to an Acceptable Level / 183
7.9 End of Chapter Problems / 183
References / 186
Chapter 8. Case Studies 187
In This Chapter / 187
8.1 Case Study: Shock Absorber Assembly / 188
8.2 Case Study: Strudel Pastry Manufacturing / 190
8.3 Case Study: Motorola Solutions Press-to-Talk
Feature / 193
8.4 Case Study: Flashlight / 200
8.5 Case Study: DC-10 Cargo Door Failure / 200
8.6 Case Study: Space Shuttle Challenger O-Ring Failure / 204
8.7 Case Study: Projector Lamp / 206
8.8 Case Study: All-Terrain Bicycle / 206
8.8.1 All-Terrain Bicycle System FMEA / 206
8.8.2 All-Terrain Hand Brake Design FMEA / 209
8.8.3 All-Terrain Brake Cable Design FMEA / 209
8.8.4 All-Terrain Process FMEA (Wheel Spoke
Installation) / 209
8.9 Case Study: Resin Lever / 213
8.10 Case Study: Power Steering / 217
8.11 Other Case Studies and Examples / 217
8.12 Web Companion to Effective FMEAs I 221
8.13 End of Chapter Problems / 221
References / 224
Chapter 9. Lessons Learned for Effective FMEAs 226
In This Chapter / 226
9.1 The Most Common FMEA Mistakes: How to Avoid Them
andAuditThem / 226
9.2 Summary of FMEA Quality Objectives / 235
9.3 FMEA Quality Audit Procedure / 235
9.4 End of Chapter Problems / 236
Chapter 10. How to Facilitate Successful FMEA Projects 241
In This Chapter / 241
10.1 FMEA Facilitation / 241
10.2 Effective Meetings / 242
10.3 Primary FMEA Facilitation Skills / 243
10.3.1 Brainstorming / 243
10.3.2 Asking Probing Questions / 244
10.3.3 Encouraging Participation / 245
10.3.4 Active Listening / 245
10.3.5 Controlling Discussion / 245
10.3.6 Making Decisions / 246
10.3.7 Confiict Management / 247
10.3.8 Facilitator Interventions / 248
10.3.9 Managing Time / 249
10.3.10 Common Facilitation Problems / 249
10.3.11 Attitude / 251
10.4 Unleashing Team Creativity / 252
10.4.1 Techniques to Stimulate Divergent
Thinking / 254
10.5 FMEA Facilitation Roles and Responsibilities / 255
10.6 How to Reduce FMEA In-Meeting Time / 261
10.7 Diffìculty Getting Consensus on Competing Ideas / 261
10.8 End of Chapter Problems / 263
References / 265
Chapter 11. Implementing an Effective Company-Wide FMEA Process 266
In This Chapter / 266
11.1 What Is a Company-Wide FMEA Process and Why
Is It Important? / 266
11.2 Management Roles and Responsibilities / 267
11.3 Effective FMEA Process / 268
11.3.1 Planning Stage / 268
11.3.2 Performing FMEAs Stage / 272
11.3.3 Review Stage / 274
11.3.4 Implementation Stage / 277
11.4 Lessons Learned in Implementing a Company-Wide
FMEA Process / 279
11.5 Company Climate for Sharing Failure Information / 281
11.6 End of Chapter Problems / 282
Chapter 12. Failure Mode Effects and Criticality Analysis (FMECA) 285
In This Chapter / 285
12.1 Introduction to FMECA / 285
12.2 When to Use FMECA / 286
12.3 Brief History of FMECA / 286
12.4 Types of FMECA / 287
12.5 Quantitative Criticality Analysis / 287
12.6 Qualitative Criticality Analysis / 289
12.7 FMECA Criticality Matrix / 292
12.8 FMECA Worksheet / 292
12.9 Summary Output of FMECA / 292
12.10 End of Chapter Problems / 294
References / 296
Chapter 13. Introduction to Design Review Based on Failure
Mode (DRBFM) 297
In This Chapter / 297
13.1 What Is DRBFM? / 297
13.2 Change Point Analysis / 300
13.3 Conducting DRBFM Projects / 302
13.4 How DRBFM Integrates with FMEA / 304
13.5 DRBFM Worksheet / 304
13.6 DRBFM Examples and Case Studies / 304
13.6.1 DRBFM Case Study 1 / 304
13.6.2 DRBFM Case Study 2 / 307
13.6.3 DRBFM Case Study 3 / 307
13.7 Design Review Based on Test Results / 309
13.8 DRBFM Glossary / 311
13.9 DRBFM Resources for Further Study / 312
13.10 End of Chapter Problems / 313
References / 315
Chapter 14. Introduction to Fault Tree Analysis (FTA) 316
In This Chapter / 316
14.1 What Is Fault Tree Analysis? / 316
14.2 FTA and FMEA / 317
14.2.1 When Should FTA Be Used in Addition to
FMEA? / 317
14.3 Brief History of FTA / 318
14.4 Models / 318
14.5 Events and Gates / 318
14.6 FTA Example / 319
14.7 FTA Glossary / 320
14.8 FTA Procedure / 323
14.9 FTA Handbooks and Standards / 324
14.10 Use of FTA on Software / 324
14.11 FTA Benefits and Limitations / 324
14.12 End of Chapter Problems / 326
References / 327
Chapter 15. Other FMEA Applications 328
In This Chapter / 328
15.1 Reliability-Centered Maintenance / 328
15.1.1 RCM and FMEA / 329
15.1.2 RCM: The Seven Basic Questions / 329
15.1.3 RCM Decision Logic Diagrams / 331
15.1.4 RCM Procedure / 331
15.1.5 History of RCM / 334
15.1.6 RCM Definitions / 335
15.1.7 RCM Case Study / 336
15.1.8 RCM Publications and Standards / 337
15.1.9 RCM Benefits / 337
15.1.10 RCM Limitations / 340
15.2 Hazard Analysis / 340
15.2.1 Hazard Analysis and FMEA / 341
15.2.2 Hazard Analysis Procedure / 341
15.2.3 Hazard Analysis Tables and Examples / 342
15.2.4 Hazard Analysis Definitions / 346
15.2.5 Hazard Analysis References and
Standards / 347
15.3 Concept FMEA / 347
15.4 Software FMEA / 348
15.4.1 General Procedure for Software
FMEAs / 351
15.4.2 Software FMEA Examples / 354
15.4.3 Software FMEA References and
Standards / 355
15.5 Failure Modes, Mechanisms, and Effects Analysis / 356
15.6 Failure Modes, Effects, and Diagnostic Analysis / 358
15.7 End of Chapter Problems / 361
References / 363
Chapter 16. Selecting the Right FMEA Software 365
In This Chapter / 365
16.1 Characteristics of Excellent FMEA Software / 365
16.2 Why Not Just Use Spreadsheet Software? / 368
16.3 Advantages of Relational Database / 368
16.4 Using the Criteria for Selecting Relational Database
Software / 369
16.5 End of Chapter Problems / 369
Reference / 370
Appendice» 371
Appendix A FMEA Scales / 371
Appendix B FMEA Worksheet Forms / 376
B.l Design FMEA Worksheet Forms / 377
B.2 Process FMEA Worksheet Forms / 382
Appendix C All-Terrain Bicycle Documents / 388
Appendix D Lists and Checklists / 392
D.l FMEA Preparation Checklists / 392
D.l.l Checklist for FMEA Preparation / 392
D.l.2 Ground Rules and Assumptions
Checklist / 393
D.l.3 Gather Information Checklist
(for System and Design FMEAs) / 394
D.l.4 Gather Information Checklist
(for Process FMEAs) / 395
D.l.5 Ready-for-First-Meeting Checklist / 395
D.2 Lists of Failure Mechanisms
(excerpts from book) / 396
D.3 FMEA Quality Objectives / 399
D.4 FMEA Facilitation Checklists / 400
D.4.1 Checklist for Effective Meetings / 400
D.4.2 FMEA Facilitator Thought-Starter
Questions / 401
D.5 FMEA Action Strategy Checklist / 405
D.6 FMEA Quality Audit Procedure / 409
D.7 FMEA Quality Survey Form / 413
Appendix E FMEA Glossary / 414
References / 418
Index 419
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| spelling | Carlson, Carl S. Verfasser aut Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis Carl S. Carlson Hoboken, NJ Wiley 2012 XXV, 435 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Wiley series in quality & reliability engineering Literaturangaben Qualitätsmanagement (DE-588)4219057-5 gnd rswk-swf Produktionswirtschaft (DE-588)4123986-6 gnd rswk-swf Produktionswirtschaft (DE-588)4123986-6 s Qualitätsmanagement (DE-588)4219057-5 s DE-604 HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025364501&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis SWB Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025364501&sequence=000003&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA Buchcover |
| spellingShingle | Carlson, Carl S. Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis Qualitätsmanagement (DE-588)4219057-5 gnd Produktionswirtschaft (DE-588)4123986-6 gnd |
| subject_GND | (DE-588)4219057-5 (DE-588)4123986-6 |
| title | Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis |
| title_auth | Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis |
| title_exact_search | Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis |
| title_full | Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis Carl S. Carlson |
| title_fullStr | Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis Carl S. Carlson |
| title_full_unstemmed | Effective FMEAs achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis Carl S. Carlson |
| title_short | Effective FMEAs |
| title_sort | effective fmeas achieving safe reliable and economical products and processes using failure mode and effects analysis |
| title_sub | achieving safe, reliable, and economical products and processes using Failure Mode and Effects Analysis |
| topic | Qualitätsmanagement (DE-588)4219057-5 gnd Produktionswirtschaft (DE-588)4123986-6 gnd |
| topic_facet | Qualitätsmanagement Produktionswirtschaft |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025364501&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025364501&sequence=000003&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT carlsoncarls effectivefmeasachievingsafereliableandeconomicalproductsandprocessesusingfailuremodeandeffectsanalysis |