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Oleh : Debrina P. Andriani Teknik Industri Universitas Brawijaya þ [email protected] 09 |FMEA FAILURE MODE AND EFFECT ANALYSIS T O TA L Q U A L I T Y M A N A G E M E N T

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Page 1: 09|FMEA · PENGERTIAN FMEA 11/02/16 4 . SEJARAH FMEA • The history of FMEA goes back to the early 1950s and 1960s. – U.S. Navy Bureau of Aeronautics, followed by the Bureau of

O le h :

Debr ina P. Andr iani Te k n ik Indus t r i Un i ve r s i t as B raw i jaya þ de br ina@ ub .ac . id

0 9 | F M E A F A I L U R E M O D E A N D E F F E C T A N A L Y S I S

T O T A L Q U A L I T Y M A N A G E M E N T

Page 2: 09|FMEA · PENGERTIAN FMEA 11/02/16 4 . SEJARAH FMEA • The history of FMEA goes back to the early 1950s and 1960s. – U.S. Navy Bureau of Aeronautics, followed by the Bureau of

OU

TL

IN

E

¡  Pengertian FMEA ¡  Sejarah FMEA ¡  Tujuan Umum FMEA ¡  Keuntungan Dari FMEA Bagi Perusahaan ¡ Manfaat FMEA ¡  DFMEA ¡  PFMEA ¡  FMEA Inputs And Outputs ¡  Severity, Occurrence, And Detection ¡  FMEA Procedure ¡  Studi Kasus

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Page 3: 09|FMEA · PENGERTIAN FMEA 11/02/16 4 . SEJARAH FMEA • The history of FMEA goes back to the early 1950s and 1960s. – U.S. Navy Bureau of Aeronautics, followed by the Bureau of

Failure • kondisi yang tidak diharapkan, penyimpangan atau

ketidaksesuaian

Mode • Mengindentifikasi hal2 yang menyebabkan

ketidaksesuaian

Effect • akibat dari ketidaksesuaian sebagaimana efek

terhadap customer, baik internal maupun eksternal

Analysis • menginvestigasi, mencari cara pencegahan atau

setidaknya mendeteksi.

PENGERTIAN FMEA

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Page 4: 09|FMEA · PENGERTIAN FMEA 11/02/16 4 . SEJARAH FMEA • The history of FMEA goes back to the early 1950s and 1960s. – U.S. Navy Bureau of Aeronautics, followed by the Bureau of

¡ (FMEA)merupakanprosesyangsistematisuntukmengidentifikasipotensikegagalanyangakantimbuldalamprosesdengantujuanuntukmengeliminasiataumeminimalkanresikokegagalanproduksiyangakantimbul

¡ TujuanutamadariFMEAadalahuntukmenemukandanmemperbaikipermasalahanutamayangterjadipadasetiaptahapandaridesaindanprosesproduksiuntukmencegahprodukyangtidakbaiksampaiketanganpelanggan,yangdapatmembahayakanreputasidariperusahaan

PENGERTIAN FMEA

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Page 5: 09|FMEA · PENGERTIAN FMEA 11/02/16 4 . SEJARAH FMEA • The history of FMEA goes back to the early 1950s and 1960s. – U.S. Navy Bureau of Aeronautics, followed by the Bureau of

SEJARAH FMEA

•  The history of FMEA goes back to the early 1950s and 1960s. –  U.S. Navy Bureau of

Aeronautics, followed by the Bureau of Naval Weapons

–  National Aeronautics and Space Administration (NASA)

•  Department of Defense developed and revised the MIL-STD-1629A guidelines during the 1970s.

•  Ford Motor Company published instruction manuals in the 1980s and the automotive industry collectively developed standards in the 1990s.

•  Engineers in a variety of industries have adopted and adapted the tool over the years.

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1.  Membantu dalam pemilihan desain alternatif yang memiliki keandalan dan keselamatan potensial yang tinggi selama fase desain.

2.  Untuk menjamin bahwa semua bentuk mode kegagalan yang dapat diperkirakan berikut dampak yang ditimbulkannya terhadap kesuksesan operasional sistem telah dipertimbangkan.

3.  Membuat list kegagalan potensial, serta mengidentifikasi seberapa besar dampak yang ditimbulkannya.

4.  Men-develop kriteria awal untuk rencana dan desain pengujian serta untuk membuat daftar pemeriksaaan sistem.

5.  Sebagai basis analisa kualitatif keandalan dan ketersediaan. 6.  Sebagai dokumentasi untuk referensi pada masa yang akan datang untuk

membantu menganalisa kegagalan yang terjadi di lapangan serta membantu bila sewaktu – waktu terjadi perubahan desain.

7.  Sebagai data input untuk studi banding. 8.  Sebagai basis untuk menentukan prioritas perawatan korektif.

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TUJUAN UMUM FMEA

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KEUNTUNGAN DARI FMEA BAGI PERUSAHAAN (FORD MOTOR COMPANY, 1992)

Page 8: 09|FMEA · PENGERTIAN FMEA 11/02/16 4 . SEJARAH FMEA • The history of FMEA goes back to the early 1950s and 1960s. – U.S. Navy Bureau of Aeronautics, followed by the Bureau of

ï  Examine the system for failures. ï  Ensure the specs are clear and

assure the product works correctly ï  ISO requirement-Quality Planning

§ “ensuring the compatibility of the design, § the production process, installation, servicing, inspection and test procedures, and the applicable documentation”

WHY DO FMEA’S?

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DESIG

N FM

EA

(DFM

EA)

DesignFMEAdigunakanuntukmenganalisisproduksebelummasukkeproses

produksi

DesignFMEAberfokuspadakemungkinankegagalan

yangdiakibatkanolehdesain

TipeFMEAinibiasanyadigunakanuntuk

menganalisishardware,functions,ataucombination

DesignFMEAbiasanyadilaksanakanpadatigalevel–sistem,subsistem,dan

levelkomponen

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¡  Process FMEA biasanya digunakan untuk menganalisis proses manufaktur dan perakitan pada level sistem, subsistem, atau komponen

¡  Tipe FMEA ini berfokus pada kemungkinan modus kegagalan pada sebuah proses yang disebabkan karena proses manufaktur atau perakitan.

PROCESS FMEA (PFMEA)

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12

FMEA INPUTS AND OUTPUTS

FMEA

Brainstorming C&E Matrix

Process Map Process History

Procedures Knowledge Experience

List of actions to

prevent causes or detect failure modes

History of actions

taken

Inputs Outputs

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The relationship between failure modes and effects is not always 1 to 1.

13

FAILURE MODES AND EFFECTS

Failure Mode 1

Failure Mode 2

Effect 1

Effect 2

Failure Mode 1

Failure Mode 2 Effect 1

Failure Mode 1 Effect 1

Effect 2 11/02/16 www.debrina.lecture.ub.ac.id

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SEVERITY, OCCURRENCE, AND DETECTION

Severity •  Seberapa serius kondisi yang diakibatkan jika terjadi

kegagalan

Occurrence •  Frekuensi terjadinya penyebab dan modus kegagalan

(failure)

Detection •  Kemampuan untuk mendeteksi atau mencegah penyebab

kegagalan

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FMEA

PR

OCED

UR

E

15

For each process input (start with high value inputs), determine the ways in which the input can go wrong (failure mode)

1

List current controls for each cause (Select a detection level for each cause)

4

Identify potential causes of each failure mode (Select an occurrence level for each cause)

3

For each failure mode, determine effects (Select a severity level for each effect)

2

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FMEA

PR

OCED

UR

E

16

Calculate the Risk Priority Number (RPN) 5

Assign the predicted severity, occurrence, and detection levels and compare RPNs

7

Develop recommended actions, assign responsible persons, and take actions. •  Give priority to high RPNs •  MUST look at severities

rated a 10

6

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RATING SCALES

Severity

Occurrence

Detection

1

10

Not Severe

Very Severe

10

1 Not Likely

Very Likely

1

10

Likely to Detect

Not Likely to Detect

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SEVERITY

GU

IDELIN

ES

Effect Rank Criteria

None 1 No effect

Very Slight 2 Negligible effect on Performance. Some users may notice.

Slight 3 Slight effect on performance. Non vital faults will be noticed by many users

Minor 4 Minor effect on performance. User is slightly dissatisfied.

Moderate 5 Reduced performance with gradual performance degradation. User dissatisfied.

Severe 6 Degraded performance, but safe and usable. User dissatisfied.

High Severity 7 Very poor performance. Very dissatisfied user.

Very High Severity

8 Inoperable but safe.

Extreme Severity

9 Probable failure with hazardous effects. Compliance with regulation is unlikely.

Maximum Severity

10 Unpredictable failure with hazardous effects almost certain. Non-compliant with regulations.

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OCCU

RR

ENCE

RA

NK

ING

Occurrence Rank Criteria

Extremely Unlikely 1 Less than 0.01 per thousand

Remote Likelihood 2 ≈0.1 per thousand rate of occurrence

Very Low Likelihood 3 ≈0.5 per thousand rate of occurrence

Low Likelihood 4 ≈1 per thousand rate of occurrence

Moderately Low Likelihood

5 ≈2 per thousand rate of occurrence

Medium Likelihood 6 ≈5 per thousand rate of occurrence

Moderately High Likelihood

7 ≈10 per thousand rate of occurrence

Very High Likelihood 8 ≈20 per thousand rate of occurrence

Extreme Likelihood 9 ≈50 per thousand rate of occurrence

Maximum Likelihood 10 ≈100 per thousand rate of occurrence 11/02/16 www.debrina.lecture.ub.ac.id 19

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DETECTIO

N

RA

NK

ING

Detection Rank Criteria

Extremely Likely 1 Can be corrected prior to prototype/ Controls will almost certainly detect

Very High Likelihood 2 Can be corrected prior to design release/Very High probability of detection

High Likelihood 3 Likely to be corrected/High probability of detection

Moderately High Likelihood

4 Design controls are moderately effective

Medium Likelihood 5 Design controls have an even chance of working

Moderately Low Likelihood

6 Design controls may miss the problem

Low Likelihood 7 Design controls are likely to miss the problem

Very Low Likelihood

8 Design controls have a poor chance of detection

Remote Likelihood 9 Unproven, unreliable design/poor chance for detection

Extremely Unlikely

10 No design technique available/Controls will not detect

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¡  RPN merupakan hasil dari skor severity, occurrence, dan detection.

¡  RPN digunakan untuk memprioritaskan tindakan. ¡  Semakin besar nilai RPN, semakin besar pula

perhatian yang diberikan. ¡  RPN berkisar antara 1-1000. ¡  Tim harus melakukan usaha untuk menanggulangi

nilai RPN yang tinggi melalui tindakan korektif.

21

RISK PRIORITY NUMBER (RPN)

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RISK PRIORITY NUMBER (RPN)

Severity Occurrence Detection RPN

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FMEA FORM

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STEP 1 : FOR EACH INPUT, DETERMINE THE POTENTIAL FAILURE MODES

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STEP 2 : FOR EACH FAILURE MODE, IDENTIFY EFFECTS AND ASSIGN SEVERITY

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STEP 3 : IDENTIFY POTENTIAL CAUSES OF EACH FAILURE MODE AND ASSIGN SCORE

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STEP 4 : LIST CURRENT CONTROLS FOR EACH CAUSE AND ASSIGN SCORE

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STEP 5: CALCULATE RPNS

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STEP 6 : DEVELOP RECOMMENDED ACTIONS, ASSIGN RESPONSIBLE PERSONS, AND TAKE ACTIONS

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STEP 7 : ASSIGN THE PREDICTED SEVERITY, OCCURRENCE, AND DETECTION LEVELS AND COMPARE RPNS

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Chi tose Indonesia Manufactur ing m e r u p a k a n p e r u s a h a a n y a n g memproduksi dan menjual furniture d a r i l o g a m d e n g a n k e r j a s a m a negara Jepang. Selama ini didalam keseharian kita ser ing menemukan beberapa kasus kerusakan kur s i l ipat . Kerusakan yang ser ing kal i d i temui pada kurs i l ipat Chi tose Yamato HAA adalah pi jakan kaki patah, bantalan rangka kursi rusak , t e r j a d i ny a k a r a t p a d a m a t e r i a l , s e r t a b a n y a k j e n i s k e r u s a k a n l a i n n y a . O l e h k a r e n a i t u u n t u k m e n c e g a h t e r j a d i n y a k e r u s a k a n tersebut , maka diper lukan evaluasi dan anal isa moda kegagalan untuk menjamin produk dapat ber fungsi d e n g a n b a i k d a n a m a n k e t i k a digunakan oleh pengguna.

P e r m a s a l a h a n d a s a r y a n g t i m b u l a k i b a t d a r i k e r u s a k a n k u r s i l i p a t Chitose Yamato HAA adalah kegagalan a p a y a n g a d a d i d a l a m s i s t e m p e n g o p e r a s i a n k u r s i l i p a t C h i t o s e Yamato HAA, apa akibat kegagalan tersebut , seberapa besar efek akibat kegagalan tersebut , dan rekomendasi y a n g d i l a k u k a n u n t u k m e n g u r a n g i e f e k k e g a g a l a n t e r u t a m a y a n g berbahaya bagi pengguna kursi l ipat .

STUDI KASUS: ANALISA MODA DAN EFEK KEGAGALAN (FAILURE MODE AND EFFECTS ANALYSIS / FMEA)

PADA PRODUK KURSI LIPAT CHITOSE YAMATO HAA

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Pemeriksaan gaya yang beker ja pada satu t i t ik berdasarkan warna yang d i tunjukkan kontur warna. Semakin gelap kontur, semakin menunjukkan bahwa gaya yang beker ja semakin besar sehingga cenderung memil ik i pe luang untuk ter jadi kegagalan

IDENTIFIKASI POTENSI KEGAGALAN

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PERHITUNGAN RPN

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REKOMENDASI PERBAIKAN M e n g g a n t i j e n i s m a t e r i a l d e n g a n material yang lebih kuat, geometri lebih t e b a l , d a n t a h a n terhadap terjadinya karat

Bagian sambungan las-lasan diperkuat dengan menggunakan kualitas las yang kuat dan teknik pengelasan yang baik

Melakukan perawatan jika kursi lipat terkena air dengan mengelap dengan sedikit oli/solar

Memperbaiki teknik pemasangan sekrup, leg shoes, dan plastic bracket supaya lebih kencang

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CONTOH FMEA

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SELESAI