Failure Mode and Effect

Analysis

MFG 340 FMEA Lab

To be done only after the Introduction to FMEA has

been completed
 FMEA Processes

As you should have already

learned, FMEA is an excellent
tool to guide one through the
process of identifying,
categorizing, prioritizing and
solving problems, or resolving
concerns. This lab will provide
you experience in using an
excellent brainstorming tool that
is helpful in the FMEA process.
 FMEA Brainstorming

An important part of FMEA is

ensuring that, as much as
possible, all possible issues or
problems have been identified.
A good tool to use in doing that
is a modified Affinity Diagram
that we will call

Post-it note brainstorming.

 Post-it Note
Brainstorming
Advantages:
Every person can be involved
without having to speak up or
verbally present their ideas and
concerns.
Even quiet people are fully
involved.
More ideas can be generated in
less time than most other
methods.
Everyone assists in categorizing
problems and issues.
 Post-it Note
Brainstorming

Disadvantages or limitations
Without verbal clarification some
ideas may not be fully understood
Lack of open discussion early in
the process may limit new ideas
that sometimes come from
hearing others ideas.
Must resist the temptation to
hurry the writing portion to
ensure all ideas are presented.
 Post-it Note
Brainstorming
Step One
State the problem or issue to be
discussed. It may be something
like What are the most severe
technical problems with the
model A1 product?
For this lab exercise the
question is:
What will be the greatest
obstacles to practicing continuous
improvement quality methods in
industry.
 Post-it Note
Brainstorming

Step Two
Each person writes one idea,
solution, item, or item on a post it
note. One per note only

Step Three
Every item, idea, etc. is posted on
a surface (wall, window, etc.) in
random order.
 Post-it Note
Brainstorming
Step four
After all have posted everything they
can think of (dont rush this process)
then the group organizes the posted
items into categories. The following
rules apply:
Any item can be moved by any person to
any category or a new one started.
If a moved item is felt by someone should
be moved again, they are free to do so. If
an item is beginning to be moved back
and forth discussion between the parties
involved would help determine if a new
item or category should be created.

d
 Post-it Note
Brainstorming
Step five
After categories have been
created then the group should
create labels for each category.

After labels have been created all

in the group should review the
categories and items in categories
to ensure that all agree with the
categories.
 Post-it Note
Brainstorming
This concludes the
brainstorming exercise. The
information now available is
excellent material generated by
a group of people and
categorized and labeled in a
relatively short time. Groups as
large as 20 have done this
exercise successfully.
 FMEA Lab
continued
To complete this lab exercise do
the following:
Discuss the severity, occurrence
and detectability of each of the
categories of issues completed in
the post-it note brainstorming
exercise.
As part of your lab write up
discuss the priorities that were
determined.
Also discuss any suggestions you
have to overcome the challenges
listed.
 FMEA Lab
continued
After completing the exercise
for this lab, complete the report
and include the following:
your observations about the
exercise
what the technique
(brainstorming) has taught you
how brainstorming has a role in
FMEA
observations regarding the FMEA
process itself.