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FMEA for Six Sigma

Prepared By: ABHIJITH M PILLAI


Date: 11/29/2012

S O
v c
Process Potential Failure Potential Effects Potential Causes
Oper. No r r
description Mode or Failure of Failure
t n
y c

Fixing the incorret


1 uneven surface 6 human error 2
workpiece position
wrong guage
2 Marking wrong position 7 2
dimension calibration

excess removal
3 Filing incorrect speed 3 unskilled labour 2
of material

worn out file no surface finish 7 bad tool 3

incorrect inaccurate non calibrated


4 Measuring 4 1
measurement workpiece scale
EA for Six Sigma
AI
Filing
Action Results

Current Responsibility S O D
R
Controls for Recommended and Target v c t
P
Prevention/Det Action Completion Action Taken r r c
N
ection Date t n t
y c n

4 48 Training 1 week workers trained 6 1 1

5 70 training 3 days training given 5 2 2

recruit only
3 18 skilled labour 2 1 1
skilled labours

3 63 change tool 1 day new tool used 4 2 1

calibrate the calibrated the


7 28 1 week 3 1 2
instrument instrument
sults

R
P
N

20

6
AIAG Compelled Rating
Rating Severity of Effect
10 Hazardous without Warning
9 Hazardous with Warning
8 Lose of primary function
7 Reduced primary function performance
6 Lose of secondary function
5 Reduced secondary function performance
4 Minor defect noticed by most customers
3 Minor defect noticed by some customers
2 Minor defect noticed by discriminating customers
1 No effect unlikely

Six-Sigma Compelled Rating


Rating Severity of Effect
10 Injure a customer or employ

9 Be illegal

8 Render product or service unfit for use


7 Cause extreme customer dissatisfaction
6 Result in partial malfunction

Cause a loss of performance which is likely to result in


5
a complaint

4 Cause minor performance loss

Cause a minor nuisance but can be overcome with no


3
performance loss
Be unnoticed and have only minor effect on
2
performance

1 Be unnoticed and no effect on performance


AIAG Compelled Rating
Likelihood of Occurrence Ability to Detect
Very high; Failure is almost inevitable Can not detect
Very high; Failure is almost inevitable Very remote chances of detection
High; Repeated failures Remote chances of detection
High; Repeated failures Very low chances of detection
Moderate; Occasional failures Low chances of detection
Moderate; Occasional failures Moderate chances of detection
Moderate; Occasional failures Moderate high chances of detection
Low; Relatively low failures High chances of detection
Low; Relatively low failures Very high chances of detection
Remote; Failure is unlikely Almost certain

Six-Sigma Compelled Rating


Likelihood of Occurrence Ability to Detect
More than one per day Defect caused by failure is not detectable

Once every 3-4 days Occasional units are checked for defects

Units are systematically sampled and


Once every week
inspected
Once per month All units are manually inspected
Manual inspection with mistake proofing
Once every three months
modifications
Process is monitored and manually
Once every six months
inspected
SPC is used with an immediate reaction to
One per year
out of control conditions
SPC is above 100% inspection surrounding
Once every 1-3 years
out of control conditions

Once every 3-6 years All units are automatically inspected

Defect is obvious and can be kept from


Once every 6-9 years
affecting the customer

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