FMEA software during the development process / product design phase

Step 1: Planning and preparation

TO DO:
To start off, the first step is to define the basic framework conditions for performing FMEA. According to the harmonized AIAG/VDA FMEA Handbook, these also include the “5Ts”:

• Intent/goal,
• Composition of the team,
• Timing/milestones,
• The catalogs designed to exploit existing knowledge (Lessons Learned),
• The interfaces right through to the end customer,
• The FMEA method used and respective FMEA tool,
• The scope and depth of observation, as well as
• Task allocation.

In practice, the creation of a so-called kick-off protocol has proven its worth when defining the conditions. This can then be used as a basis for planning the project. The aim of Step 1, on the one hand, is to create a common awareness of the effort required amongst all those involved. On the other hand, the amount of work required is reduced through proceeding in a structured fashion. The preparations in Step 1 also create the basis for subsequent analyses, such as the FMEA structure analysis, FMEA function analysis and failure analysis.

Step 2: Structure analysis

TO DO:
Structure analysis depicts the structure of the product, resp. process, via structure/Design FMEA or Process FMEA. Both the scope and depth of observation defined in Step 1 are visualized through this structure analysis. In this context, the defined system elements serve as a peg on which to hang the associated functions – and for understanding the hierarchical interrelationships.

CASQ-it FMEA:
Our FMEA software provides you with systematic support for performing structure analysis: Structure trees help you to maintain an overview of your FMEA. Graphical system nets visualize the complete product design and your process chain in the desired level of detail. Alternatively, FMEA can be intuitively created for less complex systems in the same CASQ-it module using a simplified logic in line with the 4th edition of the AIAG standard.
In this case, intelligent, self-learning catalogs independently suggest the appropriate terminology, thus creating a comprehensive knowledge database within a really short space of time. This can then be used to generate new FMEAs extremely quickly. Template FMEAs ensure that design and process changes can be swiftly applied to all the linked FMEAs. These FMEA templates, for example, group and family FMEAs, can also be used to create new, specific FMEAs within the space of a very short time.

Step 3: Function analysis

TO DO:
Function analysis is performed parallel to system analysis. The functions are assigned to the system elements based on the requirements and existing specifications as well as on empirical values. These functions are then broken down in detail according to subsystem, assembly and component, resp. into three levels, i.e. process, process step and influencing factor. Through this hierarchical integration, the interrelationships become clear so that all those involved gain a better understanding of the product/process concerned. An indispensable basis on which to build and develop your failure analysis process.

CASQ-it FMEA:
CASQ-it visualizes your function analysis in comprehensible networks. This guarantees transparency and quick navigation through interrelated functions. Whether we are talking about process or product analysis: Characteristics can be added, together with their respective tolerance specifications. Critical and safety-relevant features can be immediately identified via graphic symbols.

Being able to directly link the functions and characteristics from your Design FMEA to the respective step in your Process FMEA creates a high level of transparency. This results in a superordinate function and malfunction network that graphically illustrates the interrelationships between the product design and the respective processes.

Steps that already exist in your FMEA system are imported straight into the Control Plan – including all the product characteristics and process parameters specified in the detailed inspection plans.

Step 4: Failure analysis

TO DO:
The aim of performing failure analysis is to clearly identify the failure effects, failure modes and failure causes. These are then linked up using the hierarchical structure. These failure chains immediately show which risks in the process have a direct impact on the end customer. The customers and their suppliers – and, in turn, their suppliers, can collaborate to exploit these failure effects accordingly.

CASQ-it FMEA:
Our FMEA software systematically identifies and establishes links between failure causes, the effects of these failures and their interdependencies. This results in a complete failure chain which is depicted in clearly structured networks. In the case of a complaint, it is immediately obvious which additional effects as a result of the failure might need to be reckoned with. Information on failures, their causes and their effects are automatically transferred to standard-compliant form sheets, such as our FMEA form.

Step 5: Risk evaluation and action analysis

TO DO: The aim of conducting risk analysis is to identify and prioritize the risks. To this end, each risk is assessed in terms of its severity, occurrence and detection. Based on the harmonized AIAG/VDA FMEA Handbook, the focus is on the following objectives:

• The assignment of existing preventive and detection actions
• The rating of each failure chain with regard to its severity, occurrence and detection
• The evaluation of the failure chains and establishment of the action priority
• Collaboration between the customer and the supplier (severity)

CASQ-it FMEA:
DUsing CASQ-it FMEA, it is particularly easy to assess the functional and malfunctional interrelationships via respective catalogs. The malfunction networks provide graphical support during the cause analysis process. The multilingual, catalog-controlled failure mode selection feature helps your FMEA team to determine the necessary actions. To achieve this, the catalogs suggest suitable terminology based on that already used in other FMEAs. This is a simple and efficient method of passing on existing knowledge. When conducting risk evaluation, you can choose between standard-compliant evaluation schemes and your company’s own evaluation system.

Whether we are talking about the risk priority number (FMEA RPN) or action priority: The potential weak points, risk areas and failure causes of a product or process can be identified by your FMEA team at a glance.

CASQ-it FMEA systematically accompanies you along the path from discovering a possible failure to introducing a reliable preventive action.

Step 6: Optimization

TO DO:
For existing preventive and detection actions with an increased ACTUAL risk, an optimization process is run. The aim of this optimization process is to identify further actions and solutions which can avoid the potential risks, resp. increases the probability of their detection. This process is repeated until all the risks are at an acceptable level.

CASQ-it FMEA:
DThe clearly structured risk evaluation of all the existing preventive and detection actions directs your attention straight to those areas where there is a need to act and introduce optimization measures to mitigate the risk. Based on pre-defined responsibilities and processing deadlines, and in combination with CASQ-it’s Event Service tool, CASQ-it FMEA controls the processing of the actions to ensure that these are processed on schedule. Each employee receives a personal “To Do” list containing a list of open actions. Whether this is initiated through the FMEA module or CASQ-it TMS, the central Task Management System module: The monitoring of the processing is handled completely automatically by CASQ-it’s Event Service. Are the actions being accordingly implemented? Can the deadlines be met?

CASQ-it supports the work carried out by your FMEA moderator in a special way: All statuses are continually updated, and the specifics made immediately available. In the case of a postponement, an email is instantly dispatched by the integrated escalation manager tool.

CASQ-it FMEA creates your risk evaluation documentation in compliance with the VDA/AIAG standards and according to your own formats. Report bundling, process workflow diagrams in your Control Plan, comparative analysis and action overviews bring transparency to your risk management procedures. Your results are processed seamlessly by CASQ-it – right up until the successful completion of the product design phase. Your FMEA system achieves this by supplying the individual process steps for your Control Plan, including detailed inspection plans.

Step 7: Documentation

TO DO:
The FMEA results and plan should be summarized in one single report. The objectives of this report are to:

• Communicate the results and conclusions of the FMEA
• Establish the contents of the documentation
• Document the actions taken and their effectiveness
• Evaluate the risk after the actions have been taken
• Communicate risk reduction measures
• Document the risk evaluation process

CASQ-it FMEA:
Our FMEA solution supports the above in many ways, including:

• Seamless documentation of all the actions taken
• Output the main risks
• Generation of action overviews
• Forms
• Graphical output of the structures and networks