[Music] hello my name is kevin clay and i am one of the lean six sigma instructors here at six sigma development solutions today i'm going to give you a brief introduction into a tool called the fmea or the failure modes and effects analysis uh in lean six sigma we use this fmea as part of four tools uh for root cause analysis qualitative root cause analysis uh those four tools are the cypoc uh the input map the cne matrix and the fmea these are used in sequence from the cypot to the input map to the cne matrix to the fmea and they work in conjunction with each other to understand what a problem is uh what's causing a problem from a qualitative standpoint now in six sigma we don't just use qualitative data we use quantitative as well but we're focusing on just the qualitative side of of solving a problem in these four tools we have created brief introductory videos for each of these tools on our website so uh kind of an introduction like we're giving here for the fmea so let's get into the actual fmea you'll see it here on the screen first i'm going to start off and explain the columns all right so in the fmea the columns you see are from process step all the way through uh rpn which is called risk priority number this is really just two-thirds of the whole fmea this is the analysis side of the fmea the other third actually is that attached onto this you don't see it uh it's called uh it's basically the improved part of the fmu where we make the improvement and then we understand what was the impact of that improvement so we are only going to focus on the analysis side the columns the columns are the first two columns process step and process input um are are really what we fill out first this information uh we get from our cme matrix our cmd matrix is uh a tool where we prioritize our inputs to find out which ones are the most important inputs and then we move those inputs over into the fmea and we analyze them so uh what we see here is is in our process analysis example that we use for our green belts and our black belts in our class we have an analysis example that basically shows a whole six sigma project uh the fma being part of that so that's where this data comes from in this in this data we have found out in our process that setting up of the workstation and standard work instructions along with applying the peanut but the peanut butter and the jelly using the construction tools those are the most important inputs to us i'll take you back just uh quickly the process we're focusing on here is um is from a company called peanut butter and jelly incorporated fake company one we made up uh and they are experiencing uh uh costs for construction of their peanut butter and jelly sandwich that is higher than their target cost so from the uh previous tools cypoc input maps cv matrix we've determined that again set up standard work instructions uh applying peanut butter and jelly using the construction tools those are our our key inputs that we need to understand and improve so again the process step and process input comes from that cd matrix okay the next column is our potential failure mode and this is basically saying how does our input our process input fail all right and you're going to see here in a few minutes that um there can be many failures to one input all right there's a one-to-many relationship there and we'll get into to what that looks like okay so failure mode we have here uh one of the failure modes is that the standard work instructions aren't there they're not available okay and that has an effect on our process has an effect on our process and the effect is uh constructing the pbj to operators perceived standards all right so basically what they think the standard is or what they've developed internally because they don't they don't produce from a a written standard it's just um on-the-job training where they've learned from a previous person how to do something excuse me for that uh and then we have severity all right i'm gonna take you through the scoring mechanism here severity occurrence and detection will come back to potential causes and current controls so severity occurrence and detection are are the scoring mechanism to understand how severe that potential failure mode is to us okay and we score on a 1 to 10 scale for each of these i'll go back to these in just a minute our next row i'm sorry our next column is potential causes potential causes are basically uh what causes the failure mode so the flow is what causes the failure mode to result in the effect and again potential causes and potential failure effects and failure modes they all have a one-to-many relationship so my failure effect could have several causes could cause that failure mode to result in that effect all right so you're seeing here that the the fmva can expand all right from one input one input could equal uh several potential failure modes each potential failure mode can equal several potential failure effects uh one failure effect can equal but several potential causes all right now current controls current controls in this column we don't expand in the other columns every time i have a a new potential failure effect that goes in a different cell right that's why this expands but because we want to know uh the impact of each now in current controls we don't do that we if we have more than one current control we put that in one cell uh all of our current controls if we have multiples current controls are basically how well do we detect the failure mode all right the best current control actually not only not detects it but it prevents it all right that's the best control now uh when we get to to more severe current uh current controls or detection um we we find out that the defect happens now we need to understand how well do we detect it all right do we detect it right when it happens did we detect it you know several steps down down the system or does the customer detect it okay and our our score our detection score is really based on that okay so let's go back to store scores real quick severity is correlated to the potential failure effects all right it says how severe will the effect be it's on a 1 to 10 scale all right i'm not going to go through each of the numbers in the scale because we have a tutorial for this that is really in depth and helps you to understand exactly how to fill this out this is really more of a a high level introduction to the fmea so again severity is correlated or related to potential failure effects how severe is the effect occurrence is correlated or related to potential cause how how many times does a cause occur okay and current controls is is basically correlated to detection how well does the current control detect the failure mode and that's how those those three are are uh defined now to get the rpn or the risk priority number you take the severity times occurrence times this dissection and you will get the risk priority number now i also told you that you know this can expand so you'll see here that i've hidden some rows so i'm gonna unhide those rows oops and that should be set up let me retype that sorry so you'll see here i've got set up several times i've got standard work instructions several times and then i've got not available twice and out of date twice these are potential failure modes because somewhere in here we get down to where each of the each of the uh rows are unique all right remember how i told you this can expand and when it expands we have to backfill we we have to fill all the way back because eventually we are going to uh sort on the rpn uh the highest rpm to the lowest rpm if we do that and we don't have every row and every column filled in then we're not going to really know where some you know the potential cause or the failure effect we might not know where that came from when it comes to process step and process input okay so um hopefully you have a better understanding of the fmea the failure modes and effects analysis um we have more in-depth lesson on the uh on the fmea along with a certification on our website there's an actual uh module that we have it's it's more in-depth and it comes with a quiz at the end uh once you pass that quiz you you get a certification note saying that you understand that tool the fma tool if you're watching this video directly from youtube i will put that information in the description for that tutorial if you're watching this video from one of our articles our blogs on our website um it will be down in the blog so uh if you have any questions please don't hesitate to contact me again my name is kevin clay and i'm one of the lean six signaling instructors here at six sigma development solutions my email address is k clay at six sigma dsi.com and again if you have any questions please give me a call and have a wonderful a wonderful day [Music] bye