FAILURE MODE & EFFECT ANALYSIS is a living document Maintained during the lifetime of a product, and is continuously updated. Right from design stage, and through the manufacturing stage, potential defect prone aspects of the process are analysed in detail and remedial procedures incorporated.

Quality failures occur when a process does not meet its requirements. So, FMEA is carried out for the purpose of clearly identifying the root causes of the non-conforming condition, and recommending appropriate corrective actions. Corrective actions introduce a change to a systems design, its manufacturing processes, or its operating or maintenance procedures, to eliminate the effects of the potential failures root cause.

 

FMEA

-   starts with a clear understanding of the failure symptom

-   objectively identifies all possible causes

-   objectively evaluates Likelihood & Severity of each

-   identifies all Potential Corrective Actions

-   evaluates the results of each action

-   evaluates the Efficacy of all the corrective actions.

 

POKA-YOKE is a cost-effective technique used to ensure that a process always performs right by eliminating potential human mistakes from occurring. This Japanese term comes from Yokeru meaning to prevent and Poka which means inadvertent errors.  All FMEA documents contain specific mention of Poka-Yoke devices for potential errors and their causes.

 

POKA-YOKE identifies areas where there are chances of human error due to fatigue, repetition, newness, misunderstanding etc., and process errors due to faulty equipment, fluctuations due to power, speed etc. It is also used to ensure 100% inspection of products and process parameters using simple devices like sensors, counters, alarms etc.

 

PROGRAMME MODULES