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Process Excellence
Published in James William Martin, Operational Excellence, 2021
A process failure mode and effects analysis (PFMEA) is created by process engineering using DFMEA. PFMEA is critical for identifying potential failure points within the new process and where modifications are required to achieve target standard cost, lead times, and quality. Once a process has been designed, its work operations should be balanced based on required takt time. Takt time is calculated by dividing the available production time by the required number of units that must be produced during the available production time. As an example, if there were 480 available minutes in a day and 60 required units, then the takt time would be calculated as one unit every eight minutes. Bottleneck resources will adversely impact a system's takt time if they are not available. Although most balancing analyses focus within a system's facility at one location, balancing of workflows across operations or workstations can also be done across an entire system. In other words, if a process is geographically dispersed, its takt time can still be calculated and controlled virtually across the system. In this scenario, process measurements and controls should allow for easy interpretation of the system's status anywhere in the world at any time. This information should also be readily available to all supply chain participants. To achieve takt time reliability over time, it is also important to deploy continuous improvement initiatives such as Lean, Six Sigma, Total Productive Maintenance, and others to continually improve the new process over time.
An analysis of the influence of affordable housing system on price
Published in Dawei Zheng, Industrial, Mechanical and Manufacturing Science, 2015
The aim of this study is to recognize and index the delay risk-based reliability of projects from owners’, engineers’ and contractors’ perspective. To identify the sample population, this study investigates the building construction so as to grade the causes of design for specific delay critical factors assessing RPN for each of the group as included. According to Salleh (2009), the causes of delay factors are listed in the pilot survey asked. The aim of the study is to verify the completeness of the survey questionnaire to capture the focus needed in the study in Shiraz, Iran. From the pilot study it can be seen that all the respondents’ questionnaire is sufficient to capture the delay causes. Therefore modifications on the causes of delays are needed as reported by Salleh (2009). To determine the cause of failure in project construction, causes obtained from the literature were distributed among the participants who were asked to choose the points from 1-5 of the three factors that may result to the causes. The number that represents the highest risk or seriousness is ranked 5. The three factors include severity (S), occurrence (O) and detection (D). Risk priority number (RPN) was used to analyse the risk associated with the potential problems that are found during failure mode and effect analysis. As shown in equation 1 RPN include severity, occurrence and detection. The major differences of RPN are a function of the three variants.
Meeting or Systems Analysis?
Published in Michael K. Levine, People over Process, 2019
“Sorry Gary, on my old team everyone knew the FMEA.” Unfortunately, Guptan said this in a way that sounded like “Sorry Gary you are stupid,” but fortunately Gary had been warned. (Note – if you like Gary aren’t sure what an FMEA is, check out the section in Appendix 2 on it, page 265. It’s a powerful framework.) “It means Failure Mode and Effects Analysis. It is a standard engineering artifact. It identifies every component in the system and how it can fail, and then we add how we detect and repair the failures.”
A novel risk evaluation for vehicle failure modes using a hybrid method under fuzzy environment
Published in International Journal of Crashworthiness, 2022
Wencai Zhou, Zhaowen Qiu, Fenghui Wang, Lang Wei, Reza Langari
Nowadays, motivated by the explosive growth of vehicle population, research on how to reduce the traffic accidents has been a hot spot in the field of vehicle safety. Vehicle failure is an important cause of car crush. In order to improve the reliability of vehicle effectively, it is necessary for automobile enterprises and researchers to find an efficient risk-evaluation method to rank thousands of vehicle failure modes. As one of the most popular risk evaluation approach, Failure Mode and Effects analysis (FMEA) is used for identifying and prioritising potential failure modes by calculating the value of Risk Priority Number (RPN) which is obtained by multiplying three factors of severity, occurrence and detectability[1–3]. However, it has taken a lot of criticism for its uncertainty and inaccuracy under certain circumstances. For instance, a same crisp value of RPN may come from different combinations of its risk criteria, which may be hard to express the judgments of decision makers accurately [4,5]. Lots of researches purposed their solutions to reduce the influence of the weaknesses of the traditional FMEA. For example, many studies tried to combine the fuzzy set theory and FMEA to express the opinions of experts more accurately [6,7]. Besides, some researchers also conducted their own risk criteria to do the risk evaluation in their field instead of conventional risk criteria [8,9].
Toward robust concurrent product development across the supply chain: a risk assessment framework
Published in Journal of Engineering Design, 2020
Marcos Esterman, Shridhar Palekar, Francis Conway, Joseph Ehmann, Venus Limcharoen
Failure mode and effects analysis (FMEA) is a tool which aids to systematically identify potential failure modes, their causes and effects. For each failure mode identified a Risk Priority Number (RPN) is calculated using detection, occurrence and severity indices (Stamatis 2003). The RPN is then used to prioritise failure modes and subsequent mitigation measures are suggested. The effectiveness of this methodology depends on the ability to identify all of the potential failure modes and to properly assess the indices to calculate RPN. Evaluation of risk with FMEA for supplier interactions can be difficult as the needed information to assess risk resides with the supplier and may not be readily available.
Integrated approach for optimizing quality control in international manufacturing networks
Published in Production Planning & Control, 2019
Tobias Arndt, Mukesh Kumar, Gisela Lanza, Manoj Kumar Tiwari
Subsequently, based on this analysis, quality inspections are linked to the production process, where the identified failures emerge. Each link is then characterized by an extended risk priority number (RPNext). According to the Failure Mode and Effects Analysis (FMEA), the original RPN is calculated by multiplying indicators for the severity of the failure (S), the probability of the occurrence of the failure (O) and the probability of detecting the failure (D). In addition, the RPNext contains indicators for the increased value of the product until the discovery of the failure (V) and the replacement time (R). All indicators are rated from 1 to 10.