Page 189 - DMGT524_TOTAL_QUALITY_MANAGEMENT

Total Quality Management

Notes The Detection value is then assigned to the failure mode and finally the R.P.N value is
calculated as following:
If S = 4, O = 3, & D = 4

Then, R.P.N = S × O × D
= 4 × 3 ×4 = 48
Recommendations
For each specific product, the preventions suggested in the FMEA chart can considerably
decrease the loss to the automobile industry in terms of both money and time. The following
suggestions/recommendations are given for these products:

Flywheel
Butting face should be properly cleaned during Balancing.
Size of key lock may be adjusted according to shaft and flywheel.
In-process inspection should be adopted more frequently and strictly.
Snap gauge should be used for 100% inspection.

Cross check the machine with master piece.
Flywheel Housing
Thread Depth gauge should be used for 100% inspection.
Offset compensation should be properly given to the tool.

In-process inspection should be adopted more frequently.
Assembly of manufactured parts should be performed in such a way that it should
work satisfactorily in the field to avoid customer dissatisfaction.

Preventive maintenance should be adopted as per the given schedule.
The present work deals with the FMEA study of two products i.e. flywheel and flywheel
housing. The basic requirements of the manufacturing processes are first studied and then
the potential failure mode of the specific process is found out. After that the potential
effects of the failure modes are noted with their severity value and then the potential
causes and their prevention are calculated along with their occurrence value. The Detection
value was assigned to the failure mode and finally the R.P.N. value is calculated. FMEA
analysis may easily help in improving the efficiency of the manufacturing process thus
decreasing the number of defective products and saving of re-work cost and valuable
time. For each specific product the preventions suggested in the chart can considerably
decrease the loss to the casting industry in terms of both money and time.
Question
What does the above case study depict?

Source: http://technicaljournals.org/NPDF/IJMEAR-04-TJ-A18.pdf
12.7 Summary

Failure Modes and Effects Analysis (FMEA) is a step-by-step approach for identifying all
possible failures in a design, a manufacturing or assembly process, or a product or service.

The purpose of the FMEA is to take actions to eliminate or reduce failures, starting with
the highest-priority ones.

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