Renault - FMEA

STANDARD

Classement prvu : 01 - 33 - 200 / - - A Sce N Tl

Responsable du document F. SCHWARTZ 65810 53133

Pilote(s) technique(s) C. CARUEL 65850 57218

Date de mise jour :

Normalisation Renault Automobiles

01 - 33 - 200 / - - A

FMECA

(FAILURE MODES THEIR EFFECTS

AND CRITICALITY ANALYSIS)

Service 65810Section Normes et Cahiers des Charges

VISA RESPONSABLE(S)

SIGNATURE :

NOM :SERVICE :DATE :

22/05/00

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RENAULT 2000 Page 2/36

This document is to be considered as a whole, the parts of which must not be separated.

RENAULT 2000.No duplication permitted without the consent of the issuing department.No circulation permitted without the consent of RENAULT.

FIRST ISSUE

December 1986 - - -

REVISIONS

November 2000 - - A Complete revision.This issue originates from draft NC 1999 0171 / - - B.

REFERENCED DOCUMENTS

Quality Rule : Q00 41 C.CNOMO Standard : E41.50.530.N.

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CONTENTS

Page

GLOSSARY 5

1. FIELD OF APPLICATION 6

2. DEFINITIONS 7

3. BASIC PRINCIPLE 8

4. DETAILED PROCEDURE 11

4.1. STEP 1: INITIALIZATION 11

4.1.1. Selecting the subjects to be dealt with 11

4.1.2. Organizing the FMECA study 12

4.2. STEP 2: ANALYSING 13

4.2.1. Preparing the FMECA 13

4.2.2. Identifying potential failures 14

4.3. STEP 3: EVALUATING - DECIDING 17

4.3.1. Evaluation principle 18

4.3.2. Rating degrees 19

4.3.3. Criticality calculation 19

4.3.4. Hierarchy grading 19

4.3.5. Deciding which are the priority corrective actions 20

4.4. STEP 4: FINDING SOLUTIONS 21

4.5. STEP 5: FOLLOW-UP 22

4.6. STEP 6: APPLICATION 23

4.7. STEP 7: VERIFICATION - KNOWLEDGE TRANSFER 23

4.7.1. Verification principle 23

4.7.2. Knowledge transfer 25

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CONTENTS (continued)

ANNEX 1 SYNTHESIS SHEET (FORMAT A4) 27

ANNEX 2 CHOOSING THE SUBJECTS TO BE DEALT WITH FOR THE PRODUCT FMECA 28

ANNEX 2 (continued) CHOOSING THE SUBJECTS TO BE DEALT WITH FOR THE PROCESSFMECA 29

ANNEX 2 (continued) CHOOSING THE SUBJECTS TO BE DEALT WITH FOR THE FLOWFMECA 30

ANNEX 3 LIST OF BASIC DATA AND FUNCTIONAL ANALYSIS TO BE CONDUCTED PER TYPEOF FMECA 31

ANNEX 4 PRESENTATION OF THE ANALYSIS GRILLE 32

ANNEX 5 RATING SCALES 33

ANNEX 6 RATING SCALES 35

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GLOSSARY

FMECA : Failure Modes, their Effects and Criticality Analysis.

AMPPP3 : Accord de Montage Prototype Produit / Process phase 3.: Product / Process Prototype Assembly Go-Ahead, phase 3

APV : Aprs-Vente.After-Sales

CdC : Cahier des Charges.Product Specifications

DDHA : Direction de la Dtection, Hirarchisation et Affectation des incidents clients.Customer Incident Detection, Hierarchy and Allocation

DLI : Dpartement Logistique Industrielle.Industrial Logistics Department

DPLI : Direction de la Production et de la Logistique Industrielle.Industrial Production and Logistics Department

GFE : Groupe Fonction Elmentaire.Development Team

RPI : Risk Priority Index.

K : Cases per thousand.

LUQ : Liste Unique Qualit.Quality Reference List

PDCA : Plan, Do, Check, Act.

PIMOL : Panne Immobilisante.Off-road Vehicle Breakdown

RO : Ralisation d'Outillage.Tooling Definition

ROP : Ralisation d'Outillage Programme.Programme Tooling Definition

SdF : Sret de Fonctionnement.Operating Dependabiity

S : Rsultat d'enqute Sofres.Sofres Survey Result

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1. FIELD OF APPLICATION

Failure Modes, their Effects and Criticality Analysis (FMECA) is a product reliability preventiveanalysis method used to determine and correct failures on a system and/or item.

the FMECA is applicable:

- to the AUTOMOBILE PRODUCT during its development phase at the Engineering Centre,Production Department and Process Department and whenever the Product or ProductionProcess is modified.

- to the PRODUCTION FACILITIES during the facility design phase.

- to physical FLOW and information facilities during the operating mode development phase.

For each stage, Quality rule Q00 41 C: "Vehicle Project Milestones", indicates the intermediaryobjectives to be achieved for the various types of FMECA:- status of FMECA studies,

- results obtained,

- knowledge transfer of analyses,

in coherency with the PRODUCT/PROCESS pair development.

In the project context, the FMECA status and the results obtained are determinative items used by theQuality Department for the purposes of NOTIFICATION and APPROVAL.

It is the responsibility of the Operational Departments and Suppliers to adhere to this standard.

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2. DEFINITIONS

FMECA

Failure Modes, their Effects and Criticality Analysis is a rigorous and preventive method aimed atdetermining, then in evaluating the potential failures on a system and/or item. The investigationresults in the grading of such failures in order to take a decision on what measures should be taken. Afollow-up chart and schedule for the implementation of such corrective actions is defined. Applicationof the corrective measures is checked in the field.

Each study is the subject of knowledge transfer to be used as a diagnostic support and for the benefitof future projects.PRODUCT FMECA

The object of this analysis is the design and definition of the automobile product, which is examinedduring its development stages, prior to Tooling Go-Ahead, to ensure that the technological solutionchosen meets the quantified performance specifications and industrial constraints.

Potential failures have consequences for the motorist and/or his/her environment.

PROCESS FMECA

The object of the analysis is the design of the industrial production process (manufacturing andcontrol) of the automobile product, which is examined during the various envisaged productionoperations: manufacture, control, handling, etc., irrespective of the technology used, in order toensure that the industrial process under study will enable the volume production of a product inaccordance with the requirements specified on the drawings.

The improvement may concern the product, the process or both.

Potential failures may have consequences for the motorist and/or his/her environment.

PRODUCTION FACILITY FMECA

The object of the analysis is the production tool, machine, robot, machining assembly, tooling, etc.,which is examined during its design, to ensure that, during operation, it will satisfy the objectives ofavailability, product conformity and safety required in the specifications of the facility.

Potential failures have consequences for the facility user, i.e. the automobile product manufacturer.

NOTE: The production facility FMECA is conducted in accordance with CNOMO standardE41.50.530.N. It is not detailed in this standard.

FLOW FMECA

The object of this analysis is the physical flow of the product, its packaging and the flow of informationrelative to the operation and utilisation of an installation.

Potential failures have consequences for the Manufacturer and/or Operator and for the IndustrialLogistics Department.

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3. BASIC PRINCIPLE

1) THE FMECA CAN BE USED BY ALL TO PROMOTE QUALITY AND RELIABILITY BYADOPTING PREVENTIVE MEASURES TO MEET THE REQUIREMENTS OF THEAUTOMOBILE CUSTOMER

In the context of Customer-Supplier relations, we all have a task to accomplish, whetherindividually or as a group:

. To accomplish this task "n", we need to avail of quantified input data emanating from theSupplier responsible for task "n -1".

. As an output, we must supply results conforming to the objective in order to satisfy ourdirect Customer, who is then charged with accomplishing task "n+1".

The FMECA is a quality and reliability promotion tool that contributes to the accomplishment oftask "n". By its very implementation, it serves to validate its own designated task or tooptimize such a task before handover to the direct Customer (figure 1).

Task n-1 Task n+1

Added value

Task n

INPUT TASK

optimize

FMECA

Figure 1 - Validating the specific task by working in a preventive manner on potential risks

Each task in this chain of requirements are also examined with a view to satisfying the end-Customer, i.e. the motorist.

FMECA studies are scheduled to ensure they are completed before the key project decisiondates.

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2) "IMAGINING NEGATIVELY": 3 steps (figure 2)Step 1:

The design of a product or service is always conducted in a positive manner. A service isprovided to a customer in order to satisfy such customer. This service is then broken down intotechnical solutions, components, characteristics to ensure that the whole is operational andpleasing to the customer.

Step 2:

The FMECA draws on our critical faculties to form the most negative scenario possible: "whatcould happen to prevent this service being ensured and to what extent will the Customer beaffected?" We then list the potential causes of failure liable to prevent the service being ensured.

Step 3:

The FMECA procedure is in no way just a simple critical evaluation of the product or process. Itsmain advantage is that it focuses on the search for corrective solutions in order to optimizeproduct and production design in a predictive manner.

1 2

3

Positive Negative

1

2

3

Design in positive manner

Imagine failures

Correct potential failures

Figure 2

3) THE EFFICIENCY OF THE FMECA SYSTEM IS BASED ON 3 QUALITIES: COMPETENCE,CREATIVITY AND RIGOUR

Competence and creativity are cultivated through the exploration of the subject in questionwithin the framework of a multi-disciplinary working group, the members of which share theirrespective experience and skills in order to promote the creativity necessary to determinepotential failures, however unlikely their occurrence.

Rigour is developed by the methodical and full implementation of the whole FMECA proceduresubdivided into 7 steps (see figure 3 below).

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WHOSTEPS SIGNIFICATION - Scope -

Formalise the subject on a synthesis sheetindicating :

- the choice of subject and its limits,

- membership of the group,

- schedule,

- result follow-up.

- Coordinator- Requester- Decision maker

- Engineering Dept(RENAULT, Partner orSupplier)

1 - INITIALIZE

1

- Present the FMECA and the functionalanalysis of requirement.

- Imagine potential failures and theirconsequences for the customer using theanalysis sheet- Evaluate and grade the potential failuresaccording to predefined scales.

- Decide to implement action plans for RPIsthat are above the threshold.

2

3 3 -EVALUATE

2 - ANALYSE- Multi-disciplinary group

and coordinator

- Multi-disciplinary groupand coordinator

Search for corrective solutions. This action isconducted outside the FMECA group4

4 - SEARCH

5 5 - FOLLOW-UPAnalyse and evaluate the corrective solutionsuntil the RPIs drop below the thresholds

- Multi-disciplinary groupand coordinator

6Apply the corrective solutions selected.This action is conducted outside the FMECAgroup on the ground

- Action pilot (GFE,designer ...) RENAULT

internal or external

6 -APPLY

7

7 - CHECK

KNOWLEDGETRANSFER

Check the efficiency of the measures taken

Close the FMECA(signature).Transfer knowledge by archiving the studyin a database.

- Coordinator- Requester- Multi-disciplinary group

- Coordinator/Requester

RESULT

- Product and/or processdesigner

RESULT

RESULT

DECIDE

FOR

SOLUTIONS

Figure 3

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4. DETAILED PROCEDURE

FMECA implementation consists in methodically following the procedure in 7 steps, an approachconducive to exhaustively determining what the potential failures are and how they might beprevented. Each step is described below.

4.1. STEP 1: INITIALIZATION

Initialization consists in "revealing the problem", then in managing it over time.

This first step is crucial for the ultimate success of the study. It is formalized through the completionof the synthesis sheet (annex 1).

4.1.1. Selecting the subjects to be dealt with

Systematic implementation of the FMECA is conducive to validating what has already beenmastered, thereby avoiding unnecessary expenditure for the Company.

On the other hand, wherever there is a hint or certainty of risk, innovations, lack of knowledge ormajor stakes for the Company, the FMECA procedure should be deployed and focused on thepriorities.

Exploit and enrich existing FMECAs on similar subjects.The project manager (vehicle, system, component, production facility, etc.) and the QualityManager determine which subjects are at risk once the main general design and productionprinciples have been defined (figure 4 and annex 2).

recurrentproblem

carryoveritem

innovativeitem

localrisk

Process feedbackSingle Quality List (LUQ)

FMECA according to risk

Operating dependability + FMECA

FMECA

Identify all subjectswith potential risks :

Figure 4 - Subject choice principle

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4.1.2. Organizing the FMECA study

The party requesting the study (project manager or task "n" manager), internal or external toRENAULT and the FMECA coordinator must complete the "synthesis sheet", which serves as acontract between the requester and the group; it comprises:

- The type of FMECA (product, process, flow, etc.).- The vehicle, component, scope of the study and key dates: request, tooling definition, quality

milestone, volume production.

- The objective (K , S , PIMOL, durability, target non-conformity rate, etc.) and the motivebehind the study (see annex 1).

- The name of the requester (subject manager) and of the decision maker (critical choice anddecision maker).

- The field of application (product, process references, etc.).- The membership of the group (5 to 6 persons):

. 1 FMECA-trained coordinator.

. Participants (Engineering Centre, Process Department, Manufacturing Department, etc.)skilled on and responsible for the subject (indicate function).

- The FMECA schedule in 7 steps according to the project milestone date.- The result indicating the resolution of the potential risks.

- The location where the FMECA is archived, while in progress and once completed.

- The status of the study according to:

. the schedule,

. the clearance of potential risks (step 5),

. the verification of the results (step 7).It is the responsibility of the requester to manage the FMECA. S/he shall sign the synthesis sheetin order to close the provisional study.

- 4 key-points: a project-related product and process FMECA is conducted according to the PDCAcycle. the 4 key-points are scheduled by the FMECA study requester according to the projectmilestone dates (figure 5).

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Contract Tooling AMPPP3 Volume Production

P D C A

Figure 5

P The product and process FMECA subjects are identified (step 1 - initialiser).D Potential failures are analysed and evaluated; RPIs over the threshold are the subject of an

action plan and the curative actions are validated (steps 2, 3, 4, 5 and 6).C The identified risks are cleared for the ROP. The necessary confirmations are performed for

the AMPPP3 (step 7).A A loop is made to bridge the gap between the potential failures cleared during the FMECA

and the proven failures liable to be noticed in after-sales. The objective is to improve theefficiency of the FMECA process

4.2. STEP 2: ANALYSING

Analysis consists in investigating the conceivable high-risk points identified as such throughexperience. This search is always structured according to a functional analysis.

4.2.1. Preparing the FMECA

The purpose of this initial phase is to enable the working group to achieve the same level ofknowledge of the subject and to prompt the specialists to discuss the same subject.The functional analysis comprises (see annex 3):- the functional analysis of the requirement in order to list, characterize and grade all service

functions of the system to be studied, together with the life cycle phases. The functionalanalysis of the requirement (stated in the functional specifications) is an FMECA pre-requisite.

The FMECA group extracts the items necessary for the estimated risk study. These items areadjoined with the FMECA study.

- technical functional analysis used to explain the operational aspect of the envisaged solution,its organisation for all life cycle phases studied. This analysis is displayed in the form of blockdiagrams. The operating conditions, qualified and quantified, are listed. The block diagram is aproduct of the design phase or is drawn up by the FMECA group.

- the description of the industrial process envisaged for the volume manufacture of theproduct. The industrial process is defined in a manufacturing and control plan. The technicalsheets and the description of the operating mode are used as input data. These data aredisplayed on a process diagram (or synoptic diagram, or flow chart). The input and outputconditions (Customer-Supplier relation) are established.

The implementation of a functional analysis is mandatory to enable the members of the group to availof an identical vision of the subject and reveal the exhaustive list of effects, modes, causes ofpotential failures together with the envisaged detection methods.

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4.2.2. Identifying potential failures

The purpose of this second phase is to highlight the potential failures, whether conceivable or known,on the system under study. The failures are indicated in the form of qualitative and quantitativecriteria as follows:

Potential failure mode:

The potential failure mode: this is the manner in which the system stop operating or operateabnormally.

Potential failure modes are apprehended in the following manner:

- The operation no longer exists.

- The operation no longer stops.

- The operation is disturbed (totally, partially over time).- The operation is untimely.

- The operation ...

Notes:

the potential failure mode is expressed in physical terms:

- The potential failure mode is the product of the operating conditions (block diagram included).- The potential failure mode shall be completed, whenever possible, by quantified criteria.

Potential cause of failure:

The potential cause of failure is an initial anomaly liable to prompt the potential failure mode.

Failure mode Failure CAUSE

Manner in which the systemdoes not function

initial cause- causal chain- . . . . . . . .

- . . . . . . . .

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Notes:

- during the product FMECA:

. for each potential failure mode, seek the product characteristic or characteristics at thesource of the potential failure (explore: the material, geometry, dimensioning, etc.).

. To imagine the causes, systematically explore all bodies and contacts in the block diagram).

. For a potential failure mode, imagine 5 to 7 potential causes.

- during the process FMECA:

. Imagine the product-cause (characteristic of non-conforming product) liable to generate thepotential failure mode. Then search for the causal chain relative to the process causes, i.e."which process parameters are liable to prompt the product-cause".

. For a product-cause, imagine 5 to 7 process-causes.

Effect of potential failure:

During the product and process FMECA:

The effect of the potential failure is defined by 2 parameters:

- on the one hand, it is relative to a disturbed service function,

- on the other, it represents dissatisfaction of the automobile customer.

It is the potential failure mode that creates the disturbed function.

EFFECT of potential failure Potential failureConsequence for the

customerService function disturbed mode

Dissatisfaction ofautomobile customer

Service function disturbed:. totally. partially. ...

Manner in which the systemdoes not operate

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Notes:

- Disturbed functions are expressed according to the potential failure mode and the functionalanalysis of the requirement.

- To exhaust all possibilities, imagine:

. there is no service function,

. there is a loss of service function,

. there is untimely activation of the service function,

. the service function is downgraded (with time, mileage, etc.),

. the service function is poorly interpreted,

. ...

- For the product and process FMECA, the consequences for the automobile Customer areexpressed according to the table in annex 5.

For the flow FMECA, the Customers are the manufacturer and the central production departments(DLI) (see annex 6).Detection:

Detection is the system envisaged to prevent the potential failure cause (and/or potential failuremode), that has supposedly occurred, from reaching the Customer.During the product and process, the relevant Customer is Customer (n + 1).During the flow FMECA, the Customers are the manufacturer and the Industrial Logistics Department.

Potential failure MODE Potential failure CAUSE DETECTIONManner in which thesystem does not operate

= Initial cause:- causal chain- .......

- .......

What has been envisaged toprevent the initial failurecause (and/or potential mode)from reaching CustomerClient n + 1.

Notes:

- Under the column "detection", enter the envisaged detections (and not those to be anticipated).- Give priority to "theoretical" detections (calculations, chains of dimensions, digital simulations

and reinstallations, reviews, etc.) as opposed to "physical" detections (prototypes, test benches,vehicle tests, manufacturing quality control, non-assemblability, etc.).

- Indicate, as much as possible, the envisaged detections (qualify and quantify the parameters).- During the product and process FMECA, for economic reasons, the relevant Customer

(Customer n + 1) is the customer who comes immediately after the analysed activity.

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Analysis grille:

This is used to record:

- the references of the subject, the names of the analysts, the dates of analysis, evaluation andfollow-up.

- The aspects of the subject to be dealt with.- The list of potential failures and the detections envisaged.

NOTE: The grille is on paper format (A3) or electronic format (see annex 4).

Clientsatisfait

Service tobe ensured:Functions

TechnicalsolutionOperation

Components :Characteristics(to be specifiedto be manufactured

Customerdissatisfied

Servicenot endured

Solution malfunction Components :Characteristicsinadaptedor not in conformity

EFFET potentiel de dfaillancePotential failure mode Potential failure

cause

Synthesis Design = "Create positively"

FMECA = "Imagine negatively"

4.3. STEP 3: EVALUATING - DECIDING

Evaluation consists in quantifying the potential failures and the envisaged detection in order to assistthe requester, decision maker and those participating in the study, to define the high-prioritycorrective actions.

Evaluation is performed once the whole analysis is complete. A scale establishes the limits definingwhich risk is acceptable and which is not.

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4.3.1. Evaluation principle

The quantification is based on the chain of events leading to the perception of a failure by theCustomer and to the consequences for such customer (see figure 5).For a potential failure cause to effectively bring about a given potential failure mode at the endCustomer's, 3 conditions must be met:

1. The potential failure cause is assumed to be present. At this event, a probability P1 may beassigned.

2. If the potential failure cause is assumed to be present, it must lead to the potential failure modeconsidered. The probability assigned to this event is a conditional probability indicated as P2/1.

3. If the potential failure cause-mode is assumed to be present, to reach Customer n + 1, it mustpass the envisaged detections. The probability of non-detection is called P3.

If P is the probability of reaching the end Customer, then: P = P1 x P2/1 x P3

CAUSE

MODE

DETECTION

EFFECT(end customer) CUSTOMER

n + 1

P1

P2/1

P3

Figure 5 - Chain of events

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4.3.2. Rating degrees

The rating is based on 3 degrees and on pre-established scales, i.e.

- Gravity degree G: this is the evaluation of the effect of each potential failure as perceived bythe end-customer.

- Frequency degree F: is defined according to a pre-established scale and corresponds to theproduct of P1 x P2/1. In assigning the frequency degree, these 2 probabilities should be takeninto account.

- Non-detection degree D: is defined according to a pre-established scale and corresponds toP3.

Scales:

- product and process FMECA: the rating varies from 1 to 10 (annex 5).- flux FMECA: the rating varies from 1 to 4 for F and D and from 1 to 5 pour G (annex 6).

4.3.3. Criticality calculation

With each association of "potential failure effect, potential failure mode, potential failure cause anddetection", calculate the product of the 3 degrees: gravity, frequency, non-detection.

The result is the Risk Priority Index, otherwise known as criticality index.

RPI = G x F x D.

The evaluation is estimated by the members of the group according to databases and, by default,their knowledge and experience.

Probabilities P1, P2/1, P3, the rating degrees and the RPI are recorded and preserved on analysissheets.

4.3.4. Hierarchy grading

To obtain an overall image of the risk on the system studied, the RPIs are illustrated in the form of ahistogram.

This illustration facilitates the monitoring of improvements later on.

THSH THSH THSH

GRAVITYG

100

1 7

8 et 9

10

1 1000 RPI

CORRECTIVE ACTIONS

10 50

Gravity G

IPR

Product and process FMECA Flow FMECA

1 4

5

1 80

CORRECTIVE ACTIONS

Thresh Thresh

5 16

Figure 6

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4.3.5. Deciding which are the priority corrective actions

The purpose of this decision is to implement all resources in order to:

- attain the quality - reliability - durability objective (refer to the FMECA initialization sheet),- optimize the quality achievement cost.

Decision in terms of objective:Corrective actions are undertaken for all RPIs that overstep a previously fixed limit.

FMECA TYPE CORRECTIVE ACTION TO BE UNDERTAKENFOR:

Product and process RPI > 10 if G = 10RPI > 50 if G = 8 and 9RPI 100 if G = 1 to 7

Flow RPI > 5 if G = 5RPI > 16 if G = 1 to 4

Important:

It is the responsibility of the FMECA requester to define the thresholds for his/her own study byreference to:

- the standard,

- quality - reliability - durability objectives of the project (without such, the standard is applied).A reduction in the RPI may be obtained by focusing on the F D product factors.

PROBABILITY FMECADEGREE

product and process flow

GIt is not possible to act directly on

the consequences for the automobileCustomer

It is not possible act directly on theCustomer

(manufacturer and central productiondepartment)

F P1

P2/1P1 andP2/1

FOCUS ON THE FREQUENCY:- Reduce failure causes (act on the product definition and/or industrial

process).- Reinforce product robustness.- Combine the 2 actions.

D P3 Improve or implement a detection (watch out for cost !).

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Optimizing quality achievement costs:

At this stage of the FMECA, the cost objective is handled in 2 ways:- Reduce the costs of excess quality.

- Between 2 solutions with the same level of estimated quality, opt for the least costly by takinginto account expenditure and processing.

For all corrective actions decided upon, draw up a formalized plan on the analysis sheet:

- Enter the measures recommended to reduce the RPI (focus on P1 and/or P2/1 and/or P3).- Enter the name of the action manager (department) and the date of presentation of the proposed

corrective solution.

Important point:

The revaluation of the RPI should not be performed at this stage but at step 5.

Action plan

Recommended measureManager

DepartmentLead-time

4.4. STEP 4: FINDING SOLUTIONS

The search for corrective solutions is usually conducted outside the FMECA group.

The corrective solutions should be defined and formalized (modified drawing, manufacturing processmodified, adjoining test result, etc.) before being submitted to the FMECA group at step 5.NOTE: The FMECA requester shall authorize and support the search for corrective solutions.

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4.5. STEP 5: FOLLOW-UP

Follow-up consists in analysing and evaluation, as above ( 4.2. and 4.3.), the corrective solutionsproposed (figure 6).

Searchfor correctivesolutionsstep 4

Present corrective solutions

Analyse potential failures(complete or review analysis table)

Evaluate new itemsEliminate obsolete probabilities and degreesand add new degrees and probabilities

Adjust the indicators

RPI

Step 6

> threshold

< threshold

Follow-up date

Figure 6 - Procedure

This potential failure correction stage is continued until all RPIs at risk drop below the establishedthresholds (figure 7).

number>

threshold

check 1 check n milestonedate

calender

RPI

initialstatus

Figure 7 - Resolution curve

IMPORTANT:

The follow-up of corrective actions is crucial for the success of this analysis tool.

It is the responsibility of the study requester to ensure that the FMECA advances through the progressschedule and that the risks are cleared.

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4.6. STEP 6: APPLICATION

The corrective solutions, validated during follow-up, are implemented.

Examples:

- specification of a new technical solution,

- implementation of the definition modification,

- validation of a calculation result, simulation,

- validation of a test result,

- modification of a manufacturing plan, procedure, tooling, etc.,

- specification of a provisional surveillance plan,

- modification of operating and processing modes,

- ...

E

M

ACC

F M E C AC

F

BeforeHighlightingof potential failures

and after correctionApplication of corrective measuresand development of a productin conformity with expectations

Figure 8

4.7. STEP 7: VERIFICATION - KNOWLEDGE TRANSFER

4.7.1. Verification principle

Verification serves to achieve the objectives defined upon drawing up the "synthesis sheet".It is conducted in two stages:

1 - At the milestone date, to ensure that the corrective actions are in place and effective.

2 - During volume production, to estimate the efficiency of the FMECA study with respect toproven failures during manufacture and in after-sales.

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4.7.1.1. Milestone date verification

Depending on the results, a decision is taken on the subsequent measures to be taken on the projectin question (figure 9).

CHECKstep 7

noEFFICIENTSOLUTION

RESULTNOT TRANSMITABLETO CUSTOMER n + 1

ACTIONPLAN

RESULTTRANSMITABLE

TO CUSTOMER n + 1

Projrct continuation

Figure 9 - Decision making

The members of the FMECA group, on the basis of the development file:

- formally check that the corrective solutions are in place,

- confirm by measurement, whenever possible, the hypotheses selected for the predictedevaluation.

For example: implementation of facility capability test to determine the real P1 level, verification ofthe accuracy of a chain of dimensions and related calculations, verification of the throughput time,work in process, etc.).NOTE: The FMECA is the property of the group, each member of which shall respect the

undertakings and each modification to the FMECA file shall be the subject of concertedconsultation.

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The verification is conducted before the project decision milestone date, or, before the date oftransfer of task "n" to the internal Customer(n + 1).The verification result is co-signed in a result note adjoined to the FMECA file. It constitutes a QualityAssurance File item.

The study requester decides on the termination of the FMECA by signing the synthesis sheet.

4.7.1.2. Verification during volume production

- During manufacture: the FMECA file is used to define part of the process audit reference system.

On the one hand, it is used to check the continuity of corrective actions and, on the other, theefficiency of the FMECA study by comparing the potential failures with the real failures in theprocess.

- During after-sales: by comparing the proven failures in after-sales (DDHA list) and the potentialfailures as imagined during the FMECA study, it is possible to judge the efficiency of the study.For a system subject to an FMECA study, during volume production, there should be no failurebeyond the company quality - reliability objectives (as a priority, check that G = 8, 9 and 10).Otherwise, it is necessary to seek the cause of the FMECA non-efficiency and to remedy such,for example by:

. the further training of the coordinator,

. optimize the content of the FMECA standard,

. make the Quality Assurance acknowledgement indicators more stringent.

4.7.2. Knowledge transfer

The content of the FMECA is a written memory for the Company:

- to be used in future projects (as such or as a complement),- during the process audit at the operating phase,

- upon changes to the product or process (phase II, production centre demultiplication, etc.),- in the event of a dispute between the Customer and Supplier, or for legal purposes.

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Accordingly, a file shall be compiled and archived in paper or electronic form, comprising:

FMECAproduct process flow

The synthesis sheet. X X X

The information on the subject under study and themodifications:

- specification or its reference, X X

- drawings, diagrams or their references, X X- manufacturing plan or its reference, X X- operating and processing modes. XThe functional analysis:

- function investigation, X X X- block diagram, X X- process chart, X

- flowchart. X

The analysis, evaluation and corrective action sheets. X X X

The result notes. X X X

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ANNEX 1SYNTHESIS SHEET (FORMAT A4)

FMECA SYNTHESIS SHEETProduct FMECAProcess FMECAOther FMECA:

Vehicle: Date of request:Component: Milestone date:

Volume production date:Scope:Objectives of the study:

Causes of the study:

REQUESTER: M. Dept. DECISION MAKER: M. DeptLimits of study:

PARTICIPANTS: PermanentMM. Dept. and function

TemporaryMM. Dept. and function

COORDINATOR: M. Dept.

Weeks

Forecast

Finished

Legend Meeting: Rsteps 2 and 3

Follow-up: Sstep 5

Verification: Vstep 7

Milestone date: J

Initial Follow-upDate:

TOTAL

NbrG = 10,RPI > 10

of RPIG = 8 and 9,RPI > 50

G de 1 to 7,RPI 100

Archival location:

Decision at end of study: potential risks have been cleared. Date:Signature of requester:

PLANNING

BILAN

Nbre d'IPR seuil

initial suivi suivi jalondates

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ANNEX 2CHOOSING THE SUBJECTS TO BE DEALT WITH FOR THE PRODUCT FMECA

- Systme complexe : botier papillon motoris,sige mmoire, ...- Multitechnologique : prtentionneur :mcanique + lectronnique + ...

Complexitdu produit :

Reconduit sans dfaillance connue. Environnementou conditions d'utilisation diffrents.

Reconduit avec dfaillances suprieures l'objectifou dfaillances inconnues.

Produit ousolutiontechnique :

Contraintenouvelle oureconduite :

Concepteurdu produit :

Operting dependability studythen product FMECA

on functions or subsystemswith serious undesirable

incident

- Simple system : door closing mechanism, ...- Simplified technology: plastic injection and metallicinsert, ...- Mono-technology : stamping, painting, ...

Product FMECA

Product FMECAon product compatibility with

new data

Use feedback (LUQ)and/or product FMECA

Modified Product FMECArelative to modifications

New Operating dependabilitythen product FMECA

Innovative (keyless vehicle) Operating dependabilitythen product FMECA

Regulations

Safety

Product FMECA

Product FMECA

New supplier or supplierwith partial experience of product

Multi-disciplinary suppliers

Product FMECA

Operating dependabilitythen product FMECA

List of proven failures (after-sailes) and orquality (LUQ)

Process feedback

Existing product FMECA To be confirmed or completedfor product carryover

Feedback

- Complex system : motor-driven throttle unit,memory seat, ...

- Multi-technology: pretensioner(mechanical +electronic + ...)

Productcomplexity

Carryover without known failure. Different environmentor operating conditions.

Carryover with failures greater than objectiveor failures unknown.

Product ortechnicalsolution

New constraintor carryover

Productdesigner

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ANNEX 2 (continued)CHOOSING THE SUBJECTS TO BE DEALT WITH FOR THE PROCESS FMECA

Operating dependabilitythen process FMECA on

functions or subsystems subjectto serious undesirable

event- Process with simplistic technology :assembly, welding, ...

- Full part development processProcess FMECA

Process FMECA onproduct compatibility with

new data

Use feedback (quality)and/or process FMECA

Modified process FMECA relativeto modifications

New Operating dependability thenprocess FMECA

Innovative (laser welding) Operating dependability thenprocess FMECA

New supplier or supplierwith partial experience of process

Multi-technology suppliers

Process FMECA

Operating dependability thenprocess FMECA

Existing process FMECA To be confirmed or completedfor carryover processesFeedback

- Multi-technology process : stamping +bodywork + painting + fitting, ...

Processcomplexity

Carryover without known failure. Different environmentor operating conditions.

Carryover with failures greater than objectiveor unknown failures.

Process ortechnicalsolution

Processdesigner

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ANNEX 2 (continued)CHOOSING THE SUBJECTS TO BE DEALT WITH FOR THE FLOW FMECA

CONDITIONPERFORMANCES (volume tobe produced, production

sequence,

CONDUCTING A FLOWFMECA

product conformity) Decision ObjectiveCarryover of an existing Known and on target NOoperating or processing mode(for a vehicle, futurecomponent or new installation)

Unknown YES Improve theenvisaged operatingor processing mode.

New operating or processingmode

YES Validate theenvisaged operatingor processing mode.

Modified mode YES Analyse themodified part.

Mode with risks of a productionblockage

YES Analyse the potentialrisk part.

FLUX

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ANNEX 3LIST OF BASIC DATA AND FUNCTIONAL ANALYSIS

TO BE CONDUCTED PER TYPE OF FMECA

INPUT DATA TYPE OF ANALYSIS TO BEUSED

FMECA

PRODUCT PROCESS FLOW

Performance orfunctional specifications

Functional analysis ofrequirements (utilisation function,adaptation function, estimation,constraint function and valuecriteria)

YES YES

Drawings of systemsstudied

Functional analysis of design(block diagram)

YES

YES

Plans:-manufacturing- control- ...

with references

Process diagram (ormanufacturing and controlflowchart)

YES

Operating andprocessing mode

Functional analysis of flowand

Use existing flow diagram or ifnon-existent plot one

YES

YES

There shall be as many block diagrams as there are different life cycle phases for the subjectstudied.

As a rule, one or two block diagrams generally suffice to determine the product operation.

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ANNEX 4PRESENTATION OF THE ANALYSIS GRILLE

Product FMECA, process FMECA and flow FMECA (format A3)

Failure Modes, their Effects and Criticality Analysis

Component .......... Vehicle .......... FMECA Analysts: Dates

References:

Function Potential failure Action plan

N and/or Effect Mode Cause Detection GF D Recomm-ended

Mngr Result

process Customerconsequence

Disturbedfunction

(P2/1) (P1) (P3) measures Time Measuretaken

Legend:1: Product designation.2: Specify: product, process or flow FMECA.3: Name of FMECA participants and coordinator.4: Dates of document origin and modifications.5: Page No..6: No. used as a line marker for each potential

failure cause.7: Functions studied (product) or manufacturing

operation descriptions(process), flow management points.

8: Disturbed function and consequences for thecustomer.

9: The potential failure mode indicates the mannerin which the system does not operate.Also enter in this column the probability value: P2/1.

10: The potential cause of failure relative to theproduct is the initial anomaly that generated thepotential failure mode. The causal chain, is thestring of events that preceded the appearance ofthe cause-product.Also enter in this column, the probability value:P 1.

11: Indicate the provisions taken to prevent thecause (and/or mode) that has supposedlyoccurred, to reach customer n+1.Also indicate in this column, the probability

value P 3.12: Calculate the level of criticality (RPI) byreference to the scales:

G: gravity degree according to gravity scale.F: frequency degree according to scale andprobability product P1 x P2/1.D: non-detection degree according to

probability degree P3RPI = G x F x D

13: Indicate the measures envisaged to reduce theRPI (adjust P1 and/or P2/1 and/or P3).

14: Name of action manager and time to presentproposed corrective solution.

15: Record the corrective measure presented uponanalysis and evaluation (stage 5).16: Calculate the new RPI after analysis and

evaluation of the corrective solution proposed.

IPR

2143 4 5

6 7 8 9 10 11 12 1615141413

1

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ANNEX 5RATING SCALES

Product and Process FMECA - Gravity degree(G)

G Consequences for the motorist Service function disturbed1 The customer is not capable of detecting this

potential failure.The minimal nature of the disturbed servicefunction does not cause any perceptible effectwith regard to the performance of the vehicleor its equipment.

2 - 3 The potential failure constitutes a slightinconvenience for the customer.

The minimal nature of the disturbed servicefunction does not cause and notableinterference with the performance of thevehicle or its equipment.

4 - 5 The potential failure upsets or disturbs the. The disturbed service function, with pre-incident signs, causes a slight degradation tothe performance of the vehicle or itsequipment

6 - 7 The potential failure displeases the customer.Repair costs are moderate.

The disturbed service function, without anypre-incident signs, causes notable degradationto the performance of the vehicle or itsequipment.

8 The potential failure greatly annoys thecustomer. Repair costs are higher.

The disturbed service function, with or withoutpre-incident signs, causes the loss of afunction, without necessarily putting thevehicle off the road.

9 The potential failure is a major grievance forthe customer: off-the-road breakdown.

The disturbed causes a vehicle off-roadbreakdown.

10 The disturbed function causes a potential failure relative to safety or a failure out-of-conformity with applicable regulations.

Notes:

- If in doubt when choosing between 2 degrees, the FMECA group will always opt for the higherdegree.

- G = 10 is exclusively reserved to potential failures with an impact on safety or regulations.

- G = 9 is exclusively reserved to potential failures causing a vehicle off-road breakdown (ex:battery failure, etc).

- G = 8 is reserved for potential failures causing high repair costs.

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ANNEX 5 (continued)RATING SCALES (continued)

Scales used in the product and process FMECA

F PROBABILITY OF OCCURRENCEP1 x P2/1

D PROBABILITY OF REACHINGCUSTOMER N+1: P3

1

2

34

5

67

8910

[ 0 to 3/100 000 [[ 3/100 000 to 1/10 000 [[ 1/10 000 to 3/10 000 [[ 3/10 000 to 1/1 000 [[ 1/1 000 to 3/1 000 [[ 3/1 000 to 1/100 [[ 1/100 to 3/100 [[ 3/100 to 10/100 [[ 10/100 to 30/100 [[ 30/100 to 100 % ]

1

2

34

5

67

8910

[ 0 to 1 % [[ 1 % to 4 % [[ 4 % to 9 % [[ 9 % to 16 % [[ 16 % to 25 % [[ 25 % to 36 % [[ 36 % to 49 % [[ 49 % to 64 % [[ 64 % to 81 % [[ 81 % to 100 % ]

Note:

During the product FMECA, it is sometimes more difficult to estimate P1 and P3, in which case thedesigner may use the qualitative scale below:

Qualitative scales that can be used during the product FMECA

F EVALUATION CRITERIA D EVALUATION CRITERIA1 Characteristics and solutions already

upgraded, same environment and sameutilisation.

1 Validation on vehicle (5 x 150 000 km) andendurance test followed by a componentanalysis.

3 Characteristics and solutions alreadyupgraded, however environment andutilisation different.

3 Test on bench and/or vehicle.

5 Characteristic defined on drawing, howeverreliability not proven.

5 Chains of dimensions and calculations,digital simulation, dimensioning calculations,mock-up, ...

7 A volume production reference exists,however it is poorly defined or not known.

7 Reinstallation (at nominal, digital), drawingreview, ...

10 Characteristic not defined on drawing, or notknown or interpretable.

10 Without detection or what is envisaged isinefficient.

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ANNEX 6RATING SCALES

Flow FMECA

Gravity degree (G)

G Consequences for usersProduct Volume Order

1 Withoutconsequence

In conformity In conformity In conformity

2 Inconvenienced Non conforming reworkon line

Small loss of volume (1) Order slightly disturbed(vehicle cycling indicator(1))

3 Unhappy Non conforming reworkoff line

Medium loss of volume (1) Order moderatelydisturbed (vehicle cyclingindicator(1))

4 Very unhappy The non-conformityreaches the internalcustomer

High loss of volume (1) Order highly disturbed(vehicle cyclingindicator(1))

5 Catastrophic The non-conformity mayreach the automobilecustomer

Production stoppage

(1) The % of volume loss and cycling are defined at the beginning of the FMECA in conjunction withthe manufacturer and the Central Production Department (DPLI).

Frequency degree (F)

F Occurrence probability (P1 x P2/1)Note: in the absence of P1 and P2/1, occurrenceis indicated in days.

1 Less than once a month

2 Once a monthonce from [6 days to 20 days]

3 Once a weekOnce from [2 days to 5 days]

4 Once or n times a day

et/ou et/ou

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ANNEX 6 (continued)RATING SCALES (continued)

Flow FMECA - Non-detection degree (D)

Probability P3 that the cause or mode will reach Customer n+1

D Practical measureP3 Flow level

measureAlert Response Measure

1Detectionefficient P3 indirection of 0

YES YES YES YES

2 Moderatelyefficient YES YES YES NO

3 Slightlyefficient

YES YES NO NO

4P3 in directionof 1detection isinefficient orwithoutdetection

NO NO NO NO

Documents

Renault - FMEA