Failure Mode & Effects Analysis FMEA (Failure Mode and Effects Analysis) is a systematic method for ...
Failure Mode & Effects Analysis FMEA (Failure Mode and Effects Analysis) is a systematic method for identifying potential failure modes and documenting their severity of impact, likelihood of occurrence, and undetectability. The tool is used during the Improve phase of the DMAIC cycle to determine mitigating actions being taken to minimize severity, likelihood, and undetectability, then record the impacts of the mitigating actions on those attributes. FMEA makes preemptive improvements before failures occur to minimize risk. Design FMEA, or DFMEA, is used to minimize the risks of failures in designed products or services. Process FMEA, or PFMEA, is used to minimize the risks of failures during processes. Outside of business process improvement and lean six sigma, FMEA can be used for projects in general. Project FMEA is used to minimize risks of failures in the implementation of projects. All these types of FMEA could use the same template; however, DFMEA would address design features, PFMEA would address process steps, and Project FMEA would address project tasks/activities. Before you begin, be sure to review the following resources: Use one of the opportunities for improvement (OFIs) that you discovered during your Benchmarking Report assignment or Eight Wastes assignment as a project. You are working on the Improve phase of this project, trying to itemize failure modes so you can improve them with mitigating actions. Use the template provided to perform Process FMEA (PFMEA) by listing process steps and failure modes for each. You can use the same process that you used for your SIPOC Map assignment or Process Flow Chart assignment if you would like. Your Failure Mode & Effects Analysis must include: Organization Name Project Title Process Steps (minimum 2) Failure Modes (minimum 3 for each process step) Ratings for severity of impact, likelihood of occurrence, and undetectability for each failure mode Risk Priority Number (RPN) for each failure mode Mitigating Action to improve each failure mode Revised Ratings for severity, likelihood, and undetectability for each failure mode Revised RPN for each failure mode Upload your document following the submission instructions below. ___________________________________________________________________________________________________ Control Chart and Process Audit Two tools used in the Control phase of the DMAIC cycle are the Control Chart, often called Statistical Process Control (SPC) Chart, and the Process Audit. You will use both tools to complete this assignment. The Control Chart shows how a variable changes over time. Data are plotted in time order. A Control Chart always has a central line for the average. The chart also shows an upper line for the upper control limit (UCL) and a lower line for the lower control limit (LCL). This data helps to control processes, to predict outcomes, and to monitor the process. You will analyze a Control Chart provided in the assignment template. You are analyzing the Control Chart as part of a Process Audit. You will be looking for “out of control” conditions and where the process is not working. You want to make sure the process is stable and meets requirements, so you will do some problem solving to figure out where and how to make changes in the process. Before you begin, be sure to review the following resources Upload your document following the submission instructions below. Use one of the opportunities for improvement (OFIs) that you discovered during your Benchmarking Report assignment or Eight Wastes assignment as a project. You are working on the Control phase of this project, trying to make sure that the process improvements you made during the Improve phase are working and stay working. Use the template provided to perform a Process Audit, including analysis of the Control Chart and solving problems with out-of-control conditions. Follow the question prompts in the template to work through the problem and bring the process back under control. Fill out the yellow areas to complete the assignment. Your Process Audit report must include: Organization Name Process Title Variable Being Tracked Out-of-Control Conditions Five-Why Root Cause Analysis Containment Actions (to "rope off" or secure the situation) Corrections (to get the situation back under control) Corrective Actions (to prevent recurrence of out-of-control conditions Streamline a Process with Line Balancing Lean Six Sigma organizations can streamline their operations to be more efficient and/or effective using lean manufacturing techniques. Lean focuses on minimizing batch size, work-in-process inventory, lead time, and bottlenecks. It utilizes pull scheduling systems to dictate the flow of products and services. Line Balancing, also known as heijunka in Japanese, is a lean tool that helps with several of these issues at once by reorganizing operations and resources to match the Takt time established by the customer. You are working on an improvement project where there are three problems: the total cycle time (TCT) per unit is higher than the Takt time for some of the operations, there is some non-utilized resources waste visible at some of the production stations (station downtime), and there is transportation waste visible with people moving parts back and forth all over the place from station to station for the next operation. You will use line balancing to tackle all three of these problems. Before you begin, be sure to review the following resources: Your Line Balancing document must include: All 18 Operation Blocks Inside the Green Block All 16 Operations Arranged in Chronological Order No Resizing of Any Blocks (blocks have dimensions so any tampering will be evident) Upload your document following the submission instructions below.
