Outlines the correct procedures for doing FMEAs and how to
successfully apply them in design, development, manufacturing, and
service applications

There are a myriad of quality and reliability tools available to
corporations worldwide, but the one that shows up consistently in
company after company is Failure Mode and Effects Analysis (FMEA).
Effective FMEAs takes the best practices from hundreds of
companies and thousands of FMEA applications and presents
streamlined procedures for veteran FMEA practitioners, novices, and
everyone in between.

Written from an applications viewpoint--with many examples,
detailed case studies, study problems, and tips included--the
book covers the most common types of FMEAs, including System FMEAs,
Design FMEAs, Process FMEAs, Maintenance FMEAs, Software FMEAs, and
others. It also presents chapters on Fault Tree Analysis, Design
Review Based on Failure Mode (DRBFM), Reliability-Centered
Maintenance (RCM), Hazard Analysis, and FMECA (which adds
criticality analysis to FMEA).

With extensive study problems and a companion Solutions Manual,
this book is an ideal resource for academic curricula, as well as
for applications in industry. In addition, Effective FMEAs
covers:

* The basics of FMEAs and risk assessment

* How to apply key factors for effective FMEAs and prevent the
most common errors

* What is needed to provide excellent FMEA facilitation

* Implementing a "best practice" FMEA process

Everyone wants to support the accomplishment of safe and
trouble-free products and processes while generating happy and
loyal customers. This book will show readers how to use FMEA to
anticipate and prevent problems, reduce costs, shorten product
development times, and achieve safe and highly reliable products
and processes.

CARL S. CARLSON is a consultant and instructor in the areas of FMEA, reliability program planning, and other reliability engineering disciplines. He also currently supports clients of ReliaSoft Corporation. He has thirty years' experience in reliability testing, engineering, and management positions, including manager of product reliability at General Motors. He co-chaired the cross-industry team that developed the commercial FMEA standard (SAE J1739, 2002 version) and was a past member of the Reliability and Maintainability Symposium (RAMS) Advisory Board. He holds a BS in mechanical engineering from the University of Michigan and is a Certified Reliability Engineer.

Zusammenfassung

Outlines the correct procedures for doing FMEAs and how to successfully apply them in design, development, manufacturing, and service applications

There are a myriad of quality and reliability tools available to corporations worldwide, but the one that shows up consistently in company after company is Failure Mode and Effects Analysis (FMEA). Effective FMEAs takes the best practices from hundreds of companies and thousands of FMEA applications and presents streamlined procedures for veteran FMEA practitioners, novices, and everyone in between.

Written from an applications viewpointwith many examples, detailed case studies, study problems, and tips includedthe book covers the most common types of FMEAs, including System FMEAs, Design FMEAs, Process FMEAs, Maintenance FMEAs, Software FMEAs, and others. It also presents chapters on Fault Tree Analysis, Design Review Based on Failure Mode (DRBFM), Reliability-Centered Maintenance (RCM), Hazard Analysis, and FMECA (which adds criticality analysis to FMEA).

With extensive study problems and a companion Solutions Manual, this book is an ideal resource for academic curricula, as well as for applications in industry. In addition, Effective FMEAs covers:

• The basics of FMEAs and risk assessment

• How to apply key factors for effective FMEAs and prevent the most common errors

• What is needed to provide excellent FMEA facilitation

• Implementing a "best practice" FMEA process

Everyone wants to support the accomplishment of safe and trouble-free products and processes while generating happy and loyal customers. This book will show readers how to use FMEA to anticipate and prevent problems, reduce costs, shorten product development times, and achieve safe and highly reliable products and processes.

Series Editor's Foreword xvii

Copyrights and Permissions xix

Acknowledgments xxi

Introduction xxiii

Chapter 1 The Case for Failure Mode and Effects Analysis 1

In This Chapter 1

1.1 The Need for Effective FMEAs 1

1.2 FMEA Application by Industry 4

1.3 The Factor of 10 Rule 5

1.4 FMEA Successes 6

1.5 Brief History of FMEA 8

1.6 FMEA Standards and Guidelines 8

1.7 How to Use This Book 9

1.8 Web Companion to Effective FMEAs 10

1.9 End of Chapter Problems 10

References 11

Chapter 2 The Philosophy and Guiding Principles for Effective FMEAs 12

In This Chapter 12

2.1 What Is Philosophy and Why Does It Matter to FMEAs? 12

2.2 Guiding Principles for Effective FMEAs 13

2.3 The Role of FMEA in Design for Reliability 17

2.4 You Can't Anticipate Everything 18

2.5 End of Chapter Problems 19

References 20

Chapter 3 Understanding the Fundamental Definitions and Concepts of FMEAs 21

In This Chapter 21

3.1 Definition of FMEA 21

3.2 Primary Objective of FMEA 22

3.3 Definition of Failure Mode Effects and Criticality Analysis 22

3.4 Types of FMEAs 23

3.5 FMEA Definitions and Examples 25

3.6 Is It a Failure Mode, Effect, or Cause? 48

3.7 FMEA Glossary 49

3.8 Web Companion to Effective FMEAs 51

3.9 End of Chapter Problems 51

References 55

Chapter 4 Selection and Timing of FMEA Projects 56

In This Chapter 56

4.1 Guidelines for When to Do FMEAs 56

4.2 FMEA Project Selection Criteria 58

4.3 Preliminary Risk Assessment 59

4.4 When to Do Different Types of FMEAs 60

4.5 Responsibility for FMEAs between OEMs and Suppliers 62

4.6 Introducing the All-Terrain Bicycle Case Study 63

4.7 End of Chapter Problems 64

Chapter 5 How to Perform an FMEA Project: Preparation 66

In This Chapter 66

Use of the Bicycle Examples in the Chapter 66

5.1 The Subject of FMEA Preparation 67

5.2 Preparation Tasks Done Once for All FMEA Projects 67

5.3 Preparation Tasks for Each New FMEA Project 78

5.4 End of Chapter Problems 103

References 106

Chapter 6 How to Perform an FMEA Project: Procedure 107

In This Chapter 107

Use of the Bicycle Examples in the Chapter 107

6.1 FMEA Procedure Sequence of Steps 108

6.2 Basic FMEA Procedure 109

6.3 FMEA Linkages 152

6.4 End of Chapter Problems 158

References 161

Chapter 7 How to Develop and Execute Effective Risk Reduction Actions 162

In This Chapter 162

Use of the Bicycle Examples in the Chapter 162

7.1 Prioritize Issues for Corrective Action 163

7.2 Develop Effective Recommended Actions 165

7.3 Action Strategies to Reduce Risk 166

7.4 Examples of Recommended Actions 176

7.5 FMEA Execution Enablers 176

7.6 The Essence of Execution 182

7.7 Documenting Actions Taken 182

7.8 Ensuring Risk Is Reduced to an Acceptable Level 183

7.9 End of Chapter Problems 183

References 186

Chapter 8 Case Studies 187

In This Chapter 187

8.1 Case Study: Shock Absorber Assembly 188

8.2 Case Study: Strudel…