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Part 2: Using FMEA, DFR, Test and Failure Analysis in Lean NPD Overview • Introduction and Definitions • Part 1: Lean Product Development – Lean Vs

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Part 2: Using FMEA, DFR, Test and Failure Analysis in Lean NPD Overview • Introduction and Definitions • Part 1: Lean Product Development – Lean Vs Part 2: Using FMEA, DFR, Test and Failure Analysis in Lean NPD Overview • Introduction and Definitions • Part 1: Lean Product Development – Lean vs. Traditional Product Development – Key Elements of Lean NPD • Customer Defines Value • Front Loaded and Knowledge Based • Eliminate Redesign Waste – Reliability Requirements • Part 2: Reliability Elements of Lean NPD – Lean FMEA and DRBFM – Critical Characteristics – DFR and Physics of Failure – Accelerated Testing to Failure – Failure Analysis and Knowledge Capture Lean FMEA • Some teams attempt to lean FMEA process by creating product family FMEAs but fail to update FMEA for new applications or changes • Instead Lean FMEA Should Focus on New Design Features and Changes to Baseline Design to Assess Associated Risks Tools to Focus Lean FMEA • Diagramming Tools – Functional Block Diagram – Boundary Diagram – Parameter Diagram – Process Flow Diagram • Highlight Changes to Product or Process on the Diagrams Functional Block Diagram Annotate Retained and Changed Items & Functions Boundary Diagram Construction Subsystem 1 Subsystem 3 Subsystem 2 Interface -Physical Interface -Info Transfer -Data Transfer Consider a Functional Block Diagram of the System -External Input With Modules and Interfaces FMEA Boundary Parameter Diagram of Product, Process, System Noise • Forces Beyond Control Factors • Cause Output Variation • Environment Factors Response Signal (Output, Function) (Inputs) Product, Process, or System • Controlled by Input Function • Performance Mean, Std Dev • Static or Dynamic • Customer Requirement • May be Variable Control Factors • Functional Design Parameters • Fixed or Adjustable • Fundamental to Design of Function • Reduce Variation Elements of the P-Diagram Process Flow Diagram Annotate Retained and Changed Process Steps Selecting Process Steps for Analysis • On Process Flow Map: – Identify Steps Being Modified – Identify New Steps Required for New Product • Drill Down to Identify Sub-Steps Within the Target Steps Identified for Analysis • Complete Lean PFMEA on Selected Process Steps • Integrate with Previous PFMEA on Standard / Unchanged Process Steps Key Characteristics • Include: – Product Features – Manufacturing Processes – Assembly Characteristics • That Significantly Affect: – Product Performance – Form, Fit, Function • Lean NPD Focuses on the Critical Few Characteristics the Customer Values Key Characteristics Requirements Documents •Customer Specification •Regulatory •Dimensions •Appearance Requirements Document Drawings Robustness Tools Field History •Functional Block Diagram Item / C O D Action Results Potential Current Response & Process Potential Potential S l c e R •Boundary DiagramStep Cause(s)/ Design Recommended Target Failure Effect(s) of e a c t P S O D R Mechanism(s) Controls Actions Complete Action Mode Failure v s u e N E C E P Of Failure Date Taken s r c V C T N •P-Diagram Function Prevent Detect •Interface Matrix DFMEA & PFMEA Process Steps Customer Primary Drive Manufacturing Process Steps Assessment Special Characteristics Matrix Severity LOAD PRIMARY Op 20 Op 10 - Op 430 Op 520 Op 445 Op 500 Op 510 Op 530 Op 535 Op 120 Op 200 Op 210 Op 330 Op 110 Op 220 Op 230 Op 300 Op 310 Op 320 Op 350 Op 400 Op 410 Op 420 OP 340 OP LOAD JACK SHAFT mandrel Reserved - FIXTURE FIXTURE ring ring to shifter tube LOAD DOWELPINS TO Operate Operate press Operate Operate press Operate press - Op 100 Op 100 Step 1 Op 100 Step 2 Op 100 Step 3 load load bearing to fixture #2 - load load main shaft oil seal to Housing Housing to table Reload Reload fixture #1 - Receive Material Receive Material handling Material - Shipping Damage Shipping load load fixture #2 and mandrel Vehicle Assembly Vehicle O Housing Housing to fixture #2 Housing Housing to fixture #1 Clamp Clamp to shifter tube SEAL TO FIXTURE Que Que for final assy line - Direction of Improvement Assemble shifter lever Shifter Shifter tube to housing PRE Lubricate Lubricate bushing & seal Shifter Shifter lever to shifter tube HOUSING BUSHING TO PRE Component Manufacture Component 1.090 TO 1.110 " FACE OF PRIMARY HOUSING Move or stage for final assy Wave Wave washer to shifter lever Retaining Retaining ring to top groove Retaining ring to top groove Pre Chain Chain adj sub assy to housing Pre Re Mandrel Mandrel to main shaft bore I.D. BUSHING TO FACE OF JACK SHAFT PRE SEAL 5 G F DOWEL PINS 0.260 TO 0.270 " TO FACE 3 JACK SHAFT SEAL AGAINST H F SHOULDER 9 H F BEARING FLUSH TO SNAP RING FACE3 G F G SEAL COMPRESSION HEIGHT 9 H G H H F H H PRIMARY GASKET SEAL SURFACE9 FINISHF F Y H H H H H GG Technical Requirements, SERATION DAMAGE 5 F 0 0 0 0 9 0 3 0 3 0 0 0 9 9 0 0 0 0 0 0 0 81 81 72 41 27 54 54 81 27 45 Weighted Importance 261 Potential Critical and SignificantandCritical Potential Tools Identify Special Relative Importance Product Characteristics Characteristics Matrix Identifying Key Characteristics 10 9 8 Severity 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 Occurrence Potential Critical Characteristic Possible Annoyance Zone Potential Key Characteristic Characteristics from Requirements from Requirements and DFMEA Characteristics Potential Critical and Significant Special Characteristics Matrix CharacteristicsSpecial BEARING FLUSH FLUSH BEARING TOSNAPRING FACE SEAL COMPRESSION SEAL HEIGHT PRIMARY GASKETPRIMARY SEAL SURFACE FINISH 1.090 1.090 TO1.110 "OFFACE PRIMARY HOUSING BUSHING TOBUSHING FACE OF JACKSHAFT DOWEL PINS 0.260 PINS DOWEL0.260 TO 0.270 "TO SHOULDER SERATIONDAMAGE JACK SHAFT JACKSEAL AGAINST SEAL FACE Direction of Improvement of Direction Weighted Importance Weighted Relative Importance Relative Special Characteristics Special Matrix 5 9 9 3 9 3 5 Severity 0 Receive Material 81 H Material handling 81 H Shipping Damage M 72 M Component Manufacture 0 Vehicle Assembly Op 100 Step 1 9 M PRE-LOAD DOWEL PINS TO FIXTURE Op 100 Step 2 M 41 L L PRE-LOAD JACK SHAFT SEAL TO FIXTURE Op 100 Step 3 PRE-LOAD PRIMARY 0 HOUSING BUSHING TO FIXTURE Op 110 0 Pre-load bearing to fixture #2 Op 120 27 M Pre-load main shaft oil seal to mandrel M M Op 200 54 Housing to fixture #1 M H H H H Op 210 261 Operate press Op 220 L 3 Steps from Chart Flow Process Retaining ring to top groove Op 230 0 Steps Process Reload fixture #1 Primary Drive Manufacturing Process Steps Process Manufacturing Drive Primary M 54 M Op 300 Housing to fixture #2 M M H Op 310 81 Operate press H Op 320 3 Retaining ring to top groove 0 Op 330 Mandrel to main shaft bore I.D. OP 340 0 Operate press 0 Op 350 Re-load fixture #2 and mandrel 27 M Op 400 Housing to table 0 Op 410 Reserved H Op 420 Characteristics of Step on Effect 45 Chain adj sub assy to housing Op 430 9 L Lubricate bushing & seal 9 L Op 445 Move or stage for final assy Op 10 0 O-ring to shifter tube Op 500 0 Shifter tube to housing Op 510 0 Clamp to shifter tube Op 20 0 Assemble shifter lever 0 Op 520 Wave washer to shifter lever 0 Op 530 Shifter lever to shifter tube 0 Op 535 Que for final assy line Assessment Customer Developing the Control Plan • Prioritize Process Risks Identified in the PFMEA and the Special Characteristics Matrix • Process Flow Diagram • Lessons Learned from Similar Processes • Process Control Data from Related Processes • Measurements Required for Process Control • SPC Control Limits • Complete the Items in Control Plan Template Control Plan Items Machine, Device, Jig, For each operation that is described, identify the processing equipment machine, device, Tools for Mfg. jig, or other tools for manufacturing, as appropriate. No. Enter a cross reference number from all applicable documents such as, but not limited to, process flow diagram, numbered blue print, FMEAs, and sketches. Product Features or properties of a part, component or assembly that are described on drawings or other primary engineering info. Compilation of important product characteristics. Process Process variables that have a cause and effect relationship with the identified product characteristic. Identify those process characteristics for which variation must be controlled to minimize product variation. There may be more than one process characteristic for each product characteristic. Product/Process Specifications/tolerance may be obtained from various engineering documents, such as, but Specifications/ not limited to, drawings, design reviews, material standard, computer aided design data, Tolerance manufacturing, and/or assembly requirements. Evaluation/ Identify the measurement system being used, including, gages, fixtures, tools, and/or test Measurement/ equipment required to measure the part/process/manufacturing equipment. Technique Sample When sampling is required list the corresponding size and frequency. Control Method Brief description of how the operation will be controlled, including procedure numbers where applicable. Operations may be controlled by SPC, inspection, attribute data, mistake proofing, sampling plans, and other. If elaborate control procedures are used, reference document by ID name/number. Reaction Plan Specify the corrective actions necessary to avoid producing nonconforming products or operating out of control. May also refer to a specific reaction plan number and identify the person responsible for the action. Using the Control Plan • For Critical Characteristics, Use Control Plan to Identify: – Measurements: How, When, How Often – Controls to Keep Characteristic in Tolerance – Actions if Characteristic Out of Tolerance • Containment • Corrective Actions • Robust Design + Controlled Processes = Reliable Products DRBFM and DRBTR Design Review Based on Failure Modes & Test Results Key Elements of Mizenboushi (Reliability Problem Prevention) GD3 (Good Design, Good Discussion, Good Dissection) Toyota’s “Creative FMEA” Method Problem Prevention – GD3 • Good Design = Robust Design – Design for Reliability (DFR) – Design for Six Sigma (DFSS) • Good Discussion = Eliminate Risk – Apply Design Review Based on Failure Modes (DRBFM) to identify problems and develop countermeasures or corrections • Good Dissection = Effective Validation – Apply Design Review Based on Test Results (DRBTR) to Evaluate Effectiveness.
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