What are the best practices for optimizing maintenance and repair of a product using FMEA?

Podemos inserir as seguintes análises no DFMEA: 1. Se o produto faz parte de um sistema, é possível realizar a manuten??o ou reparo sem a necessidade de retirá-lo do sistema? 2. Se necessário retirá-lo, qual o grau de facilidade? a. é bom o acesso para esta desmontagem? b. Tem espa?o suficiente para o mantenedor poder realizar a desmontagem (tem espa?o para acesso das m?os e para utilizar as ferramentas)? 3. Est?o identificados no produto as pe?as de reposi??o? 4. Determinadas regi?es inteiri?as do produto com potencial de quebra podem se tornar componentes para que quando ocorrer a quebra, trocar somente este componente e n?o o produto inteiro ou um componente maior?

FMEA, in Six Sigma terms, is a proactive analysis led by a cross-functional team to identify potential failure modes, assess their severity and occurrence, and prioritize mitigation actions. We use FMEA for every service we launch. It involves walking through every function of every sub-component and identifying potential failure points and their impact on the entire system. Though rigorous, its value in risk reduction is immense. The FMEA framework is versatile, allowing customization to suit specific organizational requirements.

FMEA is conducted to stop system, product, or process to fail, even if we are not sure how it might fail. It's usually a team effort where we work together to find and fix problems before they happen. 1. Define Process 2. Protentional Failure Mode 3. Failure Effects and its severity 4. Cause of Failure and its likelihood 5. Current Controls in place for detection. 6. Generate RPN Number 7. Addition controls/Actions for failure mode 8. Responsible person to implement that action 9. After the additional control implemented calculate RPN=Severity*Likelihood*Detection

FMEA's informs inquiry and action for other areas of the business from the safety team to procurements. FMEA outputs can be translated to dollars in lost production and liability. This impacts decisions for the management of spares to buffering production. An FMEA must consider the repair manual trouble shooting guides and the reliability and repair records. FMEA informs investment in repairs and upgrades when it considers breakdown frequency. The FMEA is simply a formalized and professionalized method of asking "what if?". This can be applied to yoghurt or bolts holding the hatch frame in a 787 max.

EL FMEA es una metodología que permite con sus resultados gestionar la toma de decisiones en la gestion del activo y su mantenimiento además una herramienta que apalanca la confiabilidad del producto, equipo o componente, pudiendo definir niveles de criticidad para sistemas o sub sistemas. identificar aquellas fallas recurrentes y gestionar las mejoras aplicables.

1. Identify failure modes and their effects systematically. 2. Assign severity, occurrence, and detection ratings to each failure mode. 3. Calculate the Risk Priority Number (RPN) for prioritization. 4. Implement corrective actions based on identified risks. 5. Document and update the FMEA using a structured table or spreadsheet format for traceability and consistency.

When it comes to improving product performance it's worth considering that your product in this day and age has to be designed with consideration of IoT (Internet of things) to monitor its performance and maybe create a digital twin. With this well setup it therefore becomes easy to analyse and establish how the product performs normally. When failure does happen FMEA is employed with the end goal of establishing the correct actions. One thing to note here is that since we have data of when the failure occurred, then we can leverage anomaly detection algorithms and expose our product data to it so that failures can be detected or predicted early on before they occur while also using it as a test bed for maintenance recommendations.

Don't let perfection be the enemy of the good. Don't wait for the most reliable data and perfect feedback. The most important aspect is to have cross-functional expertise. All essential functions, including engineering, quality assurance, architecture, cloud, user experience, program, and any other relevant contributors, should be a part of the team. No perspective or input is considered insignificant or small. Starting FMEA during the initial design stages is best. At this point, components and subcomponents should be lined up on the design board. We did this, and it was beneficial. Please feel free to revisit this exercise at any point in the service/project lifecycle. Consistent practice will uncover surprising results.

1. Utilize data from testing, simulation, feedback, warranty, and historical records. 2. Incorporate information from standards, guidelines, best practices, and expert opinions. 3. Ensure data accuracy, relevance, and timeliness for effective analysis. 4. Verify the credibility and reliability of sources before incorporating them. 5. Base FMEA on factual evidence to enhance reliability and mitigate assumptions.

Dados confiáveis possuem origem, comparabilidade, capacidade de auditar, reprodutibilidade entre outras características. Gosto sempre de brincar com meus pares: "N?o aceite números sem criticar a origem deles. Pode ser que esteja tudo correto, mas pode ser que algo falhe". Portanto, valide números, verifique bases e tenha certeza que indicadores s?o feitos para serem reais, e n?o bonitos.

We always put together a seasoned cross function team for FMEA's. The other side is to keep it a living document based on process changes and unexpected quality/reliability issues. Use it build your control plans as well to mitigate risk. It work up front but well worth the effort.

Achieving accuracy in RPN calculation relies on the involvement of the right and appropriate departmental or functional teams. Team should prioritize customer-centricity/usability and regulatory compliance without compromising on cost-effectiveness and performance. Additionally, leveraging insights from past field failures/learnings is crucial input for effective FMEA.

paperwork. Of the Cross functional team is one task but FMEA needs an ownership by Quality to drive beyond the books and definitions of FMEA. I have encountered companies that dump rejected materials and do not attend the cost of scrap but do continue to enforce FMEA review and paperworks.

FMEA can help optimize maintenance and repair by: Preventing future breakdowns by reducing the likelihood of common and critical failures using planned maintenance and standard operating procedures Reducing response times, downtime, and health and safety risks when product failure occurs Prioritizing preventive and corrective maintenance in non-emergency situations.

Three key takeaways for FMEA would be 1) Risk Prioritization: Understanding how to quantify and prioritize risks is fundamental. This involves assessing the severity of potential failures, their likelihood of occurrence, and the ability to detect them before they impact customers or operations. By calculating the Risk Priority Number (RPN) 2) Cross-functional Collaboration: FMEA requires collaboration across disciplines - software engineering, cybersecurity, compliance, quality assurance, and user experience. Identifying potential failure modes by recognizing unique insights of each function is crucial. 3) Continuous Improvement: A continuous improvement mindset ensures that the organization remains agile, responsive to emerging threats