The process FMEA is a proven method for examining a production and assembly process for possible causes of errors as early as the plant planning and design phase. In this way, the causes of errors can be avoided with suitable measures or their detection can be guaranteed through test and inspection operations.
When carrying out the process FMEA, a planned process is broken down into all sub-processes and the occurrence of errors is played through one after the other by all equipment, system components, parts and people involved in the process, under the basic assumption that the error occurs can.
The implementation of an FMEA is often carried out using specially developed software and under the guidance of specialists or external moderators.
Errors that occur are assessed in terms of the significance of the effect (B value from 1: "insignificant error" to 10: "immediate danger to life and limb"), their probability of occurrence (A value from 1: "unlikely" to 10: "unknown / almost always"), as well as probability of detection (E-value from 1: "very high" to 10: "poor/unknown") were nominally assessed. The RPZ value (risk priority number) determined from the product of BxAxE is categorised into areas using different approaches (see image).
All operations in the green zone are due to the low risk tolerable for production. These are detected with a sufficiently high degree of probability by the in-process testing and inspection operations and are remedied with a tolerable amount of rework.
All operations in the yellow zone have a certain risk, which should be reduced by improving the prevention or detection measures so that it is in the green zone after a reassessment based on the improved measures.
Operations in the red zone cannot be accepted for production. In fact, it is not always possible to move all operations from the yellow to the green zone. A residual risk remains, which can be controlled thanks to the implementation of the FMEA. , because it is sufficiently known and can be estimated. A possible remaining residual risk can be, for example, the occurrence of an error that requires considerable rework in production, but is sufficiently unlikely.
Risks of errors occurring should always be avoided. The measures that can be planned and implemented to prevent errors extend across the entire spectrum of plant engineering and begin with the design of components as part of product development. If the FMEA is carried out early enough, i.e. before or during product development, conclusions can be drawn for development, measures should also be taken here and help to avoid errors.
A simple example is the asymmetrical design of components or the design of clear physical product features to counteract installation in the wrong orientation. These features can be implemented using suitable System technology (e.g. optical) can be queried to ensure that the components are placed on a workpiece carrier in the correct orientation. Further examples of possible measures can be found at Quality assurance measures
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