The series of posts I have recently begun on PFMEAs are rooted in my frustration at single piece defects getting to the customer factories. By this, I mean "one body missing a machined hole" or "one assembly missing a retaining pin".
Part of the manufacturing/quality struggle is to produce all parts within print specification. This struggle is addressed by dimensional controls and SPC. The PFMEA usually, almost exclusively, addresses dimensional issues. But the problema that I see passing through to customers are not that "our process shifted 10 microns over size", it is that that one machining operation was missed on one piece.
In the attached video the PFMEA is mentioned. I liked this video. The PFMEA comment was accurate.
"PFMEAs, although a great tool, are only as good as the knowledge put into them."
The video author admits that often failure modes and causes are missed in the PFMEA. What is the countermeasure to this failure mode in the NPD (new product development) process?
Thanks to TheUjigamiGuy on YouTube
A Plant Rat works in the plant, factory, refinery, or processing facility. Somehow we learn to navigate the maze. Here we can exchange information, ideas and questions to help us improve the manufacturing process. We must reduce variation and standardize our work to produce the best quality possible.
1 comment:
As you lament, dimensional controls and SPC will NOT address the "one slipped through" problem. That is the nature of SPC -- and the point of the YouTube video presentation.
A comprehensive Manufacturing Execution System (MES) will RESOLVE the problem. Especially, the Ujigami MES because it is Product Directed.
Even the challenge of "lost" historical experience is addressed in a good MES.
Start your journey of improvement by investigating MES solutions. I would like to see a blog on your findings...
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