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DM306 Exam Part 8

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What does FMEA stand for?

Failure Mode Effect Analysis

What is the main purpose of FMEA?

To identify and evaluate potential failures

In what stage of product development is FMEA most beneficial?

In the early stages of design

What does FMEA predict about a product?

<p>Which failures might occur</p> Signup and view all the answers

How does FMEA contribute to product and process design?

<p>By identifying actions to prevent failures</p> Signup and view all the answers

What are the three factors in FMEA that need to be rated?

<p>Severity, probability of occurrence, detection probability</p> Signup and view all the answers

When is it likely that two FMEAs will be undertaken in product FMEA?

<p>One at the design stage and one at the production stage</p> Signup and view all the answers

How is the risk priority number calculated in FMEA?

<p>Multiplying the severity by occurrence by detection</p> Signup and view all the answers

What does FMEA stand for?

<p>Failure Mode Effects Analysis</p> Signup and view all the answers

How many key stages are mentioned for undertaking Failure Mode Effects Analysis?

<p>Two</p> Signup and view all the answers

Why is it important to prioritize failure modes and their effects in Failure Mode Effects Analysis (FMEA)?

<p>To identify the highest risk failure modes for focused attention</p> Signup and view all the answers

What is the purpose of having a completed table listing all parts and potential failure modes in FMEA?

<p>To facilitate the identification of high-risk factors for prioritization</p> Signup and view all the answers

How does prioritization of failure modes help in Failure Mode Effects Analysis?

<p>Facilitates focusing on the most critical risks</p> Signup and view all the answers

What is the significance of risk priority numbers in Failure Mode Effects Analysis?

<p>They help in prioritizing and identifying high-risk factors</p> Signup and view all the answers

Why does the design team's ability to address only a few issues necessitate prioritization in Failure Mode Effects Analysis?

<p>To prevent the design team from being overwhelmed with tasks</p> Signup and view all the answers

In FMEA, what could happen if the top 20 risk priority numbers are not addressed first?

<p>Critical risks may not receive proper attention</p> Signup and view all the answers

What could be a consequence of addressing only low-risk failure modes in Failure Mode Effects Analysis?

<p>Ineffective risk management due to neglect of critical issues</p> Signup and view all the answers

Why is variation important in identifying high-risk failure modes during Failure Mode Effects Analysis?

<p>To have distinct differences to pinpoint the highest risk factors</p> Signup and view all the answers

What is essential when considering the impact of failures on function in Failure Mode Effects Analysis?

<p>Prioritizing and focusing on high-risk factors</p> Signup and view all the answers

How does addressing a narrow selection of issues in Failure Mode Effects Analysis affect the handling of risks?

<p>Focuses resources on high-risk factors for effective risk mitigation</p> Signup and view all the answers

What is the main drawback mentioned regarding the explosion of the shuttle engineering?

<p>Insufficient design analysis</p> Signup and view all the answers

When is it easier to solve problems in a product or process?

<p>At early stages</p> Signup and view all the answers

Which method mentioned in the text is used for failure analysis and reliability engineering?

<p>Root cause analysis</p> Signup and view all the answers

Why is it crucial to identify design flaws early in the development process?

<p>To prevent system failures</p> Signup and view all the answers

In which stage of product development does the text suggest that reliability should be considered?

<p>As early as possible</p> Signup and view all the answers

What was highlighted as a consequence of not performing sufficient analysis related to design flaws?

<p>Increased risk of system failures</p> Signup and view all the answers

Why does the text advise addressing problems when they are still simple theories?

<p>To avoid complex solutions later</p> Signup and view all the answers

What percentage of system failures in the text could have been predicted and avoided?

<p>90%</p> Signup and view all the answers

What was lacking between all the parties involved in the overall product development, according to the text?

<p>Communication</p> Signup and view all the answers

What can help make solving problems in a new product or process easier, as stated in the text?

<p>Identifying design flaws early</p> Signup and view all the answers

What is a key takeaway from the text regarding addressing design flaws?

<p>Addressing them early can prevent major consequences.</p> Signup and view all the answers

When should reliability be considered in a new product or process?

<p>As early as possible</p> Signup and view all the answers

What is the recommended approach in the text for solving problems related to new products or processes?

<p>Solve them when they are still simple theories</p> Signup and view all the answers

What percentage of system failures in the text could have been predicted and avoided?

<p>90%</p> Signup and view all the answers

Which stage of product development does the text recommend considering reliability?

<p>Early in the development process</p> Signup and view all the answers

What is the primary benefit of considering reliability in the early stages of product development?

<p>To identify and address potential failures before they occur</p> Signup and view all the answers

What is a key limitation of FMEA, as mentioned in the text?

<p>It only works if RPN numbers have levels of variation</p> Signup and view all the answers

What is the primary goal of conducting a FMEA analysis?

<p>To identify and prioritize potential failure modes</p> Signup and view all the answers

What is the significance of the RPN in FMEA?

<p>It is a measure of the relative importance of each failure mode</p> Signup and view all the answers

What is the recommended approach to addressing potential failures in FMEA?

<p>Addressing the failures with the highest RPN first</p> Signup and view all the answers

What is the primary advantage of using FMEA in product development?

<p>It allows for the identification and prioritization of potential failures</p> Signup and view all the answers

What is the role of RPN in determining the significance of potential failures?

<p>It determines the relative importance of each failure mode</p> Signup and view all the answers

What is the primary difference between FMEA and Root Cause Analysis?

<p>FMEA focuses on identifying potential failures, while Root Cause Analysis focuses on identifying the root cause of failures</p> Signup and view all the answers

What is the primary limitation of using FMEA in product development?

<p>It does not provide a complete solution to all risks</p> Signup and view all the answers

What is the significance of variation in FMEA?

<p>It enables the prioritization of failure modes based on RPN</p> Signup and view all the answers

What is the primary goal of conducting a Failure Mode Effects Analysis (FMEA)?

<p>To prioritize and mitigate potential failures in a product design</p> Signup and view all the answers

Which of the following is a potential failure mode of a corkscrew?

<p>Leaking</p> Signup and view all the answers

What is the significance of the Risk Priority Number (RPN) in FMEA?

<p>It prioritizes potential failures based on their severity and likelihood</p> Signup and view all the answers

What is the primary advantage of using FMEA in product development?

<p>It helps to identify and mitigate potential failures early in the design process</p> Signup and view all the answers

What is the primary limitation of using FMEA in product development?

<p>It is a complex and resource-intensive process</p> Signup and view all the answers

What is the primary goal of the '5 Whys' method in FMEA?

<p>To identify the root cause of a failure</p> Signup and view all the answers

What is the primary benefit of using Poka Yoke in product design?

<p>It helps to reduce operator mistakes</p> Signup and view all the answers

What is the main purpose of the '5 Whys' method?

<p>To identify the root cause of a problem</p> Signup and view all the answers

In what stage of product development is Poka Yoke most beneficial?

<p>During the design phase</p> Signup and view all the answers

What is the primary difference between Poka Yoke and FMEA?

<p>Poka Yoke is used during production, while FMEA is used during design</p> Signup and view all the answers

How does the '5 Whys' method help in reliability engineering?

<p>It helps to identify the root cause of a problem</p> Signup and view all the answers

What is the primary goal of Poka Yoke in Lean manufacturing?

<p>To eliminate product defects by preventing, correcting, or drawing attention to errors</p> Signup and view all the answers

What is the purpose of the 5 Whys method in root cause analysis?

<p>To drill down to the root cause of a problem</p> Signup and view all the answers

How does Poka Yoke help in error prevention and correction?

<p>By introducing low-cost adaptations to designs and manufacturing processes</p> Signup and view all the answers

What is the benefit of using Poka Yoke in manufacturing?

<p>It helps to eliminate product defects</p> Signup and view all the answers

What is the relationship between Poka Yoke and the 5 Whys method?

<p>Both are used for error prevention and correction</p> Signup and view all the answers

What is the outcome of using Poka Yoke in manufacturing, as illustrated in the example?

<p>Elimination of product defects</p> Signup and view all the answers

Study Notes

  • Failure Mode Effect Analysis (FMEA) is a systematic process to recognize and evaluate potential failures in a product or process, and their impacts.
  • FMEA helps identify actions to prevent or reduce the chances of failures, and it documents the entire process.
  • It complements the process of defining design requirements to meet customer satisfaction and can be used in design for safety and reliability.
  • Benefits of FMEA include improved product and process design, reduced costs related to poor quality, and enhanced productivity and reliability.
  • FMEA can be applied to product design, manufacturing processes, and systems, stimulating the development of new technologies by highlighting design flaws.
  • Three key factors in FMEA are the severity of failure, the probability of occurrence, and the probability of detection, each rated by the design team.
  • Risk Priority Number (RPN) is calculated by multiplying severity, occurrence, and detection ratings to prioritize areas for improvement in product design.

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