En PLATO E1ns E-Learning - Lesson 1 - FMEA History and First Steps

E-Learning Course for PLATO e1ns
Lesson 1:
FMEA history and first steps
06.01.2021
1
Lesson 1, part 1:
History and development of FMEA
06.01.2021
2
Watch this lesson as a video
Online videos for lesson 1
There are two videos available for this lesson. You can find both on the training content page
for this e-learning course:
▪ Part 1 - History and development of FMEA (in the video the following slides are explained in detail)
▪ Part 2 - First steps in e1ns (the video shows the practical example "live", without slides)
06.01.2021 © PLATO AG, e1ns Training
3
What is FMEA?
FMEA: Failure Mode and Effects Analysis
▪ Preventive method to analyse products and processes to prevent

potential failures
▪ Predominantly used in Development and Production
▪ Discover potential weak spots, causes and effects

© PLATO AG, e1ns Training
▪ Goal - Failure prevention instead of failure adjustment (early use!)

- Faultless Products → customer satisfaction
1/6/2021
4
A brief history of FMEA
1940... 1949: US-Millitary published FMEA Method as US Military Procedure (MIL-P-1629 )
Target
Guideline for military and suppliers to classify failures and defects in relation
to their influence on the success of a mission.
1960... 1963: NASA initiated FMEA to Apollo-Project

1965: Innovated by the aerospace industry in the USA
Target
Development of faultless products. Focus especially on parts which
are difficult to repair or maintain.
1/6/2021
5
A brief history of FMEA
1970... 1975: Applied to the Nuclear Technology,

1977: Applied to the automotive industry in 1977 (AIAG)
1980... in 1980 standardized by the VDA (Association of the German automotive industry)
from 1986 on enforced use in german automotive industry
1990... Applied to chemical and pharmaceutical industry, medical technology

and software development.
New FMEA form (VDA, 1996)
2000... The increasingly frequent request for the application of FMEA

(ISO 9000:2000; FDA; GMP etc.) results in an increased use in

pharmaceutical industry, food industry and medical technology.
2019 New handbook for harmonized FMEA standards of AIAG and VDA.
1/6/2021
6
FMEA – A Method Conquers the World
FORD “Pinto”
7
Initial Situation – The Scandal
Ford Pinto†
1970-1980
06.01.2021 © PLATO AG, System-FMEA nach VDA 4.2 Teil 1 - Methodik
✓ Most successful small car – competitor to VW Beatle

✓ Ford sells millions of cars in the 1970s
✓ Scandal because of heavy design defects
✓ Fuel tank in the back of the car exploded when car was hit in the trunk because of wrong
construction design
✓ 60 dead burn victims and more than 120 persons heavily injured
✓ Total cost for lawsuit: some million USD
✓ Huge damage for the image of FORD
✓ High risk for Ford to go bankrupt because of damage claims (Schadensersatzforderungen) in lawsuits
8
The Solution – Standards
Ford Pinto†
1970-1980
06.01.2021 © PLATO AG, System-FMEA nach VDA 4.2 Teil 1 - Methodik
1977 1978
AIAG standard by Re-call of >1,5 million cars
Ford/Chrysler/GM ✓ New fuel filler pipe
✓ Installation of protective plates
9
Motivation for FMEA
06.01.2021
10
Why FMEA?
Because of…
Standards Laws
▪ DIN EN ISO 9001 ff ▪ Product liability act
(German: „Produkthaftungsgesetz“)
▪ IATF 16949 (2016)
▪ DIN EN ISO 14971
▪ Equipment and Product Safety Act
(German: “Geräte- und Produktsicherheitsgesetz”)
FMEA is recommended in ISO 9001 as a proof for your duty

of care („Sorgfaltspflicht“) Acknowlegment of FMEA as exoneration („Entlastung“) and proof of
your duty of care
FMEA
Guide Lines Economic efficiency
▪ VDA/AIAG ▪ Warranty/good will

▪ SAE J 1739 ▪ Avoid recalls
▪ EU-GMP ▪ Avoid loss of customers
▪ Avoid costs for late changes in design
Recommends/demands FMEA ▪ Do knowledge management
11
Failure Formation and Removal
Failure formation Failure removal
75% of all failures 80% of all failures are

occur before the start Start of
removed after start
serial
of serial production production of serial production
Failure rate
➢ 40% of all warranty expenses are because of conceptual reasons

➢ 60% of all failures are repetetive failures
Product Development Production Production Test Use

definition planning
Phases during product life cycle

1/6/2021
(Source: Siemens Study with University RWTH Aachen, 1997)

12
Rule of Ten
failure prevention failure correction
Entwickeln und Planen manufacturer

Beschaffen und Herstellen Prüfen und customer
Vertreiben
„An undetected failure does lead to
failure removal costs which are
increasing tenfold in each product life
cycle phase„
100.00 €
(Source: Daimler Benz/FhG-ITP, Aachen)
costs per failure
10.00 €
1.00 €
0.10 €
planning design development production test application

1/6/2021
13
Conclusion “Why FMEA?”
Because FMEA is an established method to ensure that required product features are
met.
▪ Early detection and evaluation of possible failures during the design phase
▪ Prioritized handling of problems
▪ Definition of counter actions (prevention or detection)

▪ The FMEA documents the generated knowledge and avoids repetition of

failures
14
End of lesson 1, part 1
06.01.2021
15
Lesson 1, part 2:
Getting to know e1ns
Some simple first steps
06.01.2021
16
Watch this lesson as a video
Online videos for lesson 1
There are two videos available for this lesson. You can find both on the training content page
for this e-learning course:
▪ Part 1 - History and development of FMEA (in the video the following slides are explained in detail)
▪ Part 2 - First steps in e1ns (the video shows the practical example "live", without slides)
17
First steps – Goal: filling the FMEA form manually
18
First steps – how to log in
Please use the web address of the training cloud which you have received by PLATO.
You will also receive your access data with username and password.
Your login page will look similar to this example:
1. Web address
2. Username
3. Password: plato
4. Database: DemoEng
19
Video Tutorial
Follow this link to open a PLATO video on Youtube which demonstrates the basic handling
of e1ns and how to fill data into an empty FMEA form.
▪ https://youtu.be/ftdmxAPZqbA
20
And now…
Let‘s jump into the software and learn some basic handling of e1ns!
21
Quiz for lesson 1
Online self-test
▪ Click here to start a quiz for lesson 1. Good luck!

06.01.2021
22
End of lesson 1
... continue with lesson 2!
06.01.2021
23

En PLATO E1ns E-Learning - Lesson 1 - FMEA History and First Steps

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

En PLATO E1ns E-Learning - Lesson 1 - FMEA History and First Steps

Uploaded by

Copyright:

Available Formats

E-Learning Course for PLATO e1ns

FMEA: Failure Mode and Effects Analysis

▪ Preventive method to analyse products and processes to prevent

▪ Predominantly used in Development and Production

▪ Discover potential weak spots, causes and effects

▪ Goal - Failure prevention instead of failure adjustment (early use!)

1940... 1949: US-Millitary published FMEA Method as US Military Procedure (MIL-P-1629 )

1960... 1963: NASA initiated FMEA to Apollo-Project

1970... 1975: Applied to the Nuclear Technology,

1990... Applied to chemical and pharmaceutical industry, medical technology

2000... The increasingly frequent request for the application of FMEA

(ISO 9000:2000; FDA; GMP etc.) results in an increased use in

✓ Most successful small car – competitor to VW Beatle

FMEA is recommended in ISO 9001 as a proof for your duty

▪ VDA/AIAG ▪ Warranty/good will

Failure formation Failure removal

75% of all failures 80% of all failures are

➢ 40% of all warranty expenses are because of conceptual reasons

Product Development Production Production Test Use

Phases during product life cycle

(Source: Siemens Study with University RWTH Aachen, 1997)

Entwickeln und Planen manufacturer

planning design development production test application

▪ Prioritized handling of problems

▪ Definition of counter actions (prevention or detection)

▪ The FMEA documents the generated knowledge and avoids repetition of

▪ Click here to start a quiz for lesson 1. Good luck!

You might also like