How to Create a Successful FMEA Program

Imagine a team has performed a couple of failure mode and effects analyses (FMEAs) and the outcomes have been positive. In fact, the results have been so successful that the company wants to expand use of the technique enterprise-wide. How can this best be done? Most companies start their FMEA programs by performing process FMEAs. […]

A Comparison of Measurement System Analysis Metrics: Part 2 of 2

A simulation study was undertaken to quantify the relationship between guard banding, percent tolerance (also known as the precision-to-tolerance [P/T] ratio), and the probability of misclassification – all in the presence of varying distributions for both part values and gage error. A response surface designed experiment was utilized to generate a balanced set of factor level […]

A Comparison of Measurement System Analysis Metrics: Part 1 of 2

Measurement system analysis has been a major part of process characterizations and improvements, with key guidance from the original Automotive Industry Action Group reference manual. There has been some critical review, particularly of summary metrics such as gage repeatability and reproducibility (GR&R) and percent tolerance (also known as precision-to-tolerance ratio) and what are considered acceptable […]

Manage Control Limits When Implementing Statistical Process Control

Statistical process control (SPC) is the application of statistical methods to identify and control the special cause of variation in a process. Control charts, in theory, are used in product and process development to analyze processes. When a process is shown to be in control in both an average and range chart the process can […]

Supplement FMEA with a Risk Priority Matrix for Better Results

Within the world of risk management – a common aspect of improvement projects – there is a distinction between response and mitigation. A response is taken in reaction to risk, while mitigation is undertaken proactively. Thus, responses are implemented once risk materializes, and mitigation actions must be planned and implemented before a risk presents itself. […]