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FMEA for non-product processes

Discussion in 'FMEA - Failure Modes and Effects Analysis' started by Andy Nichols, Jun 17, 2021.

  1. Andy Nichols

    Andy Nichols Moderator Staff Member

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    Has anyone had experience of applying FMEA to non-product processes, such as Purchasing, training, etc?
     
  2. Miner

    Miner Moderator Staff Member

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    I have applied it several times. My non-automotive company is strengthening their new product introduction process by implementing a formal APQP approach. Since some of the tools are new to our quality personnel, I put together training documents and did an FMEA on some of the key tools (e.g., MSA, capability) to identify risks. I have also developed a Metrics FMEA, which may be used to identify how a new metric can be manipulated or drive the wrong behavior. I used that on a purchasing project to guide them in developing better metrics.
     
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  3. S1D3K1CK

    S1D3K1CK Active Member

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    That's very interesting! How successful has this been for the personnel involved?
     
  4. Miner

    Miner Moderator Staff Member

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    It's still in the early stages (APQP implementation), but the people responsible for the roll out have incorporated the identified risks into the various documents that they have developed, so it looks good.
     
  5. Andy Nichols

    Andy Nichols Moderator Staff Member

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    I'm interested to see that it's confined to APQP. Have you tried it on, let's say, the procurement process? I have completed a PFMEA on turning a requisition into a supplier PO and it seems like a LOT of work for very little reward. None of the RPNs really would do much for organizations I'm familiar with.
     
  6. Miner

    Miner Moderator Staff Member

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    So far, I am focusing on new processes, not on existing processes. If I were to look at an existing process, I would focus on a process that is high risk and/or demonstrated a lot of issues.
     
  7. Andy Nichols

    Andy Nichols Moderator Staff Member

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    Why not simply audit the processes for a) compliance to planned arrangements and b) effectiveness?
     
  8. Miner

    Miner Moderator Staff Member

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    It is looking at it from a different perspective. One way is looking at it from the "Am I doing it as planned and is it working well so far?", and the other is looking at it from the "Is there anything that has not, but could go wrong?" perspective.
     
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  9. Andy Nichols

    Andy Nichols Moderator Staff Member

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    Yup, that seems reasonable. It seems to me, that the application of an FMEA is a lot of work for little reward.
     
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  10. Kerri

    Kerri Member

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    Totally agree Andy. I also considered looking at processes as well as product processes but my head nearly exploded
     
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  11. Andy Nichols

    Andy Nichols Moderator Staff Member

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    :D
     
  12. BradM

    BradM Moderator Staff Member

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    Like most of the other stuff we've been toying with for the last 25 years, :) it can be very useful or can be a complete waste of time. :

    If you develop good/ reasonable weights, I would think it be a pretty easy objective way to focus on the highest weight items. Would keep down the subjectivity and stuff.