Call Us Today! 1.248.374.1718|info@HarpcoSystems.com

FMEA Ratings – What They Mean and Why Most People Set Them Incorrectly

There is a high likelihood that every FMEA you have ever created has one or more rating columns filled out incorrectly and as a result the effectiveness of your FMEAs is greatly reduced!

The primary purpose of the Design FMEA and Process FMEA is to allow companies to efficiently manage risk.  No company has unlimited resources. When properly used the Design FMEA and Process FMEA help companies target the use of their limited resources to achieve the greatest reduction in design and manufacturing related risk.  To be used effectively as risk management tools, one must properly populate the rating columns of the Design FMEA and Process FMEA. If you have participated in the creation of a Design FMEA or Process FMEA there is a high likelihood that you have spent considerable time populating the rating columns.  More importantly, there is a 99% probability you have filled out one or more of the rating columns incorrectly. 

Did you know:

  1. Every major national and international FMEA Manual/Standard/Guideline in publication including the latest AIAG VDA FMEA Handbook instructs the users to populate one of the most important rating columns in both the Design FMEA and Process FMEA incorrectly. 
  2. RPN and SxO calculations should never be used to determine what to work on in a Design FMEA or Process FMEA.
  3. Many replacements for the RPN such as the new AIAG VDA FMEA Handbook “Action Priority” or “AP” share some of the weakness of RPN and should not be used if you want to effectively target your resources at the highest risk issues.
  4. Design engineers should never identify “Special Characteristics” for the Process FMEA Class Column for manufacturing personnel.  This one action is costing manufacturing companies millions of dollars.  
  5. Contrary to what many “FMEA Experts” teach, there is no link between special characteristics in the Design FMEA and Process FMEA Class columns.
  6. The removal of the Class column from the Design FMEA in the AIAG VDA FMEA Handbook will significantly reduce the effectiveness of the Design FMEA as a design risk management tool.
  7. The latest ratings in the AIAG VDA FMEA Handbook will lead to both increased FMEA creation time with a proportional decrease in FMEA effectiveness.

In the weeks to come, these topics and several others related to the proper population of FMEA rating columns will be explained in our “Taking the Mystery and Misery Out of FMEA Ratings” series.  If you would like to be placed on a mailing list for each of the articles in the series that we guarantee will take your understanding of Design FMEA and Process FMEA Ratings to the next level click on the following link.

FMEA Ratings – What They Mean and Why Most People Set Them Incorrectly2019-12-31T16:30:15-05:00

2018 Guangbin Yang Reliability Symposium

2018 Guangbin Yang Reliability Symposium

Come meet us at Oakland University for the 2018 Guangbin Yang Reliability Symposium on Thursday August 30. The event is sponsored by ASQ Detroit. We’ll be manning a booth from 7am-5pm.

We’d love to give you a quick software demo, but if you want to just stop by and talk shop that’s great too!

More information on the event is here. To register for the event – it’s free – click here.

We have a busy schedule of events across the country in the coming months, including presentation of new papers. An announcement will be up in this space next week.

2018 Guangbin Yang Reliability Symposium2018-08-21T13:42:56-05:00

Webinar: Ten Things You Need to Know About Implementing ISO 9001:2015-Compliant Risk-Based Thinking

The folks at Quality Digest are hosting a webinar for us. Scheduled for January 17 (Wednesday), it is titled “Ten Things You Need to Know About Implementing ISO 9001:2015-Compliant Risk-Based Thinking”.

The concept of risk-based thinking has been implicit in previous editions of ISO 9001 through requirements planning, review and improvement. The ISO 9001-2015 standard requires companies to explicitly use risk-based thinking to manage their business. If you want to implement an ISO 9001-2015 compliant Quality Management System (QMS) that uses risk-based thinking to risk optimize your QMS processes and select opportunities there are ten things you need to know.

Join Harpco Systems’ Richard Harpster who has over 30 years of experience in implementing risk-based Quality Management Systems for this webinar that will explain key ISO 9001-2015 risk-based thinking requirements as well as provide examples of what ISO 9001-2015 compliant risk-based thinking implementation looks like throughout the product development process.

There will be a 15 minute Q&A period at the end of the webinar. Sign up here.

Webinar: Ten Things You Need to Know About Implementing ISO 9001:2015-Compliant Risk-Based Thinking2018-01-15T16:50:41-05:00

Review: ASQ Conference on Quality Standards

2016 ASQ International Conference on Quality Standards

In November Harpco Systems’ CEO Rich Harpster gave a pair of talks for the ASQ Conference on Quality Standards at the Marriott City Center in Pittsburgh PA:

Your Supplier’s FMEAs Tell You More About Your Suppliers Than You Know

Implementing Risk-Based Thinking Required for ISO 9001:2015 Compliance

Despite the small overall size of the conference both talks filled their respective rooms. We were especially enthused by the response to the first talk. Here is the blurb ASQ used to advertise the talk:

Review of supplier FMEAs is a commonly used practice for risk assessment of supplier product designs and manufacturing processes. This hour long presentation will show you how to perform a quick 10 to 15-minute analysis of the design and process FMEA contents to gain insight into weaknesses of the supplier’s QMS and the risk exposure and potential financial cost they can incur to your company.

Basically we taught attendees how to rip bad FMEAs apart. Seems a lot of people are unhappy with their suppliers’ FMEAs. We are looking to take this talk to other places. Especially places where folks can bring their actual FMEAs to use as live examples.

We’ve posted a version of the talk as a page on our website: Design Specs & Design requirements: Your Suppliers’ FMEA’s. We’re thinking of making the slide deck available as well. Email us if you’re interested.

Review: ASQ Conference on Quality Standards2017-06-28T07:22:38-05:00

ASQ International Conference on Quality Standards

2016 ASQ International Conference on Quality Standards

Looking for ideas to help your company meet the new ISO 9001:2015 Standard requirements? In November Harpco Systems’ CEO Rich Harpster will present two talks at ASQ International Conference on Quality Standards 2016 in Pittsburgh PA. The conference is being held November 14 & 15 at the Pittsburgh Marriott City Center pictured above.

Implementing Risk-Based Thinking Required for ISO 9001:2015 Compliance

This 2 hour workshop introduces implementation of risk-based thinking to guide companies in the identification and management of risk during product design, product manufacturing, and provision of services. You will learn how to identify the key sources of risk, determine their magnitude, and identify which sources of risk represent the greatest threat and must be worked on. Finally, you will learn to overcome the obstacles to implementing risk-based thinking in your company.

Your Supplier’s FMEAs Tell You More About Your Suppliers Than You Know

Review of supplier FMEAs is a commonly used practice for risk assessment of supplier product designs and manufacturing processes. This hour long presentation will show you how to perform a quick 10 to 15-minute analysis of the design and process FMEA contents to gain insight into weaknesses of the supplier’s QMS and the risk exposure and potential financial cost they can incur to your company.

There will be a Q&A session after each talk. If you are attending this conference we’d love to meet you! Shoot us your contact info in an email and we’ll get in touch. Rich will be at the conference all week and is happy to answer any questions you may have on a wide variety of topics including ISO 9001:2015, Risk Based PLM®, FMEAs, Pittsburgh and golf. Seriously; Rich was born & raised in the Pittsburgh area and if you want to talk Steelers & Penguins he’s your guy.

Can’t attend the conference and want a copy of the paper? Fill out the form and we’ll send it when the published version is available from ASQ.

ASQ Standards 2016 Contact Form

Name
Email
Company
Phone

I'm going!Not going, but would love the paper

ASQ International Conference on Quality Standards2017-03-02T10:36:02-05:00

We’re Going To RAMS 2016!

Reliability & Maintainability Symposium 2016 in Tuscon AZ

Looking for ideas to help your company meet the new ISO 9001:2015 Standard requirements? Harpco Systems’ CEO Rich Harpster will present

How FMEAs Can Be The Cornerstone Of An ISO 9001:2015 Compliant Risk Based Quality Management System

at RAMS (Reliability & Maintainability Symposium) 2016 in Tuscon AZ. The conference is being held at the gorgeous Loews Ventana Canyon resort pictured above.

There will be a Q&A period after the talk. Rich will be at the conference all week and is happy to answer any questions you may have on a wide variety of topics including ISO 9001:2015, Risk Based PLM® and FMEAs. Shoot us your contact info and we’ll get in touch.

Can’t attend the symposium and want a copy of the paper? Fill out the form and we’ll send it when the published version is available from IEEE.

RAMS 2016 Contact Form

Name
Email
Company
Phone

I'm going!Not going, but would love the paper

We’re Going To RAMS 2016!2017-03-02T10:36:02-05:00