Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
31-Jul-98
rev 1
most attention.
Introduction
Descriptions
System
Subsystem
Component
Design Lead
Key Date
FMEA Number
Prepared By
FMEA Date
Revision Date
Core Team
Page
of
Coolant
containment.
Hose connection.
Coolant fill. M
Crack/break.
Burst. Side wall
flex. Bad seal.
Poor hose rete
Leak
Over pressure
Burst, validation
pressure cycle.
D
e
t
R
P
N
Recommended
Action(s)
Responsibility &
Target Completion
Date
Actions Taken
0
64 Test included in
prototype and
production
validation testing.
0
0
0
Page 3
0
0
Risk
Priority Number - The combined weighting of
Severity, Likelihood, and Detectability.
RPN
= Sev X Occ X Det
0
New RPN
Current Design
Controls
New Det
S
Potential Failure Potential Effect(s)
e
Mode(s)
of Failure
v
New Occ
Item / Function
New Sev
Action Results
Potential
P
Cause(s)/
r
Mechanism(s) of o
Failure
b
0
0
0
0
0
Page 4
FMEA Number
Component
Potential
Failure Mode and Effects Analysis
(Design FMEA)
Design Lead
Key Date
Revision Date
System
Subsystem
Prepared By
FMEA Date
Core Team
Page
of
Customer sends
in a quote
request for
product.
Requirement
entered and
verified by
Inside Sales in
config. tool.
Sales identifies
need for CII or
SHC
Customer needs
not fully met by
delivered
system.
7 Human error
1 Design
configuration
tool.
System
compatability
requirements
not evaluated by
config. tool.
3 Human error
1 Order verified by
a configuration
tool.
9 Continue order
verification by
configuration
tool.
Specific packing,
labeling and
shipping
requirements
may not be fully
addressed.
On time delivery
and integraty of
the product may
be compramised
if this issue is
not addressed.
7 Requirements
Overlooked.
63 Publish
comprehensive
procedure for
the 1st Article
Process.
Position of the
Loss of business
DHR in ICD
with the
label packet not customer.
identified by GE.
Requirment in
Purchase
Specification for
mousepad, but
not identified on
Bill of Material.
ICD Card
content
requirements
not identified in
Build Procedure.
1 Requirements
Overlooked.
3 Customer
Inspection
Instruction/
Special
Handling Codes
Process 033001-02
5 CII 033-001-006
Recommended
Action(s)
Responsibility &
Target Completion
Date
Actions Taken
New RPN
R
P
N
System,
Software,
Integration and
Shipping
requirements
overlooked by
customer.
Data entry error
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
Current Design
Controls
D
e
t
Potential Effect(s)
of Failure
New Det
S
e
v
Potential Failure
Mode(s)
New Occ
Item / Function
New Sev
Action Results
P
Potential Cause(s)/
r
Mechanism(s) of
o
Failure
b
21 Use
configuration
tool when
available.
5 Revisit contents
of GE CII 033001-006 to
assure all
requirements
are clearly
commumicated
to the
warehouse
operators and
quality
technicians
using these
documents.
Customer
shipping
requirements
reviewed by
quality
assurance in 1st
Article process.
QA and Pack
and Ship Team
reviews
customer
requirements
during a 1st
Article.
Specific packing,
labeling and
shipping
requirements
may not be fully
addressed.
Customer's full
expectations
may not be
realized.
Inside sales
submits Sales
Order
Authorization
request to
TECenter.
7 Requirements
overlooked.
3 Customer
requirements
physically
verified by
quality
assurance
during the 1st
Article process.
63 Continue
current
pracices.
1 Human Error
1 Customer
requirements
verified by a
TECenter
engineer.
3 Continue
current
practices.
TECenter
Requirements
Engineer reviews overlooked by
the design to
Engineer
determain if
additional data
is required.
Customer's full
expectations
may not be
realized.
3 Requirements
Overlooked.
6 Customer
requirements
verified by a
TECenter
engineer.
54 Continue
current
practices.
Appropriate
individuals are
contacted to
resolve issues.
Order
Processing Delay
1 Process Failure
1 Individuals are
contacted to
resolve issues.
1 Continue
current
practices.
Customer's full
expectations
may not be
realized.
1 Process Failure
1 Customer
requirements
verified by a
TECenter
engineer.
1 Continue
current
pracices.
Another
Requirements
engineer
overlooked by
performs quality two Engineer
check of the
design.
Customer's full
expectations
may not be
realized.
7 Process Failure
3 Customer
requirements
verified by a
TECenter
engineer.
63 Continue
current
pracices.
Completed
design
verification is
sent to
appropriate
organization.
Order
Processing Delay
1 Process Failure
1 Verification is
sent to
appropriate
organization.
1 Continue
current
pracices.
Appropriate
individuals not
available.
Design
verification
misrouted
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
Requirements
are defined and
capability to
meet/ accept
requirements.
Requirements
may be missed
or capibilty to
meet
overestamated
Customer's full
expectations
may not be
realized.
1 Process Failure
1 Requirements
are defined and
to meet
requirements.
1 Continue
current
pracices.
Inside Sales
Wrong price and Customer's full
quotes price and availability
expectations
availability
provided to
may not be
customer
realized.
3 Process Failure
1 Price provided to
customer
3 Continue
current
pracices.
Order
Processing Delay
1 Process Failure
1 Reprocess Order
Order
Processing Delay
3 Human Error
1 Reprocess Order
1 Continue
current
pracices.
3 Continue
current
pracices.
Order approved
by Asset
Management.
Approval not
timely
Order
Processing Delay
1 Process Failure
1 Expidite Process
1 Continue
current
pracices.
Order approved
by credit.
Approval not
timely
Order
Processing Delay
1 Process Failure
1 Expidite Process
Determaination
made that
product is
available for
build.
All product
required for the
order may not
be available at
the start of the
build.
(1) Product
delivery date
requirements
may not be met.
(2) Workspace
occupied for an
order awaiting
Product is not
available for
integration of
other orders.
5 Needed
components are
not available at
the time of need.
3 Assure product
availability
before the order
commitment is
given to
customer.
1 Continue
current
pracices.
15 Continue
current
practices.
Inside sales
expedites with
Asset to provide
ship date.
Shipdates may
not be accurate
Customer's full
expectations
may not be
realized.
1 Needed
components are
not available at
the time of need.
1 Expidite Process
1 Continue
current
practices.
Order approved
by Asset Mgmt.
and e-mail sent
to Integration.
e-mail may be
misrouted
Order
Processing Delay
1 Process Failure
1 Expidite Process
1 Continue
current
practices.
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
Project Manager
reviews order for
special or
internal
instructions.
Order
processing
requirements
may be
overlooked
Customer and
processing
needs not
identified could
prevent timely
processing of
the order.
3 Processing
requirements
overlooked.
1 Project Manager
order review.
3 Continue
current
practices.
Order
Processing Delay
5 Needed
components are
not available at
the time of need.
45 Continue
current
practices.
Customer's full
expectations
may not be
realized.
3 Needed
components are
not available at
the time of need.
3 Expidite Process
Integration
Center
Operations
Manual 093009-OPSMNL
1 Expidite Process
3 Continue
current
practices.
Order is
forwarded to
Production
Engineer for
review.
Determanation
made for a 1st
Article build.
Order may be
misrouted
Order
Processing Delay
1 Process Failure
1 Expidite Process
1 Continue
current
practices.
Customer's full 7
expectations
may not be
realized.
Customer's full 3
expectations
may not be
realized.
Order
3
Processing Delay
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
105 Continue
current
practices.
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
27 Continue
current
practices.
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
3 Continue
current
practices.
Order
3
Processing Delay
Needed
1
components are
not available at
the time of need.
Expidite Process 1
3 Continue
current
practices.
Order is
scheduled for
production.
Order
3
Processing Delay
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
3 Continue
current
practices.
Whse Operator
reviews parts to
SOA & SCN.
Order
3
Processing Delay
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
9 Continue
current
practices.
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
Order
3
Processing Delay
All components 3
are not available
at the time of
need.
Individuals are
contacted to
resolve issues.
Integration
Kitting and
Packing 153001-01
Individuals are
contacted to
resolve issues.
27 Continue
current
practices.
Techs. Check
product against
SOW and build
instructions.
Order
5
Processing Delay
All components 3
are not available
at the time of
need.
15 Continue
current
practices.
Integration
Techs. inspect
parts and
chassis.
Materials may
Order
7
not be compliant Processing Delay
All components 3
are not available
at the time of
need.
QA Inspection
and Test
Procedure 103001-03
63 Continue
current
practices.
No NT Resource
Kit
Missing Video
Board
Loss of business 1
with the
customer.
Requirements
Overlooked.
QA Inspection
and Test
Procedure 103001-03
Techs. Integrate
& Power-Up
System
System may be
integrated
incorrectly
Order
7
Processing Delay
Individuals are
contacted to
resolve issues.
QA Inspection
and Test
Procedure 103001-03
147 Continue
current
practices.
Integration
Techs. Test
system.
System and
Order
10 Needed
10 QA Inspection
parts may not be Processing Delay
components are
and Test
compliant
not available at
Procedure 103the time of need.
001-03
100 Continue
current
practices.
Quality techs.
inspect product
for build
requirements.
Specific build
requirements
may not be fully
addressed.
25 Continue
current
practices.
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
On time delivery 5
and integraty of
the product may
be compramised
if this issue is
not addressed.
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
5 Update Build
Procedures to
clearly define
product
requirements
specific to the
model being
integrated.
IO panel not
Loss of business 1
installed
with the
Label on CPU
customer.
Incorrect
No feet or other
components
installed
No extension
cables
Missing cables
IO panel gasket
not installed
Wrong ICD
cards provided
Dome calibrater
included
Human Error
Build Procedure 5
for individual
PathSpeed
Model
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
9 Continue
current
practices.
Control of
requirements
may be lost
Order
1
Processing Delay
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
1 Continue
current
practices.
Order
3
Processing Delay
Requirements
Overlooked.
Individuals are
contacted to
resolve issues.
9 Continue
current
practices.
Design Process
reinitiates
Control of
requirements
may not be
complete
Wrong Shipping
method may be
used
Order
3
Processing Delay
Process Failure
Individuals are
contacted to
resolve issues.
3 Continue
current
practices.
On time delivery 7
and integraty of
the product may
be compramised
if this issue is
not addressed.
Process Failure
Individuals are
contacted to
resolve issues.
7 Continue
current
practices.
Specific packing,
labeling and
shipping
requirements
may not be fully
addressed.
Customer
Inspection
Instruction/
Special
Handling Codes
Process 033001-02
90 Continue
current
pracices.
Product serial
numbers
scanned into
Genesis.
Change made
after batch
release
Whse. invoices
and ships order
per customer's
shipping
method.
Quality techs.
inspect
shipment for
CII/SHC
requirements.
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
25 Update Build
Procedures to
clearly define
product
requirements
specific to the
model being
integrated.
10
Human Error
CII 033-001-006 3
On time delivery 7
and integraty of
the product may
be compramised
if this issue is
not addressed.
Needed
3
components are
not available at
the time of need.
Individuals are
contacted to
resolve issues.
Coordinator
closes project &
files quality
records.
Documents may 3
not be
retrievable
Documents may 1
not be
retrievable
Individuals are
contacted to
resolve issues.
Documents not
filed correctly
Houston Mayer
Six Sigma Blackbelt
August 21, 2000
9 Revisit contents
of GE CII 033001-006 to
assure all
requirements
are clearly
commumicated
to the
warehouse
operators and
quality
technicians
using these
147 Continue
documents.
current
practices.
3 Continue
current
pracices.
11
Severity
Effect
Hazardous without
warning
Hazardous with
warning
Very High
SEVERITY of Effect
Ranking
10
High
Moderate
Low
Very Low
Minor
Very Minor
None
No effect
Page 12
9
8
7
Severity
Page 13
Severity
Page 14
Severity
Page 15
Severity
Page 16
Severity
Page 17
Probability
PROBABILITY of Failure
Very High: Failure is almost inevitable
10
1 in 3
1 in 8
1 in 20
1 in 80
1 in 400
1 in 2,000
1 in 15,000
1 in 150,000
<1 in 1,500,000
Page 18
Detectability
Detection
Absolute
Uncertainty
Very Remote
Remote
Very Low
Low
Moderate
Moderately High
High
Very High
Almost Certain
Page 19
Ranking
10
9
8
7
6
5
4
3
2
1
EXAMPLE
System
Subsystem
Component
Design Lead
Core Team
Item / Function
Potential Failure
Mode(s)
Seals
Coolant
containment.
Hose
connection.
Coolant fill. M
Sensor mount.
Seal
Compression set
Sensor mount.
Seal
Loosen during
sensor
assembly/servic
e
Sensor mount.
Seal
Damaged
internal thread
Sensor mount.
Seal
Damaged
external thread
Page 20
EXAMPLE
System
Subsystem
Component
Design Lead
Core Team
Item / Function
Potential Failure
Mode(s)
Stress crack
Stress crack
Stress crack
Corrosion
Puncture
Seam fail
Corrosion
Burst fail
Page 21
EXAMPLE
System
Subsystem
Component
Design Lead
Core Team
Item / Function
Potential Failure
Mode(s)
Plugged
Ballooning
Page 22
EXAMPLE
Potential
Failure Mode and Effects Analysis
(Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By
FMEA Date
Page
of
P
Potential Cause(s)/
r
Mechanism(s) of
o
Failure
b
Current Design
Controls
D
e
t
R
P
N
Recommended
Action(s)
Responsibility &
Target Completion
Date
0
0
Leak
8 Gasket material
7 Pressure cycle
w/cold shock.
56 Use imported
material
2 Added rib.
16 Implement
holding rib in
design. New
fitting design.
Prototype
validation.
Cannot install
sensor
5 Damaged during
installation or
transportation
10
Cannot install
wire nut
4 Damaged during
shipment to
piracicaba
12 Damaged fitting
not used by
Piracicaba
Leak
Failed mount
Over pressure
Vibration
Burst, validation
pressure cycle.
Vibration w/road
tapes
64 Test included in
prototype and
production validation
testing.
135 Obtain GMB
vibration road tape.
Page 23
Actions Taken
New Det
S
e
v
New Occ
Potential Effect(s)
of Failure
New Sev
Action Results
EXAMPLE
Potential
Failure Mode and Effects Analysis
(Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By
FMEA Date
Page
of
Hose leak
P
Potential Cause(s)/
r
Mechanism(s) of
o
Failure
b
Overpressure. Poor
clamp
Current Design
Controls
Burst, validation
pressure cycle
w/GMB clamps.
D
e
t
2
Recommended
Action(s)
Responsibility &
Target Completion
Date
0 Operator instruction
Thermal cycle
R
P
N
ADD
RECOMMENDED
ACTION system
functionality
56 Included in Product
Specification
Coolant quality.
7
Contamination.
Environment - int/ext.
SWAT, service
simulation. Coolant
evaluation.
External damage.
Coolant velocity. No
reinf sawcut.
Environment - int/ext. 1
SWAT, service
simulation.
Over pressure
contamination.
Burst/leak pressure
10
be evaluated. Zince
lined tubes may
need to be released.
Simulated service
test w/GMB coolant
to be performed.
Page 24
Actions Taken
New Det
S
e
v
New Occ
Potential Effect(s)
of Failure
New Sev
Action Results
EXAMPLE
Potential
Failure Mode and Effects Analysis
(Design FMEA)
FMEA Number
Key Date
Revision Date
Prepared By
FMEA Date
Page
of
P
Potential Cause(s)/
r
Mechanism(s) of
o
Failure
b
Contamination.
Coolant quality.
Over pressure
contamination.
Current Design
Controls
D
e
t
1
R
P
N
Recommended
Action(s)
Responsibility &
Target Completion
Date
56 GMB coolant to be
evaluated. GMB to
study engine
cleanliness.
360 GMB to study engine
cleanliness.
Clustomer profile to
be determined.
0
0
0
Page 25
Actions Taken
New Det
S
e
v
New Occ
Potential Effect(s)
of Failure
New Sev
Action Results
EXAMPLE
New RPN
on Results
0
0
0
0
Page 26
EXAMPLE
New RPN
on Results
0
0
0
0
Page 27
EXAMPLE
New RPN
on Results
0
0
0
Page 28