The process FMEA is used to identify potential errors in production or business processes early, evaluate them, and derive appropriate measures for risk minimization. The goal is to identify process weaknesses and sustainably improve the stability and quality of operations. This can reduce sources of error and increase efficiency.
You can download the data here: FMEA-Process.atb
In this excerpt, a process FMEA was conducted for the assembly of a cordless screwdriver. The image shown below depicts the area of the FMEA that was defined in advance, i.e., the status at the time of recording.
Interpretation of the results
Based on the task priority number, it is evident that a measure was rated with H. This measure should be prioritized, meaning it should be implemented as quickly as possible to reduce the risk.
The RPZ number results from the multiplication of Significance × Occurrence × Detection.
Nowadays, more and more work is done with the AP. The AP stands for task priority and places greater emphasis on the significance of the error consequence. You can see the AP table in the image below.
In the Improve phase, select the process FMEA and the number of rows you want to evaluate, then click Create Worksheet.
Preliminary Work
- Altitude analysis: Sometimes a process FMEA that considers a complete process is too comprehensive. In this case, the process must be delimited.
- Clearly classify the process activities within a process. A process activity usually contains a verb. For example, inserting, screwing, soldering, …
RPZ (Risk Priority Number): Product of evaluation criteria for risk assessment
Occurrence: Probability that an error occurs in the process
Significance: Impact of the error on the product or customer
Detectability: Probability of detecting the error in the process