Failure Mode And Effect Analysis: Ford Motor Co., Ford Motor Co)

Failure mode and effects analysis (FMEA) has long been used as a planning tool during the development of processes, products, and services. In developing the FMEA, the team identifies failure modes and actions that can reduce or eliminate the potential failure from occurring. Input is solicited from a broad group of experts across design, test, quality, product line, marketing, manufacturing, and the customer to ensure that potential failure modes are identified. The FMEA is then used during deployment of the product or service for troubleshooting and corrective action. The standard FMEA process evaluates failure modes for occurrence, severity, and detection (Chrysler Corp., Ford Motor Co., and General Motors Corp., 1995). The multiplication

It is used to develop features and goals for product and process, in identifying critical of product/process factor, designing customaries the potential problems, establishing the control to prevent the errors and prioritizing the process submit to ensure reliability. FMEA most commonly applied but not limit to design (DFMEA) and manufacturing process (PFMEA). Design failure mode and effect analysis (DFMEA) identify the potential failure of design before they occur.DFMEA then goes to establish a potential effects of the failures, there causes, how often and when they might occur and their potential seriousness.

Process failure mode and effect analysis (PFMEA) is systemized group of activities intended to recognized and evaluated the potential failure of a product/process and its effect .indentify action which could eliminate or reduce the occurrence or improve the defect ability, document the process and track change to avoid the potential failure cause.

2.2 FMEA approach FMEA is carried out by a cross-functional team of experts from various departments. Normally, a team is formed at the planning stage of a new product based on a concurrent engineering approach. The team analyzes each component and subsystem of the product for the failure modes. Then, the potential causes and effects are

RPN is a decision factor based on three ratings: Severity (S), Occurrence (O) and Detection (D). These ratings are scaled with numbers between 1 and 10 [38]. The analysis starts from the basic structure of the system and particularly from those system elements for which accurate information about failure mode and its causes are available. By analyzing the functional relationships among these elements, it is possible to identify the possibility of propagation of each type of failure to predict its effects on the production performance of the entire system. This is an inductive method to analyze failure modes using down-top methodology [39]. The FMEA is a formalized but subjective analysis for the systematic identification of possible root causes and failure modes and the estimation of their relative risks. The main goal is to identify and then limit or avoid risk within a design. Hence, the FMEA drives towards higher reliability, higher quality and enhance safety [40]. FMEA concentrates in identifying the severity and criticality of failures. FMEA is a fully bottom-up approach [41]. Risk Priority Number, which is the product of the severity, occurrence and detection ratings is calculated as RPN = S x O x D. The RPN must be calculated for each cause of failure. RPN shows the relative likelihood of a failure mode, in that the higher number, the higher the failure mode. From RPN, a critical summary