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Using Process Failure Mode Effects Analysis to Evaluate Risk and Opportunities in Manufacturing

Presenter: Patsy Brown, Quality Director, Lennox Industries, Stuttgart, AR, USA

Keywords: PFMEA, Risk, Quality Assessment

Industry: Automotive, Customer Service, Manufacturing

Level: Intermediate


ABSTRACT

At Lennox Industries, we chose to re-create our quality evaluation system into a risk and opportunity based system, using the severity and detection criteria that are defined in the PFMEA process. Since the PFMEA process is well defined and targets corrections and improvements opportunities with the highest risk, it is a natural tool to utilize as a model for this activity.

Steps include:

• Develop new process flowcharts, refine existing ones as needed

• Conduct the Process FMEA for each assembly station, including on-line and off-line operations

o Determine severity, based on automotive industry criteria for each failure mode. Evaluate from customer’s perspective and impact on assembly lines

o Define and record rationale for each severity rating

o Determine detection ratings, based on the automotive industry criteria, due to the type of evaluations and degree of error proofing present in the process

o Calculate RPNs and take appropriate actions

• Develop risk-based Product Quality Audit defect classification system and audit strategy, based on the severity rankings from the PFMEAs.

o Re-define defect descriptions and classify according to severity ratings from PFMEA

o Include rationale for each defect description

o Develop online reporting scheme utilizing scoring criteria and collecting data on number of occurrences

• Develop risk-based Process Audit scheme based on the failures likely to impact customer and manufacturing

o Focus process quality auditors on steps with greatest assembly risk

o Add process evaluations to those with poor detection methods

• Develop opportunity-based continual improvement system for the assembly lines.

• Deploy the defect classification system to Field Quality technicians.

Realized benefits will be described.

 

Call for Proposals

Proposal Submission Deadline:
October 11, 2019

Acceptance notification date:
November 11, 2019

Early Registration Deadline:
February 11, 2020

Please make sure to review and prepare the material needed before you start the on-line Proposal Submission Form. Click here to see Proposal Submission Guidelines.

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Multiple Proposals: You may submit multiple proposals.

Conference Registration Fee:
The conference registration fee is waived for the principal speaker of accepted proposals. Speakers are responsible for their travel expenses and arrangements. Co-speakers will receive a 30% discount for the conference that they are presenting at.

Length of Presentations: Technical sessions are typically 35 minutes. There will be a limited number of "double" sessions, 70 minutes, at the end of each day.


You will need the following to submit a proposal

Proposal Title: Maximum 80 characters including spaces. 

Keywords:Please include three keywords with a maximum of 100 characters, including spaces. 

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Abstract: The Abstract should be 1,500 to 5,000 characters (note that it is Characters, NOT words), including spaces.

Biography: The Biography must be 1,500 to 5,000 characters, including spaces.

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(*) based on previous conference attendance


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