Overview: Failure mode effects analysis (FMEA) has long been part of advanced
quality planning (AQP), a set of activities whose purpose is to plan
quality into a product and its manufacturing process. The Automotive
Industry Action Group’s (AIAG’s) and German Association of the
Automotive Industry’s (VDA’s) newest manual (2019) improves
significantly on the previous methods. It includes a very logical and
comprehensive process that identifies potential failure modes, their
causes (previously mechanisms), and effects. It improves on the previous
approach to the Severity, Occurrence, and Detection ratings, with the
latter depending on the nature of the process’ prevention and detection
controls.The Action Priority rating is from a tabulated matrix that gives the
most weight to the failure mode’s Severity rating and then to its
Occurrence rating. This is superior to the risk priority number (RPN)
which is the product of three ordinal numbers [1].Areas Covered in the Session:
Role of PFMEA in Advanced Quality Planning
Seven step PFMEA process
1. Planning and preparation; include the scope of the PFMEA which can
include safety as well as quality and continuity of operations.
Foundation or generic PFMEAs are previously completed PFMEAs for the
same product family, which takes advantage of group technology (a common
set of tools and process steps for a related group of parts).
2. Structure analysis; identification of the overall process and its
objectives (process item), process steps (operations), and process work
elements (factors that affect the process steps); the latter are
similar to the categories in a cause and effect diagram.Speaker: William Levinson Bill Levinson, P.E., FASQ is the owner of Levinson Productivity Systems,
P.C. which specializes in quality management systems, industrial
statistics, and lean manufacturing. He is the author of numerous books
and articles on management and quality and a leading authority on Henry
Ford’s universal code for world-class performance.Tags: CAPA, Corrective and Preventative, Detection controls, Engineering, Failure analysis, FMEA, Function analysis, Manufacturing, Optimization, PFMEA, Prevention controls, Process Failure Mode Effects Analysis, quality, Quality Control, Quality Improvement, Quality Management, Risk analysis, risk assessment, Structure analysis
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