U.S. patent application number 13/435082 was filed with the patent office on 2012-10-04 for risk charts for failure mode and effect analysis.
This patent application is currently assigned to Caterpillar Inc.. Invention is credited to Jason W. Flanagan, Jasmeen K. Harsh, Michael Ye.
Application Number | 20120254710 13/435082 |
Document ID | / |
Family ID | 46928463 |
Filed Date | 2012-10-04 |
United States Patent
Application |
20120254710 |
Kind Code |
A1 |
Flanagan; Jason W. ; et
al. |
October 4, 2012 |
RISK CHARTS FOR FAILURE MODE AND EFFECT ANALYSIS
Abstract
A method to facilitate a failure modes and effects analysis
(FMEA) project associated with one or more components or process
during a product development cycle is provided. The method includes
displaying on the user interface one or more information pages
associated with sequential order of elements to be completed by one
or more FMEA analysts. The method further involves receiving with
an aid of the user interface textual inputs from the one or more
FMEA analysts for the one or more information pages associated with
the sequential orders of elements. The method further includes
developing a risk chart for tracking a risk mitigation progress for
the FMEA project associated with the one or more components or
process during the product development cycle. The risk charts
include a Criticality Matrix Risk Chart (CMRC) and a Pro-active
Reliability Risk Chart (PRRC).
Inventors: |
Flanagan; Jason W.; (Peoria,
IL) ; Harsh; Jasmeen K.; (Peoria, IL) ; Ye;
Michael; (Peoria, IL) |
Assignee: |
Caterpillar Inc.
Peoria
IL
|
Family ID: |
46928463 |
Appl. No.: |
13/435082 |
Filed: |
March 30, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61470744 |
Apr 1, 2011 |
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61470715 |
Apr 1, 2011 |
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Current U.S.
Class: |
715/202 |
Current CPC
Class: |
G06Q 10/0631 20130101;
G06Q 10/06395 20130101 |
Class at
Publication: |
715/202 |
International
Class: |
G06F 17/20 20060101
G06F017/20 |
Claims
1. A computer-implemented method to facilitate a failure modes and
effects analysis (FMEA) project associated with one or more
components or process during a product development cycle, the
method comprising: displaying on the user interface one or more
information pages associated with sequential order of elements to
be completed by one or more FMEA analysts; receiving with an aid of
the user interface textual inputs from the one or more FMEA
analysts for the one or more information pages associated with the
sequential orders of elements; and developing a risk chart for
tracking a risk mitigation progress for the FMEA project associated
with the one or more components or process during the product
development cycle, based on the information associated with the
sequential order of elements.
2. The computer implemented method of claim 1, wherein developing
the risk chart includes developing a single risk chart for multiple
FMEA projects.
3. The computer implemented method of claim 1, wherein the risk
chart includes a criticality matrix risk chart (CMRC) and a
pro-active reliability risk chart (PRRC).
4. The computer implemented method of claim 3, wherein the CMRC is
based at least in part on a severity value associated with at least
one potential effect of failure, and an occurrence value associated
with at least one potential cause of failure.
5. The computer implemented method of claim 3, wherein the CMRC
includes three zones based on the severity value and the occurrence
value.
6. The computer implemented method of claim 5, wherein three zones
includes: a. a risk mitigation zone; b. a probable risk mitigation
zone; and c. a risk free zone.
7. The computer implemented method of claim 6, wherein the risk
mitigation zone includes at least one combination of potential
causes of failure and potential effects of failure having a
correlation of the severity value and the occurrence value greater
than a predetermined threshold.
8. The computer implemented method of claim 7, wherein each of the
at least one combination of the potential causes of failure and the
potential effects of failure in the risk mitigation zone includes
at least one recommended action.
9. The computer implemented method of claim 6, wherein the probable
risk mitigation zone includes at least one combination potential
causes of failure and potential effects of failure having a
correlation of the severity value and the occurrence value greater
than a predetermined threshold.
10. The computer implemented method of claim 9, wherein each of the
at least one combination of the potential causes of failure and the
potential effects of failure in the probable risk mitigation zone
includes at least one of a prevention and detection controls.
11. The computer implemented method of claim 9, wherein each of the
at least one combination of the potential causes of failure and the
potential effects of failure in the probable risk mitigation
includes at least one recommended action if an Risk Priority Number
(RPN) for those combinations is greater than a pre-determined
value.
12. The computer implemented method of claim 11, wherein the RPN is
based on a correlation between the severity value, the occurrence
value and a detection value.
13. The computer implemented method of claim 12, wherein the
detection value is associated with each of the at least one
combination of the potential causes of failure and the potential
effects of failure.
14. The computer implemented method of claim 13, wherein the
detection value is taken as a predetermined number to calculate the
RPN if no inputs are provided for the detection value.
15. The computer implemented method of claim 6, wherein the risk
free zone includes at least one combination potential causes of
failure and potential effects of failure having a correlation of
the severity value and the occurrence value lesser than a
predetermined threshold.
16. The computer implemented method of claim 6, wherein the three
zones are separated with at least one of a color code, a hatch
pattern, and a heat map.
17. The computer implemented method of claim 2, wherein the CMRC
includes an initial CMRC, a forecast CMRC and a current CMRC.
18. The computer implemented method of claim 17 further including
comparing the initial CMRC and the current CMRC to track the risk
mitigation progress for the FMEA project.
19. The computer implemented method of claim 17, wherein the
initial CMRC is based on an initial severity value and an initial
occurrence value associated with a combination of at least one
potential cause of failure and at least one potential effect of
failure.
20. The computer implemented method of claim 19 further including
revising an initial CMRC based on a revised initial occurrence
value associated with the combination of the at least one potential
cause of failure and the at least one potential effect of
failure.
21. The computer implemented method of claim 14, wherein the
initial occurrence value is revised based on an execution of at
least one prevention control associated with the combination of the
at least one potential cause of failure and the at least one
potential effect of failure.
22. The computer implemented method of claim 17, wherein the
current CMRC is based on a current severity value, and a current
occurrence value associated with a combination of at least one
potential cause of failure and at least one potential effect of
failure.
23. The computer implemented method of claim 22, wherein the
current severity value and the current occurrence value is based on
an execution of at least one recommended action associated with the
combination of the at least one potential cause of failure and the
at least one potential effect of failure.
24. The computer implemented method of claim 17, wherein the
forecast CMRC is based on a forecast severity value, and a forecast
occurrence value associated with a combination of at least one
potential cause of failure and at least one potential effect of
failure.
25. The computer implemented method of claim 24, wherein the
forecast severity value and the forecast occurrence value is based
on an presumption execution of at least one recommended action
associated with the combination of the at least one potential cause
of failure and the at least one potential effect of failure.
26. The computer implemented method of claim 3, wherein the CMRC on
the user interface provides a path to view a status report
including information associated with the sequential order of
elements.
27. The computer implemented method of claim 26, wherein the
information in the status report includes: a. one or more of an
item, or process step; b. requirement associated with item or
process step output; c. at least one potential failure mode
associated with the item or process; d. an initial severity value,
an initial occurrence value and an initial detection value
associated with a combination of at least one potential effect
failure and at least one potential cause of failure associated with
the potential mode of failure; e. one or more prevention or
detection controls associated with the combination of the at least
one potential effect failure and the at least one potential cause
of failure; f. a validation identification of the FMEA project; g.
one or more recommended action associated with the combination of
the at least one potential effect failure and the at least one
potential cause of failure; h. a forecasted severity value, a
forecasted occurrence value and a forecasted detection value
associated with the combination of the at least one potential
effect failure and the at least one potential cause of failure; i.
a current severity value, a current occurrence value and a current
detection value associated with the combination of the at least one
potential effect failure and the at least one potential cause of
failure; j. the one or more FMEA analysts assigned for an execution
of the one or more prevention or detection controls and the one or
more recommended actions; and k. a start date, target completion
state associated with the one or more prevention or detection
controls and the one or more recommended actions.
28. The computer implemented method of claim 27, wherein the
sequential order of elements includes one or more visual
descriptors associated with the elements of the sequential order of
elements.
29. The computer implemented method of claim 28, wherein the one or
more visual descriptors provides a status or issues associated with
the elements.
30. The computer implemented method of claim 27, wherein the status
report provides a path to view and edit information associated with
the elements of the sequential order of elements.
31. The computer implemented method of claim 26, wherein the status
report provides a path on to export the status report in MS
Excel.
32. The computer implemented method of claim 3, wherein the PRRC is
based on a timeline for risk mitigation during the FMEA project and
a Dealer Repair Frequency (DRF).
33. The computer implemented method of claim 32, wherein the PRRC
includes a mean DRF, a design DRF, a glide-path DRF, a capability
DRF, a target DRF, a current DRF, and a history DRF.
34. The computer implemented method of claim 33, wherein a mean DRF
is a failure rate spread for a limited time-period in a product
lifecycle.
35. The computer implemented method of claim 33, wherein the design
DRF is determined based on an initial occurrence value associated
with a combination of at least one potential effect of failure and
at least one potential cause of failure.
36. The computer implemented method of claim 33, wherein the
glide-path DRF is based on a completion of prevention and detection
controls and recommended actions within a required target date of
completion.
37. The computer implemented method of claim 36, wherein a history
of the glide-path DRF is recorded in a pre-determined time range to
track a progress of the risk mitigation for the FEMA project during
the product development cycle.
38. The computer implemented method of claim 33, wherein the
capability DRF is based on a lowest occurrence value associated
with a combination of at least one potential effect of failure and
at least one potential cause of failure.
39. The computer implemented method of claim 33, wherein the target
DRF is based on a specified target timeline provided by the one or
more FMEA analysts for the risk mitigation.
40. The computer implemented method of claim 39, wherein the target
DRF is provided by the one or more FMEA analysts on the user
interface.
41. The computer implemented method of claim 33, wherein the
current DRF is based on an initial revised occurrence value on a
successful execution of the prevention and detection controls
associated with a combination of at least one potential effect of
failure and at least one potential cause of failure.
42. A system comprising: a processor for facilitating a failure
modes and effects analysis (FMEA) project associated with one or
more components or process during a product development cycle, a
tangible, non-transitory memory configured to communicate with the
processor, the tangible, non-transitory memory having instructions
stored thereon that, in response to execution by the processor,
cause the processor to perform operations comprising: displaying on
the user interface one or more information pages associated with
sequential order of elements to be completed by one or more FMEA
analysts; receiving with an aid of the user interface textual
inputs from the one or more FMEA analysts for the one or more
information pages associated with the sequential orders of
elements; and developing a risk chart for tracking a risk
mitigation progress for the FMEA project associated with the one or
more components or process during the product development cycle,
based on the information associated with the sequential order of
elements.
43. An article of manufacture including a non-transitory, tangible
computer readable medium having instructions stored thereon that,
in response to execution by a computer-based system for
facilitating a failure modes and effects analysis (FMEA) project
associated with one or more components or process during a product
development cycle, cause the computer-based system to perform
operations comprising: displaying on the user interface one or more
information pages associated with sequential order of elements to
be completed by one or more FMEA analysts; receiving with an aid of
the user interface textual inputs from the one or more FMEA
analysts for the one or more information pages associated with the
sequential orders of elements; and developing a risk chart for
tracking a risk mitigation progress for the FMEA project associated
with the one or more components or process during the product
development cycle, based on the information associated with the
sequential order of elements.
Description
RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of
priority from U.S. Provisional Applications No. 61/470,744 by Jason
Wayne Flanagan et al., filed Apr. 1, 2011, and U.S. Provisional
Application No. 61/470,715 by Jasmeen K. Harsh et al., filed Apr.
1, 2011, the contents of which are expressly incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present disclosure generally relates to Failure Mode and
Effects Analysis (FMEA) and more particularly to develop risk
charts in FMEA.
BACKGROUND
[0003] Every product or process is subject to different types or
modes of failure. Potential failures may have costly consequences
or effects. Hence, it is essential to effectively and efficiently
monitor the entire production cycle of the product and its
manufacturing process in order to identify the potential failures
and the associated relative risks at an early stage and achieve a
better quality product.
[0004] Generally, Failure Mode and Effect Analysis (FMEA) is
conducted in order to identify causes and effects of the potential
failure in the manufacturing process and/or the design of the
product, prioritize action plans to reduce the potential failures,
track and evaluate results of the action plans and eventually
minimize or eliminate the potential failure and the associated
risk. The FMEA may be conducted for a design of the product or for
a process of manufacturing the product.
[0005] Typically, FMEAs are conducted manually, involving the use
of excel spread sheets. This known technique proves to be time
consuming and cumbersome in situations where the FMEA is being
conducted for a product having a relatively large number of parts
or numerous process steps. Additionally, the technique is prone to
human errors. Moreover, in some instances, manually monitoring the
progress of the FMEA, tracking the progress of the action plans or
evaluating the success of risk mitigation may be difficult and
challenging.
[0006] Therefore, there is a need for an automated system and
method for performing the FMEA process and enabling an analyst to
monitor and track the progress of risk mitigation.
SUMMARY OF THE DISCLOSURE
[0007] In an aspect of the present disclosure, a
computer-implemented method is provided to facilitate a failure
modes and effects analysis (FMEA) project associated with one or
more components or process during a product development cycle. A
real time FMEA status is viewable through a user interface which
indicates the progress of the FMEA project. The method includes
displaying on the user interface one or more information pages
associated with sequential order of elements to be completed by one
or more FMEA analysts. The method further involves receiving with
an aid of the user interface textual inputs from the one or more
FMEA analysts for the one or more information pages associated with
the sequential orders of elements. Further, the method includes
developing a risk chart for tracking a risk mitigation progress for
the FMEA project associated with the one or more components or
process during the product development cycle. The risk charts
include a Criticality Matrix Risk Chart (CMRC) and a Pro-active
Reliability Risk Chart (PRRC).
[0008] In another aspect of the present disclosure, a system is
provided that includes a processor for facilitating a failure modes
and effects analysis (FMEA) project associated with one or more
components or process during a product development cycle. The
system also includes a tangible, non-transitory memory configured
to communicate with the processor, the tangible, non-transitory
memory having instructions stored thereon that, in response to
execution by the processor. The processor performs the operation of
displaying a real time FMEA status is viewable through a user
interface which indicates the progress of the FMEA project. The
processor further performs the operation of displaying on the user
interface one or more information pages associated with sequential
order of elements to be completed by one or more FMEA analysts. The
processor further performs the operation of receiving with an aid
of the user interface textual inputs from the one or more FMEA
analysts for the one or more information pages associated with the
sequential orders of elements. Further, the processor performs the
operation of developing a risk chart for tracking a risk mitigation
progress for the FMEA project associated with the one or more
components or process during the product development cycle. The
risk charts include a Criticality Matrix Risk Chart (CMRC) and a
Pro-active Reliability Risk Chart (PRRC).
[0009] In yet another aspect of the present disclosure, an article
of manufacture is provided that include a non-transitory, tangible
computer readable medium having instructions stored thereon that,
in response to execution by a computer-based system for
facilitating a failure modes and effects analysis (FMEA) project
associated with one or more components or process during a product
development cycle. The computer-based system is configured to
perform operation of displaying a real time FMEA status is viewable
through a user interface which indicates the progress of the FMEA
project. The computer-based system is further configured to perform
operation of displaying on the user interface one or more
information pages associated with sequential order of elements to
be completed by one or more FMEA analysts. The computer-based
system is further configured to perform operation of receiving with
an aid of the user interface textual inputs from the one or more
FMEA analysts for the one or more information pages associated with
the sequential orders of elements. Further, the computer-based
system is configured to perform operation of developing a risk
chart for tracking a risk mitigation progress for the FMEA project
associated with the one or more components or process during the
product development cycle. The risk charts include a Criticality
Matrix Risk Chart (CMRC) and a Pro-active Reliability Risk Chart
(PRRC).
[0010] Other features and aspects of this disclosure will be
apparent from the following description and the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an overview of an exemplary environment in which
an Graphical User Interface (GUI) module to facilitate a failure
modes and effects analysis (FMEA) project may be deployed, in
accordance with various embodiments of the present disclosure;
[0012] FIG. 2 is an exemplary implementation of the GUI module for
facilitating the FMEA project, according to an embodiment of the
present disclosure;
[0013] FIG. 3 is an exemplary user interface window for selecting a
type of the FMEA project, according to an example embodiment of the
present disclosure;
[0014] FIG. 4 is an exemplary user interface window for creating a
selected type of FMEA project, according to an example embodiment
of the present disclosure;
[0015] FIG. 5 is an exemplary user interface window for receiving
information associated with the FMEA project, according to an
example embodiment of the present disclosure;
[0016] FIG. 6 is an exemplary user interface window for linking one
or more projects with the FMEA project, according to an example
embodiment of the present disclosure;
[0017] FIG. 7 is an exemplary user interface window for displaying
a FMEA navigator under the FMEA project, according to an example
embodiment of the present disclosure;
[0018] FIG. 8 is an exemplary user interface window to add one or
more team members associated with the FMEA project, according to an
example embodiment of the present disclosure;
[0019] FIG. 9 is an exemplary user interface window for creating a
session associated with the FMEA project, according to an example
embodiment of the present disclosure;
[0020] FIG. 10 is an exemplary user interface window for creating
an item under the FMEA project, according to an example embodiment
of the present disclosure;
[0021] FIG. 11 is an exemplary user interface window for receiving
additional information associated with the item in the FMEA
project, according to an example embodiment of the present
disclosure;
[0022] FIG. 12 is an exemplary user interface window for editing
information associated with the item in the FMEA project, according
to an example embodiment of the present disclosure;
[0023] FIG. 13 is an exemplary user interface window for providing
one or more requirements associated with the item in the FMEA
project, according to an example embodiment of the present
disclosure;
[0024] FIG. 14 is an exemplary user interface window for adding one
or more failure modes associated with the requirements in the FMEA
project, according to an example embodiment of the present
disclosure;
[0025] FIG. 15 is an exemplary user interface window for providing
additional information associated with the failure modes in the
FMEA project, according to an example embodiment of the present
disclosure;
[0026] FIG. 16 is an exemplary user interface window for editing
the information associated with the failure modes in the FMEA
project, according to an example embodiment of the present
disclosure;
[0027] FIG. 17 is an exemplary user interface window for adding one
or more potential effects of failure associated with the failure
modes in the FMEA project, according to an example embodiment of
the present disclosure;
[0028] FIG. 18 is an exemplary user interface window for adding one
or more potential causes of failure associated with the failure
modes in the FMEA project, according to an example embodiment of
the present disclosure;
[0029] FIG. 19 is an exemplary user interface window for providing
additional information associated with the potential causes of
failure in the FMEA project, according to an example embodiment of
the present disclosure;
[0030] FIG. 20 is an exemplary user interface window for selecting
one or more controls for the FMEA project, according to an example
embodiment of the present disclosure;
[0031] FIG. 21 is an exemplary user interface window for adding
detection controls for the potential cause of failure in the FMEA
project, according to an example embodiment of the present
disclosure;
[0032] FIG. 22 is an exemplary user interface window for providing
information associated with the detection control in the FMEA
project, according to an example embodiment of the present
disclosure;
[0033] FIG. 23 is an exemplary user interface window for displaying
the detection control in a tree structure format in the FMEA
navigator, according to an example embodiment of the present
disclosure;
[0034] FIG. 24 is an exemplary user interface window for adding one
or more prevention controls in the FMEA project, according to an
example embodiment of the present disclosure;
[0035] FIG. 25 is an exemplary user interface window for displaying
the prevention control in a tree structure format in the FMEA
navigator, according to an example embodiment of the present
disclosure;
[0036] FIG. 26 is an exemplary user interface window for adding one
or more recommended actions in the FMEA project, according to an
example embodiment of the present disclosure;
[0037] FIG. 27 is an exemplary user interface window for selecting
a type of recommended action in the FMEA project, according to an
example embodiment of the present disclosure;
[0038] FIGS. 28-31 are exemplary user interface windows for
providing information associated with the recommended actions in
the FMEA project, according to an example embodiment of the present
disclosure;
[0039] FIG. 32 is an exemplary user interface window for displaying
the recommended action in a tree structure format in the FMEA
navigator, according to an example embodiment of the present
disclosure;
[0040] FIG. 33 is an exemplary user interface window for editing
the information associated with the recommended action in the FMEA
project, according to an example embodiment of the present
disclosure;
[0041] FIG. 34 is an exemplary user interface window for adding
product information in the FMEA project, according to an example
embodiment of the present disclosure;
[0042] FIG. 35 is an exemplary user interface window for displaying
a real time FMEA status as a Summary in the FMEA project, according
to an example embodiment of the present disclosure;
[0043] FIG. 36 is an exemplary user interface window for presenting
a status report run from Summary in the FMEA project, according to
an example embodiment of the present disclosure;
[0044] FIG. 37 is an exemplary user interface window for viewing
projects associated with a FMEA analyst, according to an example
embodiment of the present disclosure;
[0045] FIG. 38 is an exemplary user interface window for viewing
information under Design Verification Plan and Report (DVP&R)
in the FMEA project, according to an example embodiment of the
present disclosure;
[0046] FIGS. 39-41 is an exemplary user interface window for
syncing and replacing a plurality of FMEA projects in a validation
project, according to an example embodiment of the present
disclosure;
[0047] FIG. 42 is an exemplary user interface window for presenting
a Criticality Matric Risk Chart (CMRC) in the FMEA project,
according to an example embodiment of the present disclosure;
[0048] FIG. 43 is an exemplary user interface window for comparing
an initial CMRC with a current CMRC in the FMEA project, according
to an example embodiment of the present disclosure;
[0049] FIG. 44 is an exemplary user interface window to view a
report from the CMRC in the FMEA project, according to an example
embodiment of the present disclosure;
[0050] FIG. 45 is an exemplary user interface window for presenting
a Pro-active Reliability Risk Chart (PRRC) in the FMEA project,
according to an example embodiment of the present disclosure;
[0051] FIG. 46 is an exemplary user interface window for providing
information in a coverage table in the FMEA project, according to
an example embodiment of the present disclosure;
[0052] FIG. 47 is an exemplary user interface window for providing
information in a coverage table in the validation project,
according to an example embodiment of the present disclosure;
[0053] FIG. 48 is a block diagram of an exemplary computer-based
system, according to an example embodiment of the present
disclosure; and
[0054] FIG. 49 is an exemplary process flow for facilitating the
FMEA project, according to an example embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0055] The detailed description of exemplary embodiments in the
disclosure herein makes reference to the accompanying drawings and
figures, which show the exemplary embodiments by way of
illustration only. While these exemplary embodiments are described
in sufficient detail to enable those skilled in the art to practice
the disclosure, it should be understood that other embodiments may
be realized and that logical and mechanical changes may be made
without departing from the spirit and scope of the disclosure. It
will be apparent to a person skilled in the pertinent art that this
system can also be employed in a variety of other applications.
Thus, the detailed description herein is presented for purposes of
illustration only and not of limitation. For example, the steps
recited in any of the method or process descriptions may be
executed in any order and are not limited to the order
presented.
[0056] The present disclosure is described herein with reference to
block diagrams and flowchart illustrations of methods, and computer
program products according to various aspects of the disclosure. It
will be understood that each functional block of the block diagrams
and the flowchart illustrations, and combinations of functional
blocks in the block diagrams and flowchart illustrations,
respectively, can be implemented by computer program
instructions.
[0057] These computer program instructions may be loaded onto a
general purpose computer, special purpose computer, or other
programmable data processing apparatus to produce a machine, such
that the instructions that execute on the computer or other
programmable data processing apparatus create means for
implementing the functions specified in the flowchart block or
blocks. These computer program instructions may also be stored in a
computer-readable memory that can direct a computer or other
programmable data processing apparatus to function in a particular
manner, such that the instructions stored in the computer-readable
memory produce an article of manufacture including instruction
means which implement the function specified in the flowchart block
or blocks. The computer program instructions may also be loaded
onto a computer or other programmable data processing apparatus to
cause a series of operational steps to be performed on the computer
or other programmable apparatus to produce a computer-implemented
process such that the instructions which execute on the computer or
other programmable apparatus provide steps for implementing the
functions specified in the flowchart block or blocks.
[0058] Accordingly, functional blocks of the block diagrams and
flow diagram illustrations support combinations of means for
performing the specified functions, combinations of steps for
performing the specified functions, and program instruction means
for performing the specified functions. It will also be understood
that each functional block of the block diagrams and flowchart
illustrations, and combinations of functional blocks in the block
diagrams and flowchart illustrations, can be implemented by either
special purpose hardware-based computer systems which perform the
specified functions or steps, or suitable combinations of special
purpose hardware and computer instructions. Further, illustrations
of the process flows and the descriptions thereof may make
reference to user windows, prompts, etc. Practitioners will
appreciate that the illustrated steps described herein may comprise
in any number of configurations including the use of windows,
hypertexts, hyperlinks, popup windows, prompts and the like. It
should be further appreciated that the multiple steps as
illustrated and described may be combined into single windows but
have been expanded for the sake of simplicity. In other cases,
steps illustrated and described as single process steps may be
separated into multiple windows but have been combined for
simplicity.
[0059] It is further noted that a "user device" may include, for
example, any of computer, laptop, mobile phone, cellular
telephones, beepers, pagers, iPods.RTM., personal digital
assistants (PDAs), Blackberry.RTM. type devices and/or any device
capable of receiving and presenting emails.
[0060] The systems, methods and computer program products disclosed
in conjunction with various embodiments of the present disclosure
are embodied in systems and methods for facilitating Failure Mode
and Effect Analysis (FMEA) during a product development cycle.
[0061] The present disclosure is described in more detail herein in
terms of the above disclosed exemplary embodiments of system,
processes and computer program products. This is for convenience
only and is not intended to limit the application of the
disclosure. In fact, after reading the following description, it
will be apparent to one skilled in the relevant art(s) how to
implement the following system in alternative embodiments.
[0062] FIG. 1 is an overview of an exemplary environment 100 for
facilitating FMEA, in accordance with various embodiments of the
present disclosure. The environment 100 includes a server 102, a
repository 104, a user device 106, a communication network 108 and
a Graphical User Interface (GUI) module 110. The server 102, the
repository 104, the user device 106 and the GUI module 110 may
communicate with each other over the communication network 108.
Examples of the communication network 108 may include a wide area
network (WAN), a local area network (LAN), an Ethernet, Internet,
an Intranet, a cellular network, a satellite network, or any other
suitable network for transmitting data. The communication network
108 may be implemented as a wired network, a wireless network or a
combination thereof. In an embodiment, the GUI module 110 may be
accessed through the server 102, by the user device 106 for
facilitating the FMEA associated with one or more components or
process during the product development cycle.
[0063] User device 106 may be any device capable of communicating
with the server 102. In one embodiment, a user (herein after
referred to as FMEA analyst) may have the user device 106 to
communicate with the server 102 on which the graphical user
interface module 110 may be deployed. In one example, the user
device 106 may be a data processing system such as, for example, a
mobile device, any suitable personal computer, a laptop,
minicomputer, Personal Digital Assistant (PDA), or the like. Those
skilled in art can appreciate that user device 106 includes an
operating system (e.g., Windows NT, 95/98/2000, OS2, UNIX, Linux,
Solaris, MacOS, etc.) as well as various conventional support
software and drivers typically associated with computer. The user
device 106 may also include an internal memory, an external memory
and a cache. The user device 106 may also include one or more
browsers (e.g., Microsoft.RTM. Internet explorer, Mozilla.RTM.
Firefox, etc.) through which an email server may be accessed.
Alternatively, user device 106 may include a user email program
such as a Microsoft.RTM. Outlook, Mozilla.RTM. Thunderbird,
Pegasus.RTM. Mail, and the like, for downloading, reading, replying
and/or forwarding the email. Although, a single user device is
illustrated herein for exemplary purposes, one skilled in art can
appreciate that there can be more than one user device.
[0064] The repository 104 and/or one or more databases associated
with the GUI module 110 may employ any type of database, such as
relational, hierarchical, graphical, object-oriented, and/or other
database configurations. Common database products that may be used
to implement the databases include DB2 by IBM (White Plains, N.Y.),
various database products available from Oracle Corporation
(Redwood Shores, Calif.), Microsoft Access or Microsoft SQL Server
by Microsoft Corporation (Redmond, Wash.), or any other suitable
database product. Moreover, the databases may be organized in any
suitable manner, for example, as data tables or lookup tables. Each
record may be a single file, a series of files, a linked series of
data fields or any other data structure. Association of certain
data may be accomplished through any desired data association
technique such as those known or practiced in the art. For example,
the association may be accomplished either manually or
automatically. Automatic association techniques may include, for
example, a database search, a database merge, GREP, AGREP, SQL,
using a key field in the tables to speed searches, sequential
searches through all the tables and files, sorting records in the
file according to a known order to simplify lookup, and/or the
like. The association step may be accomplished by a database merge
function, for example, using a "key field" in pre-selected
databases or data sectors.
[0065] More particularly, a "key field" partitions the database
according to the high-level class of objects defined by the key
field. For example, certain types of data may be designated as a
key field in a plurality of related data tables and the data tables
may then be linked on the basis of the type of data in the key
field. The data corresponding to the key field in each of the
linked data tables is preferably the same or of the same type.
However, data tables having similar, though not identical, data in
the key fields may also be linked by using AGREP, for example. In
accordance with one aspect of the system, any suitable data storage
technique may be utilized to store data without a standard format.
Data sets may be stored using any suitable technique, including,
for example, storing individual files using an ISO/DEC 7816-4 file
structure; implementing a domain whereby a dedicated file is
selected that exposes one or more elementary files containing one
or more data sets; using data sets stored in individual files using
a hierarchical filing system; data sets stored as records in a
single file (including compression, SQL accessible, hashed via one
or more keys, numeric, alphabetical by first tuple, etc.); Binary
Large Object (BLOB); stored as ungrouped data elements encoded
using ISO/IEC 7816-6 data elements; stored as ungrouped data
elements encoded using ISO/IEC Abstract Syntax Notation (ASN.1) as
in ISO/IEC 8824 and 8825; and/or other proprietary techniques that
may include fractal compression methods, image compression methods,
etc.
[0066] In one exemplary embodiment, the ability to store a wide
variety of information in different formats is facilitated by
storing the information as a BLOB. Thus, any binary information can
be stored in a storage space associated with a data set. The BLOB
method may store data sets as ungrouped data elements formatted as
a block of binary via a fixed memory offset using one of fixed
storage allocation, circular queue techniques, or best practices
with respect to memory management (e.g., paged memory, least
recently used, etc.). By using BLOB methods, the ability to store
various data sets that have different formats facilitates the
storage of data associated with the system by multiple and
unrelated owners of the data sets. For example, a first data set
which may be stored may be provided by a first party, a second data
set which may be stored may be provided by an unrelated second
party, and yet a third data set which may be stored, may be
provided by an third party unrelated to the first and second party.
Each of these three exemplary data sets may contain different
information that is stored using different data storage formats
and/or techniques. Further, each data set may contain subsets of
data that also may be distinct from other subsets.
[0067] In one embodiment, the graphical user interface (GUI) module
110 may enable the FMEA analyst to facilitate an FMEA project
associated with one or more components or process during the
product development cycle. The GUI module 110 may enable the FMEA
analysts to view a real time FMEA status through a user interface
112 provided by the GUI module 110. The real time FMEA status may
enable the FMEA analysts to track a progress of the FMEA project.
Further, the GUI module 110 displays one or more information pages,
on the user interface 112, associated with a sequential order of
elements essential to the FMEA project. The GUI module 110 may
further enable to receive textual inputs, from the FMEA analysts,
for the required information associated with the sequential order
of elements. The sequential order elements are used to identify a
potential effect and cause associated with a problem in functioning
of the product, and further helps in eliminating the problem. The
GUI module 110 may further enable the FMEA analysts to organize the
sequential order of elements in a tree structure format, based on
the information, received from the FMEA analyst, associated with
the sequential order of elements. The tree structure enables the
FMEA analyst to access the information pages associated with the
sequential order of elements and update the information in real
time during the product development cycle.
[0068] In an embodiment, the GUI module 110 develops one or more
risk charts in the user interface 112 based on the information
associated with the sequential order of elements. The risk chart
enables the FMEA analyst to track a risk mitigation progress for
the FMEA project during the product development cycle.
[0069] Referring to FIG. 2, an exemplary implementation of the GUI
module 110 is depicted, according to an embodiment of the
disclosure. As illustrated in FIG. 2, the GUI module 110 is may be
deployed on the server 102 and is communicatively coupled to the
repository 104, and the user device 106. In an embodiment, the GUI
module 110 may enable the FMEA analysts to facilitate a FMEA
project on the user interface 112. The GUI module 110 may include a
display module 202, a receiving module 204, an organization module
206 and a developing module 208.
[0070] In operation, the display module 202 is configured to
provide a path on the user interface 112 to create the FMEA project
associated with one or more components or process steps during a
product development cycle. The FMEA project may include a Design
FMEA Project (DFMEA), a Process FMEA Project (PFMEA) or a
validation project. The validation project may include a
combination of multiple DFMEAs, PFMEAs or a combination of multiple
DFMEAs and PFMEs. Moreover, the validation project may be formed by
combination of multiple other validation projects.
[0071] In an embodiment, the FMEA project involves one or more team
members (herein after referred to as FMEA analysts) for a
completion of various tasks that may be associated with the
sequential order of elements in the FMEA project. The FMEA analyst,
who may have a team leader role, may create a new FMEA project
through the GUI module 110. The display module 202 may provide a
path to the FMEA analyst to create a new FMEA project. As
illustrated in FIG. 3, the display module 202 may provide a user
interface window 300 to enable the FMEA analyst to create the new
FMEA project.
[0072] In one embodiment, the user interface window 300 may include
a "+New" dropdown tab to select a project type, such as the DFMEA
project, the PFMEA project or the validation project. As
illustrated in FIG. 4, on selecting the project type, the display
module 202 may provide a user interface window 400 for creating the
selected type of the FMEA project. In an exemplary embodiment of
the disclosure, the figures represent that the type of the project
selected is a DFMEA project, however, it is apparent to a person
who is ordinary skilled in the art that the type of project may
include any of the DFMEA, the PFMEA or the validation Project and
the selection shown in the figures do not limit the scope of the
disclosure.
[0073] Further, the receiving module 204 may receive the required
information from the FMEA analyst to successfully create the DFMEA
project. As illustrated in FIG. 4, the required information may
include basic Key information such as the title of the project, the
Automotive Industry Action Group (AIAG) edition to be followed for
the project, the type of FMEA, the part number, etc. In an
embodiment, the part number may be imported from the repository 104
by clicking on the "+Add" tab.
[0074] Further, as illustrated in a user interface window 500 in
FIG. 5, from "Additional Info" tab, the receiving module 204 may
receive additional information, from the FMEA analyst, associated
with the FMEA project. The additional information may include
information such as the start date and other important dates
associated with the FMEA project, FMEA case, whether the FMEA
project is shared, hours of operation, notes etc.
[0075] Furthermore, from "Systems/Codes" tab, information
associated with major system, system, subsystem, may be received
from the FMEA analyst. Also, some organization specific codes about
the systems and the components and item may also be received from
the FMEA analyst.
[0076] On successfully receiving the required information from the
FMEA analyst to create the new FMEA project, the GUI module 110, as
illustrated in FIG. 6, may provide a user interface window 600
under "Properties" tab. The window 600 includes information related
to the newly created FMEA project. The display module 202 also
provides a "+Add Related" tab on the window 600 to link other
projects related with the FMEA project. The other related projects
may include New Product Introduction (NPI) project for developing
new products and Continuous Product Improvement (CPI) projects that
are used to solve existing problems in the product for which the
FMEA project is being created.
[0077] Subsequently, as illustrated in the FIG. 7, the display
module 202 may enable the FMEA analyst to navigate the FMEA project
through a user interface window 700 under the "FMEA" tab. On
selecting the "FMEA" tab, the FMEA analyst is able to view an "FMEA
Navigator" 710 on the user interface 112 to view the one or more
sequential order of elements under the FMEA project.
[0078] As illustrated in FIG. 8, the display module 202 may provide
a user interface window 800, in the "Team" sub-tab under an
"Overview" tab, to add one or more team members as FMEA analysts in
the FMEA project. In an embodiment, the FMEA analyst that has
created the new FMEA project is added as the team leader for the
FMEA project by default. Subsequently, the team leader may add
other team members by clicking on a "+Add Team Member" tab. The
team members may be searched across the organization by their names
or organizational IDs by clicking on "Find Team Member" tab. The
team leader may further provide roles based access control to the
team members. In one embodiment, the team leader may change a team
member's role at any time. A team member may be assigned the
validation role only if that team member has validation access.
Different roles such as the role of a facilitator, a project
coordinator etc., may be assigned to the team members.
[0079] As illustrated in FIG. 9, the display module 202 may enable
the FMEA analysts to create a session for recording a date stamp of
the session and the attendance of the FMEA analysts who has
participated in the session. As illustrated in a user interface
window 900, the FMEA analyst may click on the "Session" sub tab
under "Overview" tab to record the details of every meeting or
session held for the FMEA project. Further, the FMEA analyst who
has initiated the session may enter details of the session such as
the title of the session, the date stamp, maturity indicator that
indicates the development level of the project, the duration of the
session, notes, and the attendance of the team members etc. The
FMEA analyst may also enter the revision level of the session if
there is any update in the session information. For example, the
revision level 1 indicates that the session is conducted for the
first time, and any updates in the session may increment the
revision value by 1. In an embodiment, an error message is
displayed if any required field is left blank in the window. In
various embodiments of the present disclosure, the FMEA analysts
may edit the information associated with the session at any stage
during the course of the FMEA project.
[0080] Once the FMEA project is created, the display module 202 may
display one or more information pages associated with the
sequential order of elements to the FMEA analysts, to enable the
receiving module 204 to receive textual inputs for the sequential
order of elements. In various embodiments of the disclosure, the
sequential order of elements is based on the type of the FMEA
project. However, FIGS. 10-33 represents the sequential order of
elements for the DFMEA project, it is apparent to a person who is
ordinary skilled in the art that the GUI module 110 is capable of
creating and handling any type of projects such as the DFMEA, the
PFMEA and the validation projects and the description related to
the DFMEA project in the figures do not limit the scope of the
disclosure.
[0081] In an embodiment, as illustrated in FIG. 10, the display
module 202 may provide a path through the "FMEA Navigator" to
access a user interface window 1000 to create an item for the DFMEA
project. Within an existing DFMEA project window, the "FMEA
Navigator" 710 may be displayed by selecting the "FMEA" tab.
Further, on clicking a "+" sign on the FMEA Navigator, an
information page is displayed to the FMEA analyst within the window
1000 for creating a "New Item". Subsequently, the receiving module
204 may receive the key information about the item under the "Key
Info" tab from the FMEA analyst. For example, the FMEA analyst may
enter the Item name under the "Key Info" tab.
[0082] Further, as illustrated in FIG. 11, a plurality of
additional information may be received from the FMEA analyst under
the "Additional Info" tab. The display module 202 displays an
information page on a user interface window 1100 to enable the
receiving module 204 to receive the additional information
associated with the item. The additional information may include,
but not limited to, a part number of the item. In one embodiment,
the item part number may be imported from the repository 104. On
clicking the "+Add" button on the window 1100, the display module
202 may display the existing organization part number for the item.
In one embodiment, the FMEA analyst may add more than one part
number to the item. As will be understood by a person skilled in
the art, an error message is displayed to the FMEA analyst every
time when there is any required field that is left blank. Also, if
the entered part number for the item already exists in any other
DFMEA project, then also an error message is displayed, and the
data may not be saved until the error is corrected.
[0083] In various embodiments of the present disclosure, the
information provided by the FMEA analyst for the item is editable.
As illustrated in FIG. 12, the display module 202 provides an "Edit
Item" tab on a user interface window 1200 to edit the information
associated with the item. Also, the display module 202 updates the
"FMEA Navigator" 710 to display the added item name under the FMEA
project title. In an embodiment, the organization module 206 adds
the item name in a tree structure format under the FMEA Project
title in the "FMEA Navigator" 710, as illustrated in the user
interface window 1200.
[0084] In an embodiment, as illustrated in FIG. 13, the display
module 202 provides a user interface window 1300 for providing one
or more requirements associated with the item. The user interface
window 1300 may be accessed by selecting the item on the "FMEA
Navigator" 710 and then selecting the "+Add Requirement" tab. On
selection of the "+Add Requirement" tab, the display module 202
opens an information page to enable the receiving module 204 to
receive textual inputs, from the FMEA analyst, for the one or more
requirements associated with the item. In one embodiment, the FMEA
analyst may enter the requirement name and description associated
with the requirement, and click on the "OK" button. The FMEA
analyst may further provide the additional information by selecting
the "Additional Info" tab on the window 1300. In an embodiment, as
the FMEA analyst clicks on the "OK" button, the organization module
206 adds the requirement in a tree structure format under the item
name on the "FMEA Navigator" 710 as illustrated in FIG. 14.
[0085] In various embodiment of the present disclosure, the FMEA
analyst may at any time edit the requirement by clicking on an
"Edit Requirement" tab, and enter the updated information about the
requirement. As will be understood by a person ordinary skilled in
the art, a particular item within the FMEA project may have
multiple requirements that may be defined in a similar manner as
described above. Also, all the requirements associated with the
item may show up under the item in a tree structure format.
[0086] Subsequently, as illustrated in FIG. 14, the display module
202 may provide a user interface window 1400, to add one or more
potential failure modes associated with the requirement. The
potential failure mode indicates a condition of inability of an
item to perform a desired function in a desired manner. The user
interface window 1400 may be accessed by selecting the requirement
on the "FMEA Navigator" 710 and then selecting the "+Add Failure
Mode" tab, which provides an information page in the user interface
window 1400. Subsequently, the receiving module 204 may receive the
key information about the failure mode under "Key Info" tab from
the FMEA analyst. For example, the FMEA analyst may enter the name
of the failure mode and the description associated with the failure
mode. Further, the FMEA analyst may also add the NPI/CPI issues to
the failure mode if required. The NPI/CPI issues may be stored in
external databases and may be imported from the external databases
by selecting the "Add NPI/CPI Issues" tab on the user interface
window 1400. It will be understood that the description for adding
a failure mode is explained with respect to a single failure mode;
however, there may be more than one failure mode associated with a
single requirement of an item.
[0087] Subsequently, as illustrated in the FIG. 15, the FMEA
analyst may also enter a plurality of additional information, in a
user interface window 1500, about the failure mode under the
"Additional Info" tab. The additional information may include a
problem description (PD) category and PD code. A PD code is a two
digit code that describes a failure. For example, there may be
different codes for different failure modes such as "Accident or
Abuse", "Vibrates/Shakes", "Smokes Excessively", etc. Further, a PD
category may be defined as a category of similar PD codes. For
example, "System Malfunction" may be a PD category that includes a
plurality of PD codes corresponding to different failure modes. In
one embodiment, the FMEA analyst may select a desired PD category
from a list of predefined categories. In a further embodiment, a
list of predefined PD codes may also be presented to the FMEA
analyst to facilitate selection of the desired PD code for the
failure mode.
[0088] In an embodiment, as the FMEA analyst clicks on the "OK"
button in the user interface window 1500, the organization module
206 adds the failure mode in the tree structure format under the
requirement on the "FMEA Navigator" 710 as illustrated in FIG. 16.
In one embodiment, a specific symbol such as, a "*" symbol, may be
added next to the failure mode icon on the tree structure provided
under the "FMEA Navigator" 710 to indicate that one or more NPI/CPI
issues are associated with the failure mode.
[0089] In a further embodiment, the FMEA analyst may also edit the
failure mode by selecting the requirement from the "FMEA Navigator"
710, clicking on the Failure Modes tab, and double clicking the
failure that needs to be edited. This provides the failure mode
information page in an editable format, as shown in a user
interface window 1600. The FMEA analyst may subsequently edit the
information provided under the "Key Info" tab and the "Additional
Info" tab associated with the failure mode. In one embodiment, the
FMEA analyst may also remove the PD category and the PD code. For
example, the PD code is automatically removed on removing the PD
category. In one embodiment, a warning message may be displayed to
the FMEA analyst to confirm the deletion of the PD category and the
PD code. Further, the FMEA analyst may also edit the NPI/CPI issues
associated with the failure mode, by either removing the associated
issues or by adding new issues by importing them from the
repository.
[0090] Subsequently, as illustrated in FIG. 17, the display module
202 may provide a user interface window 1700, to add one or more
potential effect of failures associated with the potential failure
modes. The potential effect indicates a potential outcome of a
failure mode as perceived by a customer. The user interface window
1700 may be accessed by selecting the "Failure Mode" on the "FMEA
Navigator" 710 and then selecting the "+Add Effect" tab, which
provides an information page in the user interface window 1700.
Subsequently, the FMEA analyst may select "Create A New Effect" tab
to enable the receiving module 204 to receive the textual inputs,
from the FMEA analyst, for the information associated with the
potential effect of failure. The information may include the name
of the effect, the description of the effect and an initial
severity value associated with the effect. In one embodiment, the
initial severity value is a ranking of the effect based on its
severity. In various embodiments of the disclosure, the ranking may
be pre-defined according to an organization standard. In an
alternate embodiment, the initial severity value may be assigned
based on a well-known industry standard such as an AIAG (Automotive
Industry Action Group) standard. In one embodiment, the initial
severity value may be imported from an external database or the
repository 104, and the FMEA analyst may select the initial
severity value by selecting the "Choose" button and double clicking
on the severity ranking to select that severity value. In an
alternate embodiment, in order to keep the severity value
consistent throughout the project, the FMEA analyst may select an
existing effect that is used in other failure modes within the same
FMEA project. On adding the effect, the organization module 206
displays the potential effect of failure in a tree structure format
added under the potential mode of failure in the "FMEA Navigator"
710, as illustrated in FIG. 18.
[0091] In a further embodiment, the FMEA analyst may also delete
the effect from the failure mode by clicking on a minus (-) sign
displayed besides the "+" sign on the "FMEA Navigator" 710. In one
embodiment, a confirmation window is popped up to facilitate the
FMEA analyst to confirm the deletion of the effect from the failure
mode.
[0092] Subsequently, as illustrated in FIG. 18, the display module
202 may provide a user interface window 1800, to add one or more
potential cause of failures associated with the potential mode of
failure. The cause is defined as a condition that induces a failure
mode. The user interface window 1800 may be accessed by selecting
the "Failure Mode" on the "FMEA Navigator" 710 and then selecting
the "+Add Cause" tab, which subsequently provides an information
page in the user interface window 1800. This enables the receiving
module 204 to receive textual inputs, from the FMEA analyst, for
information associated with the potential cause of failure. The
FMEA analyst may enter the name of the cause, the description of
the cause along with important notes and an initial occurrence
value associated with the cause under the "Key Info" tab in the
user interface window 1800. In one embodiment, the initial
occurrence value indicates the likelihood that the cause will
actually happen. The occurrence value may be pre-defined in an
external database or the repository 104 according to an
organizational standard or a well-known industry standard such as
the AIAG standard.
[0093] Further, as illustrated in the FIG. 19, the FMEA analyst may
enter the additional information associated with the potential
cause of the failure, in the user interface window 1900 under the
"Additional Info" tab. The additional information associated with
the potential cause of failure may include a mechanism of failure,
a classification code, a part number and a part name. The mechanism
of failure is a physical, chemical, electrical, thermal, or other
type of process that results in a failure mode. Further, the causes
may be classified under different categories and these
classification categories may be assigned a code referred to as the
classification code. The part number may be a standard
organizational format number for the part of the product such as a
bolt that has failed due the cause of the failure. Further, the
FMEA analyst may also enter the additional Part name for the cause.
In one embodiment, the part name may be stored in an external
database or repository, and the FMEA analyst may search the part
name by importing the list of part names from the database and
selecting the desired part name for the cause. For example, by
clicking on a "Find" button next to the part name displayed on the
interface, a "Part Name Search" information page pops up.
Subsequently, the FMEA analyst may select the type of part from a
drop down list. Further, the FMEA analyst may search using a
keyword, a list of available part names. Furthermore, the desired
Part Name may be selected from the list and the selected Part Name
is added under the "Additional Info" tab in the user interface
window 1900. Subsequent to the completion of the information page
in the user interface window 1900, the organization module 206
displays the cause in a tree structure format under the failure
mode in the "FMEA Navigator" 710, as illustrated in FIG. 21.
[0094] In a further embodiment, the FMEA analyst may also edit the
information added for the cause by clicking on an "Edit Cause" tab
subsequent to selecting the potential cause from the tree structure
on the "FMEA Navigator" 710.
[0095] In various embodiment of the present disclosure, every
failure mode may have multiple effects and every effect may have
multiple causes. Therefore, it shall be understood that there may
be multiple combinations of causes and the effects for every
failure mode associated with the requirement of every item in the
DFMEA project.
[0096] In an embodiment, subsequent to enter the potential cause
and potential effect for the potential failure mode associated with
the requirement, the receiving module 204 may receive, from the
FMEA analyst, information associated with a plurality of prevention
and detection controls for every cause and effect combination. In
one embodiment, for every combination of the potential cause and
the corresponding potential effect, if a correlation of the initial
occurrence value of the cause and the initial severity value of the
effect is greater than a predetermined threshold, then one or more
detection and prevention controls may be recommended for that
potential cause and potential effect combination.
[0097] As will be understood, a detection control reflects how well
a test or series of tests may find a design flaw; i.e. detect that
a failure mode has happened or detect the presence of a cause.
These are the controls that detect a defect that already exists.
However, the detection control does not alter the initial
occurrence value. As will be understood by a person skilled in the
art, the detection controls identify a detection value that
indicates the likelihood that a cause will actually happen. The
detection value if defined within a range from 1 to 10, 1 being the
lowest likelihood and 10 being the highest likelihood. In one
embodiment, the detection controls may be predefined and stored in
a database where standards work instructions, working tools and
other standard instructions of an organization may be stored. For
example, the detection controls may be stored in the repository
104.
[0098] Further, the prevention controls are the controls that are
specifically related to the reduction or elimination of a cause.
These are the controls that prevent a defect from being made. In
one embodiment, the prevention controls can reduce occurrence value
associated with the cause. For example, the FMEA analyst may add a
prevention control for controlling a cause of failure by reducing
the occurrence value associated with the cause. In one embodiment,
the prevention controls may also be predefined and stored in a
separate database within the organization.
[0099] In one embodiment, the FMEA analyst may add a plurality of
detection controls and prevention controls for various failure
modes, their associated causes and effects. For example, the FMEA
analyst may add a pick list of detection and prevention controls to
the FMEA project that may be used in the project at any later
stage. The detection controls and the prevention controls may be
generic in nature that may be implemented for multiple combinations
of causes and effects. In one embodiment, the FMEA analyst may
import the detection controls as well as the prevention controls
from excel spreadsheet, various databases external to the system
etc.
[0100] As illustrated in FIG. 20, the display module 202 provides a
user interface window 2000 to select one or more controls for the
combination of cause and effects. The FMEA analyst may access the
window 2000 by selecting a "Controls Pick List" sub tab under the
"Overview" tab on the user interface 112. Subsequently, the FMEA
analyst may click on the "Edit Pick List" sub tab which provides an
information page including a combination of elements. Further, the
FMEA analyst may select the desired combination of elements for
which the detection controls and prevention controls are required.
Subsequent to the selection of the combination by the FMEA analyst,
a complete list of detection controls available for that
combination is displayed to the FMEA analyst. Further, the FMEA
analyst may refine the list by selecting the appropriate detection
controls as desired. In one embodiment, the FMEA analyst may click
the check boxes next to the detection controls in the list. In a
further embodiment, detection control list may include a test id
and a description field. The test id indicates the unique
identification number that may be specific to the organizational
formats. In a further embodiment, the description indicates the
description of the detection control test to be performed.
[0101] Subsequently, the FMEA analyst may add the prevention
controls to the initial pick list by clicking on a "Next" button
after adding the detection controls. In one embodiment, the FMEA
analyst may import the prevention controls from external databases
or repository 104. As will be understood, the FMEA analyst may add
the prevention controls at any point in time during the FMEA
project. All the prevention controls that are already associated
with the project are listed on the list at the top with a different
color background in the initial pick list. In one embodiment, the
FMEA analyst may search for a keyword to get the entire list of
prevention controls available for the keyword. For example, the
keyword may be the name or part of the name of the item or failure
mode etc. Subsequently, the FMEA analyst may select the required
prevention controls for the case by clicking on the check boxes
besides the controls. Further, the detection and the prevention
controls selected by the FMEA analyst may be listed in the initial
pick list and associated with the project.
[0102] In one embodiment, the FMEA analyst may import the detection
controls and the prevention controls from any other FMEA project as
well. In a further embodiment, the FMEA analyst may also edit the
pick list to include additional detection and prevention controls,
or removing the detection and the prevention controls. In a yet
another embodiment, the FMEA analyst may also create new detection
and prevention controls.
[0103] In one embodiment, the FMEA analyst may add a specific
detection control from the initial pick list created by the FMEA
analyst. In another embodiment, the FMEA analyst may create a new
detection control in case when the desired detection control is not
included in the initial pick list.
[0104] As illustrated in FIG. 21, the display module 202 provides a
user interface window 2100, to add detection controls associated
with the potential cause. The FMEA analyst may access the user
interface window 2100 by selecting the "Cause" in the "FMEA
Navigator" 710 and then selecting "Add Control/RA" tab.
[0105] Further, the FMEA analyst may select "Detection Control"
from the drop down under the "Add Control/RA" tab and subsequently,
a "New Detection Control" information page opens in a user
interface window 2200, as illustrated in the FIG. 22. Subsequently,
the FMEA analyst may select "Select From Pick List" tab and an
"Initial Control Pick List" tab. Subsequently, the entire pick list
of the detection controls is displayed with the Test id and the
test description. The receiving module 204 may then receive the
textual inputs, from the FMEA analyst, associated with required
information to be filled in the "New Detection Control" information
page on the user interface window 2200. For example, the required
information may include the initial control, control name,
procedure process, Test ID, associated with, information under "Key
Info" and "Additional Info" tab etc. The information associated
with the detection control may include a detection value that may
be entered by the FMEA analyst for that control. In one embodiment,
the detection value may be selected from a list of predefined
values stored in external databases or repository 104.
[0106] In an embodiment, the FMEA analyst may also add some general
category detection controls that may not be already included in the
initial pick list. The FMEA analyst may add the general detection
control by selecting the "Cause" in the "FMEA Navigator" 710 and
then selecting "Add Control/RA" tab.
[0107] Further, the FMEA analyst may select "Detection Control"
from the drop down under the "Add Control/RA" tab and subsequently,
a "New Detection Control" information page opens, where the FMEA
analyst may select the "Create A Control" tab. Further, the FMEA
analyst may enter the control name. In one embodiment, the Test Id
field may indicate the detection control to be "General" category
detection control. The FMEA analyst may further associate the
detection control with a failure mode or a cause of the failure
mode, as desired. In a further embodiment, the FMEA analyst may add
the other information about the control and subsequently add the
detection control to the FMEA project. For example, the information
may include the test plan procedure, the test id, test purpose, the
type of test, test classification, the acceptance criteria etc. As
will be understood, if the detection control is added to a failure
mode, then by default all the causes related to the failure mode
may have access to that detection control.
[0108] In a further embodiment, the detection control may be edited
by the FMEA analyst at any point of time with the FMEA project. In
one embodiment, the added detection control must be approved by a
validation engineer in case of a DFMEA project. However, in an
alternate embodiment, a team leader's approval is required for
every created detection control in case of a PFMEA project. In one
embodiment, only an Admin person or the approving person may be
authorized to change the approval status of a detection control. In
an alternate embodiment, the validation engineer and the team
leader may reject the detection control if desired. In a further
embodiment, the date and time stamps of the approval of the
detection control may be viewed on the interface 112. Subsequent to
the approval of the detection control, the results for the
detection control may be edited to include the desired results for
every detection control test procedure.
[0109] Subsequent to the successful completion of creation of the
detection control, the organization module 206 displays the
detection control in a tree structure format under the cause on the
"FMEA Navigator" 710, as illustrated in a user interface window
2300 of FIG. 23. Further, the user interface window 2300 also
provides the information such as, associated cause, detection
control information, Test Id, detection value, responsible FMEA
analyst, occurrence value, etc.
[0110] In a further embodiment, the FMEA analyst may also delete a
desired detection control. For example, the FMEA analyst may
highlight the desired detection control and click on the minus (-)
sign next to the "+" sign on the "FMEA Navigator" 710. In one
embodiment, the FMEA analyst may be presented with a confirmation
message to delete the selected detection control.
[0111] Subsequent to adding the detection controls, the FMEA
analyst may also add a plurality of prevention controls to the
failure modes and the associated causes. In one embodiment, the
FMEA analyst may add a prevention control from the initial pick
list or create a new prevention control, if the desired prevention
control is not included in the initial pick list.
[0112] As illustrated in the FIG. 24, the display module 202
provides a user interface window 2400, for adding one or more
prevention controls. In an embodiment, the FMEA analyst may select
a "Cause" in the "FMEA Navigator" 710 and subsequently select "Add
Control/RA" tab to open a "New Prevention Control" information page
as illustrated in the user interface window 2400. Further, the FMEA
analyst may click on "Select From Pick List" tab that displays a
list of prevention controls from the initial pick list. Further,
the FMEA analyst may select the prevention control from the list of
available controls and click "OK". In one embodiment, the FMEA
analyst may add information about the prevention control. For
example, the information may include the prevention control
description, document ID and date fields. In one embodiment, the
FMEA analyst may also enter key information about the prevention
control, such as the occurrence value, the forecast occurrence
value, planned end date, description etc. The forecast occurrence
value indicates the probable occurrence value of the cause after
implementing the prevention control. In one embodiment, the
forecast occurrence value may be imported from external databases
or from repository 104.
[0113] In an alternate embodiment, the FMEA analyst may create a
new general category prevention control, if the prevention control
is not already included in the initial pick list. For example, with
the FMEA open and the cause of failure highlighted in the "FMEA
Navigator" 710, click on "+Add Control/RA" tab and select
"Prevention Control" tab. Subsequently, the "New Prevention
Control" information page opens, where the FMEA analyst may click
the "Create A General Control" tab. Further, the FMEA analyst may
enter the "Control Name". In one embodiment, the Test ID field will
say "General". Furthermore, the FMEA analyst may enter test
information under "Key Info" tab such as the "Associated With"
field to be associated with either a failure mode or cause, the
description of the prevention control, planned end date etc.
[0114] Subsequent to adding all the required information, the
organization module 206 displays the prevention control in a tree
structure format under the "Cause" on the "FMEA Navigator" 710, as
illustrated in a user interface window 2500 of FIG. 25. Further,
the user interface window 2500 also provides the information such
as, associated cause, detection control information, Test Id,
detection value, responsible FMEA analyst, occurrence value,
etc.
[0115] In a further embodiment, the FMEA analyst may also edit the
prevention control at any point of time during the FMEA project. In
a further embodiment, the FMEA analyst may also define the team
member responsible for executing the test plan of the prevention
control. In a further embodiment, the prevention control may be
approved only by a team leader of the project. As will be
understood, the team leader may approve every prevention control
created for every failure mode and cause. In an alternate
embodiment, the team leader may also reject the prevention control.
If the team leader approves the control, then a date and time stamp
associated with the approval is displayed on the window. In a yet
another embodiment, the FMEA analyst may delete the prevention
control in a similar manner as described for deletion of the
detection control from the FMEA project.
[0116] Subsequent to adding a plurality of detection and prevention
controls, the display module 202 may enable the FMEA analyst to add
a plurality of recommended actions. The recommended actions are the
actions taken to mitigate risk associated with the cause and effect
combination. There are two types of recommended actions: "gather
data" and "change design" for a DFMEA project. In an embodiment, if
the correlation of the severity value and the occurrence value
associated with a cause/effect combination is higher than a
predetermined threshold to indicate the combination a high risk
combination, then a recommended action may be executed. In a yet
another embodiment, if the correlation of the severity and
occurrence value associated with a cause/effect combination is
lower than the predetermined threshold to indicate a probable risk
associated, however, a correlation of the severity, occurrence and
the detection value that is a risk priority number (RPN) associated
with the cause/effect combination is higher than a second
predetermined threshold, say 100, then a recommended action may be
associated with the combination of the cause and the effect. The
RPN value is a product of the severity value of the effect, the
occurrence value of the cause and the detection value of the cause.
At the time of evaluating the RPN value, the RPN value is referred
to as an initial RPN value using the initial severity, initial
occurrence and initial detection value associated with the
cause/effect combination. In an embodiment, the initial RPN value
may change based an execution of the prevention control as it may
revise the initial occurrence value.
[0117] In one embodiment, the recommended actions that result in a
design change or new design features are referred to as the "Change
Design" recommended action. These can either eliminate the
possibility of the failure mode or reduce the occurrence of the
failure. In a further embodiment, the type of recommended action
used in a DFMEA project when there is not enough data to know about
the potential risk, then these recommended actions are referred to
as the Gather Data type recommended actions.
[0118] In one embodiment, whenever changes are required to be made
to the design of the item, a "change design type" recommended
action is required. This captures the whole description of the
change and also how that change will be verified.
[0119] As illustrated in FIG. 26, the display module 202 provides a
user interface window 2600, for adding one or more recommended
actions. The FMEA analyst may access the user interface window 2600
by selecting the "Cause" in the "FMEA Navigator" 710 and
subsequently selecting "Recommended Action" from the "Add
Control/RA" tab.
[0120] Subsequently, a "New Recommended Action" information page
opens in a user interface window 2700, as illustrated in FIG. 27.
Further, the FMEA analyst may select the type of the recommended
action. In one embodiment, the FMEA analyst may select "Change
Design" type of the recommended action.
[0121] Further, as illustrated in a user interface window 2800 in
FIG. 28, the FMEA analyst may enter the required information such
as the title of the action and the information in "Key Info" under
the "Test Plan" tab. The information may include the association of
action (with failure or cause), forecast values of severity,
occurrence, detection, the team member responsible for execution of
the action, required target date, the description. The forecast
values indicate the probable values after completion of the
recommended actions. In an embodiment, the forecast values
associated with the recommended actions may be predefined and
stored in an external database, and may be imported by clicking the
"Choose" button. The values of the forecast severity, occurrence
and detection may be based on the AIAG edition implemented in the
GUI module 110.
[0122] Further, as illustrated in FIG. 29, the FMEA analyst may
enter the additional information in a user interface window 2900,
under the "Additional Info" for the "TEST PLAN" tab. The additional
info may include test purpose, type of result, acceptance criteria,
test environment, classification of test, type of test, type of
machine, any suggestion to modify the test, expected planned
product, planned test location etc. Additionally, the FMEA analyst
may enter the planned start date, planned end date, planned
duration, notes etc., of the action.
[0123] Subsequently, as illustrated in FIG. 30, the FMEA analyst
may enter the additional information, in a user interface window
3000, in "Key Info" under a "Change Design" tab. The information
may include the team member assigned the task, the target date,
completion date, the description of the changed design. Further, as
illustrated in FIG. 31, the FMEA analyst may enter in the
"Additional Information" in a user interface window 3100 under the
"Change Design" tab. The information may include a description
related to the action taken by the team member. As will be
understood by a person skilled in the art, the FMEA analyst may
also create a new recommended action for "gather data" type, in a
similar manner as described above.
[0124] In an embodiment, the FMEA analyst may add a recommended
action of "Action type" when there is no design change and there is
enough information available to know about the potential risk.
These "Action Type" actions may also be added to the FMEA project
in a similar manner as explained above.
[0125] Subsequent to adding all the required information, the
organization module 206 displays the recommended action in a tree
structure format under the "Cause" on the "FMEA Navigator" 710, as
illustrated in a user interface window 3200 of FIG. 32.
[0126] Further, the FMEA analyst may edit the recommended actions
at any point of time during the FMEA project. The recommended
actions may be edited by highlighting the recommended action and
clicking on the "Edit Recommended Action" tab. Subsequently, an
"Edit Recommended Action" page opens and the FMEA analyst may
update the information associated with the recommended action. In
one embodiment, the recommended actions may be approved by the team
leader of the project. As will be understood by a person skilled in
the art, every recommended action for every cause/effect
combination may be approved by the team leader. On approval of the
action, the date and time stamp may be viewed on the "Edit
Recommended Action" window. In one embodiment, subsequent to the
approval of the recommended action, the results associated with the
recommended actions may be added. In an alternate embodiment, the
team leader may reject the recommended action and the results tab
may not be editable after rejection of the recommended action.
[0127] As illustrated in FIG. 33, the display module 202 provides a
user interface window 3300, to the FMEA analyst under the "Results"
tab to provide the information on an execution of the recommended
action by the responsible FMEA analyst. The information may include
a test status, a validation status, an actual severity, an actual
occurrence, an actual detection, name of the FMEA analyst that
executed the action, and the actual end date. In an embodiment, the
actual severity, occurrence and detection may be selected based on
an industry standard definition and may be selected based on
pre-defined values stored in an external database or in repository
104.
[0128] In further embodiments, as illustrated in FIG. 34, the
display module 202 may provide a user interface window 2700, to add
product information for the FMEA project. The user interface window
3400 may be accessed by selecting the "Product" sub tab under the
"Overview tab. Subsequently, the FMEA analyst may select the "Edit
Selections" tab. Further, the FMEA analyst may enter information
about the product such as the product types, product family, the
sales mode, the serial number of the product, the manufacturing
facilities etc. In one embodiment, the FMEA analyst may use arrow
keys to select or deselect an option. In one embodiment, the
product information may be predefined and stored in an external
database. The entire list may be imported from the database to
select the desired information. In a further embodiment, the FMEA
analyst may add multiple options for every field.
[0129] In an embodiment, the FMEA analyst may also add related FMEA
projects, NPI and CPI projects and other similar projects to the
current FMEA project. A list of related FMEA projects may be
imported from an external database and displayed, wherein the FMEA
analyst may select the desired project to be added to the current
FMEA project. In one embodiment, the FMEA projects listed may
include various fields such as the test ID, the Project title, type
of project, maturity indicator that indicates whether the project
is completed or pending or under development status.
[0130] In a further embodiment, the FMEA analyst may add related
NPI projects or CPI projects to the FMEA project. In a yet further
embodiment, the FMEA analyst may also add other related internal
projects within an organization in a similar manner as described
above.
[0131] In an embodiment, the FMEA analyst may add a one or more
attachments that may be used for the sequential order element in
the FMEA project at any point in time. For example, an attachment
may be any document or a presentation etc. that may be required for
an element in the FMEA project. For example, the FMEA analyst may
click on an "Attachment" tab and subsequently click on an "Upload
Attachment" sub tab. Further, an "Add Attachment" pop up
information page opens up. Subsequently, by clicking on a "+" sign,
the FMEA analyst may add an attachment from a local or a shared
drive. Similarly, an attachment may also be removed by clicking on
a minus (-) sign displayed besides the attachment in the
"Attachment" tab. In a further embodiment, the FMEA analyst may
download the attachment; edit the details of the attachment etc. In
a yet another embodiment, the FMEA analyst may also add hyperlinks,
notes, or any other characteristics that may be used as a
additional information related to any element of the sequential
order in the FMEA project.
[0132] In an embodiment, the GUI module 110 provides a real time
FMEA status, associated with the FMEA project, through the
"Summary" Tab. In an embodiment, the FMEA analyst may view more
than one projects assigned to him under the "Summary" tab. For
example, a single team member may be a team leader for one project,
may be responsible for validation of detection controls in another
project and so on. Therefore, the FMEA analyst may get a list of
all the projects assigned, on logging on to the system by using
appropriate credentials. For example, there may be a "My FMEA
Projects" tab that lists all the projects assigned to the FMEA
analyst.
[0133] In one embodiment, the FMEA analyst may login to the user
interface 112 and click on the "My FMEA Projects" tab, to view a
particular FMEA project details. Further, the FMEA analyst may
search the entire "My FMEA Projects" list by using a keyword
search. Further, the FMEA analyst may select the desired FMEA
project, and subsequently click on the "Summary" tab of the project
to view the details of the project.
[0134] As illustrated in FIG. 35, in a user interface window 3500,
the "Summary" tab may indicate a tabular form of data related to
the FMEA project. In one embodiment, the FMEA form within the
"Summary" tab may include the plurality of sequential elements that
are added for the FMEA project as explained above. For example, the
summary table may include the item name, the requirements
associated with items, the failure modes associated with the
requirements, the causes, the effects, the initial occurrence value
of the cause, the initial severity value of the effect, the initial
detection value associated with the cause, and an initial RPN value
associated with every cause effect combination. In a further
embodiment, the table may also include the controls listed for
those cause/effect combination and the type of control such as a
prevention control or a detection control. In a further embodiment,
the summary table may be updated in real time. For example, as soon
as a change occurs in any information, i.e., an FMEA analyst enters
the current value of the severity, occurrence, detection value and
the resultant RPN value etc., the summary table reflects the
updated information immediately in real time. As will be
understood, the real time update of the summary table facilitates
the FMEA analyst to track the FMEA project in real time and
required actions may be taken on an immediate basis.
[0135] In one embodiment, if there are multiple effects associated
with a single cause, then for evaluating the RPN value, the effect
with the highest severity is considered. For example, if for cause
1, there are four effects namely, effect 1 having initial severity
value of 4, effect 2 having initial severity value 7, effect 3
having initial severity value of 2 and effect 4 having initial
severity value of 3, then automatically the effect with the highest
severity value, i.e., effect 2 in this case is selected to evaluate
the RPN value for this cause/effect combination for an item. Ina
further embodiment, if there is no initial detection value
specified for a cause, then a default value may be taken for
evaluating the initial RPN value. In an example, the initial
default detection value may be defined specific to an organization,
such as a value of 10 may be considered as the default detection
value. As will be understood by a person skilled in the art, there
may be multiple items and multiple cause/effect combination for
each item in an FMEA project, therefore, there are RPN values
associated with each cause/effect combination of each item. In one
embodiment, the portion on the left side of the table from the RPN
value is referred to as an initial view for the initial severity
and occurrence values.
[0136] In a further embodiment, the summary table may also include
other fields such as a recommended action to be implemented for a
particular cause/effect combination, the team member responsible
for executing the recommended action, the target date, the actual
actions taken etc. Subsequent to the execution of the recommended
actions, the actual or current severity value, occurrence value,
detection value and the current RPN value may also be displayed in
the summary view. As will be understood, the actual or current
values of severity, occurrence, detection and RPN may be same or
different than the forecasted values entered into the project while
adding the recommended actions to the FMEA project as described
earlier. For example, the recommended action may not be successful
as expected and therefore may not reduce the occurrence and the
severity value as expected or as forecasted by the team leader. In
one embodiment, the right side of the table from the RPN value
column may be referred to as a current view for the current
severity and occurrence values.
[0137] In an embodiment, the summary report may be exported into an
excel file by clicking on the "Export" button given on the
"Summary" tab on the interface 112. In a still further embodiment,
the summary table may indicate different symbols to indicate
incomplete information about an element, an overdue task, a
required recommended action for a specific cause, a linked related
NPI/CPI issues etc. For example, a triangle displayed besides an
element indicates that the element is not complete, i.e., all the
required fields for that element are not filled. Similarly, a red
flag displayed besides a cause or an effect indicates that a
recommended action is required to be executed to eliminate the
cause or the effect to lower or eliminate the risk associated. In a
further embodiment, a clock symbol displayed besides a control or
an action indicates that the action execution is overdue its
desired target date. Furthermore, a "*" symbol displayed besides a
failure mode may indicate linked related NPI/CPI issues.
[0138] In an embodiment, the FMEA analyst may hide the columns that
may not be required at the time of analysis, by clicking on a
"Toggle Columns" tab. Subsequent to clicking on the "Toggle
Columns" tab, a list of all the columns in the table is displayed
to the FMEA analyst, wherein the FMEA analyst may select the
columns to hide and click on the "OK" button to save the settings.
Subsequently, the FMEA analyst may again click on the "Toggle
Columns" tab to get the list back and deselect the columns to view
all the columns in the summary table.
[0139] As illustrated in FIG. 36, the FMEA analyst may also run
status reports for a status check of controls and recommended
actions pending in the FMEA project. In an embodiment, the FMEA
analyst may click on the "Toggle Status Report" tab on the
interface to view the overdue controls and recommended actions in a
user interface window 3600. For example, the status report table
may include the recommended action identifier, the description of
the action, planned start date, planned end date, assigned to etc.
In another embodiment, the team member responsible for executing
the overdue controls and/or the recommended actions may be notified
automatically through an email for executing the controls on an
urgent basis.
[0140] In an embodiment, a notification message may be displayed on
the top of the summary table as soon as the FMEA analyst clicks on
the "Summary" tab, indicating that there are a one or more
recommended actions and/or controls that are overdue their target
date.
[0141] In a further embodiment, every cell of the summary table is
clickable to facilitate the FMEA analyst to edit or add a new
element and its information. For example, on double clicking on an
element in a cell, the FMEA analyst is automatically redirected to
the EDIT page of that element, where the FMEA analyst may edit the
information about that element or create a new element. For
example, if the FMEA analyst double clicks on a recommended action
cell having a recommended action 1, then a pop-up window of "Edit
Recommended Action" opens up, and subsequently the FMEA analyst may
edit the information stored for that recommended action in a
similar manner as described earlier in the description. Similarly,
on double clicking any element in a cell of the summary table, the
FMEA analyst may be redirected to the page for editing and adding a
new element.
[0142] As illustrated in a user interface window 3700 in FIG. 37,
the FMEA analyst may view all the projects and the tasks in
addition to their timelines, target dates etc., by viewing a "My
Actions" sub tab under the "My FMEA Projects" tab. Further, the
FMEA analyst may receive reminders near a due date for a task
assigned. For example, based on a target date or completion date
for a prevention control execution, the FMEA analyst may be
reminded automatically through an email that the prevention control
execution is due on the specific target date.
[0143] In a further embodiment, the FMEA analyst may view a
complete Design Verification Plan and Report (DVP&R) for the
entire product or process by clicking on a "DVP&R" tab. A
DVP&R may be defined as a method to plan and document testing
activity through each phase of a product or a process development
starting from the inception to the ongoing refinement of the
project. In one embodiment, the FMEA analyst may monitor the entire
project by viewing the DVP&R table under the "DVP&R" tab,
as illustrated in a user interface window 3800 in FIG. 38.
[0144] In one embodiment, the DVP&R table may include the
information related to the controls, the recommended actions, the
responsible person, the target dates, the associated failure modes,
the description of the controls and the recommended actions etc.
For example, the FMEA analyst may view the status of execution of
the controls and the recommended actions in the DVP&R
table.
[0145] In one embodiment, an indication about incomplete controls
and recommended actions by displaying a triangle besides the
incomplete control and/or recommended action. Further, the FMEA
analyst may double click on the control and/or the recommended
action to subsequently open the "Edit Control" information page.
Subsequently, the FMEA analyst may update the control and/or the
recommended action by completing the required information. In a
still further embodiment, the FMEA analyst may run a status report
from the "DVP&R" tab by clicking on the "Toggle Status Report"
tab and viewing and utilizing the status report in a similar manner
as described above for the "Summary" tab. Additionally, the FMEA
analyst may also hide the columns to be viewed in a similar manner
as described above for the "Summary" tab, by clicking on the
"Toggle Columns" tab on the interface. Additionally, the columns in
the DVP&R table may be sorted alphabetically in order to
facilitate the FMEA analyst to view the desired information.
Further, the FMEA analyst may also export the DVP&R table into
an excel file for future usage.
[0146] As illustrated in a user interface window 3900 in FIG. 39,
the GUI module 110 may enable the FMEA analyst to sync and replace
a plurality of FMEA projects in a validation project. For example,
if two or more FMEA projects have a plurality of controls that may
be common to these projects, then the controls for these projects
may be synced. As will be understood by a person skilled in the
art, only same types of controls may be synced together. For
example, only a detection control may be synced with another
detection control. Similarly, only a prevention control may be
synced with another prevention control. In a further embodiment, if
a synced control is completed for one project, then it may not be
required to execute it repeatedly for all the other projects,
however, it may be marked completed for every other project for
which the control is synced. In a still further embodiment, for the
synced controls, the FMEA analyst may edit only the common fields
of the synced controls. However, a plurality of unique fields may
not be editable for every synced control.
[0147] As illustrated in window 3900, the FMEA analyst may click on
the "DVP&R" tab and subsequently select the controls and/or the
recommended actions to sync, and further click a "SYNC" tab as
illustrated in FIG. 39.
[0148] Subsequent to clicking on the "SYNC" tab, a "Sync"
information page opens up that displays the selected controls
and/or the recommended actions, as illustrated in a user interface
window 4000, in FIG. 40. Further the FMEA analyst may select the
entire master row shown in the window and subsequently, click "OK".
The selected controls are synced and only one row i.e. master row
shows up in DVP&R table, as illustrated in a user interface
window 4100, in FIG. 41.
[0149] In one embodiment, an email confirmation is sent out to the
team leader(s) listing the information regarding synced controls.
In a further embodiment, the FMEA analyst may select the master row
and click "Single Test Report" tab on the interface 112 to view all
the controls and their information that were synced. In a still
further embodiment, the single test report may also be exported to
an excel file for future references. In another embodiment, the
FMEA analyst may also replace the synced controls and/or the
recommended actions by selecting the control to be replaced and the
control for replacing the previous control and subsequently
clicking on the "Replace" button shown on the interface 112.
[0150] In an alternate embodiment, the FMEA analyst may add a
process FMEA (PFMEA) project. As will be understood by a person
skilled in the art, a PFMEA is an analytical technique used by a
manufacturing-responsible engineer or a team of engineers as a
means to assure that, a plurality of potential failure modes and
their associated causes and effects have been considered and
addressed to minimize the risk associated. In one embodiment, the
PFMEA may be created, and the several sequential elements may be
added, edited and viewed in a similar manner as described above for
a DFMEA project.
[0151] Further, the PFMEA may include a process step, a plurality
of desired outputs associated with every process step etc. For
example, the functional requirements may be added to the PFMEA for
every process step that indicate the desired output of a process
step when performing the step normally. Further, a failure mode, a
potential effect of the failure mode, potential cause of the
failure mode may be added for every functional requirement and
every process step of the PFMEA project. Similar to a DFMEA
project, the PFMEA project may include a severity value for the
effect of failure, an occurrence value associated with the cause of
failure mode, a detection value for the cause of failure mode and
an RPN value for every cause/effect combination in the PFMEA
project. In a further embodiment, the prevention controls,
detection controls and the recommended actions may be added and
implemented in a similar manner as done for a DFMEA project. In one
embodiment, the detection controls and the prevention controls may
include a prototype that may be imported from external database or
the repository 104.
[0152] In one embodiment, the developing module 208 develops a risk
chart for the FMEA project associated with the sequential order of
elements, explained above, during the product development cycle.
The risk chart enables the FMEA analysts to track a risk mitigation
process for the FMEA project through the product development cycle.
In an embodiment, the developing module 208 is adapted to develop a
risk chart for a single FMEA project or for a validation project
that includes multiple FMEA projects.
[0153] The developing module 208 may develop two types of charts,
namely a Criticality Matrix Risk Chart (CMRC) and a Proactive
Reliability Risk Chart (PRRC). However, it will be understood by a
person skilled in the art, the number of charts and the type of
charts are exemplary and may be extended to include similar
functionalities.
[0154] In one embodiment, a CMRC may be used to visually present a
criticality of potential failure modes and the risks associated
with those failures. The CMRC is based on a correlation of severity
values associated with potential effects of failure, and occurrence
values associated with potential causes of failures.
[0155] As illustrated in user interface window 4200 of FIG. 42, the
CMRC is formed as a grid which is divided in three different zones:
a risk mitigation zone 4210, a probable risk mitigation zone 4220
and a risk free zone 4230. The CMRC is divided in the three zones
4210, 4220, and 4230 based on the severity and occurrence values
for each combination of cause and effect in the FMEA project or the
validation project.
[0156] As illustrated in FIG. 42, the occurrence values are plotted
on an X-axis of the grid and the severity values are plotted on a
Y-axis of the grid. Each cell with in the grid includes a total
number of cause and effect combinations from the FMEA project
corresponding to the occurrence and severity values plotted in the
CMRC. For example, consider a cell in the grid at the position of
severity value 8 and occurrence value 1, then the value entered in
this cell, say 48, indicates that there are 48 unique cause and
effect combination in the FMEA project that have severity value of
8 and occurrence value of 1. Similarly, absence of any value in a
grid cell indicates there is no such cause and effect combination
corresponding to those severity and occurrence values.
[0157] In an embodiment, the three zones 4210, 4220, and 4230 in
the grid may be populated based on industry standards, such as an
AIAG standard. However, it will be appreciated that the grid may be
updated to adapt with updates in the industry standards.
[0158] In an embodiment, the risk mitigation zone 4210 includes all
such combination of potential causes of failure and potential
effects of failure that have a correlation of the severity value
and the occurrence value greater than a predetermined threshold.
The threshold value may be based on the AIAG standard. Each of the
cause and effect combinations in the risk mitigation zone may
include one or more recommended actions from the FMEA analyst to
mitigate the risk associate with those cause and effect
combinations. The criticality of the risk associated with a
cause/effect combination is based on the severity value and the
occurrence value of the effect and the cause respectively.
[0159] In an embodiment, the probable risk mitigation zone 4220
includes all such combination of potential causes of failures and
potential effects of failure that have a correlation of the
severity value and the occurrence value greater than a
predetermined threshold. The threshold value may be based on the
AIAG standard. Each of the cause and effect combinations in the
probable risk mitigation zone 4220 may include one or more controls
such as prevention controls or detection controls. Further, in an
embodiment, if any combination of potential causes of failure and
potential effects of failure in the probable risk mitigation zone
4220 has an RPN value greater than a pre-determined value, then all
those combinations have one or more recommended actions. The RPN is
based on a correlation between the severity value, the occurrence
value and the detection value. The detection value is associated
with each combination of the potential causes of failure and the
potential effects of failure. In an embodiment, the detection value
is taken as a predetermined number to calculate the RPN if no
inputs are provided by the FMEA analyst for the detection
value.
[0160] In an embodiment, the risk free zone 4230 includes all such
combination potential causes of failure and potential effects of
failure that have a correlation of the severity value and the
occurrence value lesser than a predetermined threshold. The
threshold value may be based on the AIAG standard. Each of the
cause and effect combinations in the risk free zone 4230 may not
need any controls or recommended actions.
[0161] In various embodiments, the three zones 4210, 4220 and 4230
may be visually separated from each other by color codes, a hatch
pattern or the like. However, it will be apparent to a person
skilled in the art that the three zones may be visually separated
by using any other method known in the art.
[0162] In an embodiment, the CMRC may include an initial CMRC,
forecast CMRC and a current CMRC. As illustrated in user interface
window 4300 of FIG. 43, the FMEA analyst may track a progress of
the risk mitigation in the FMEA project by comparing the initial
CMRC and the current CMRC. The display module 202 may provide the
user interface window 4300 under the "Reports" tab for the selected
FMEA or validation project. The initial CMRC is based on an initial
severity value and an initial occurrence value associated with a
combination of at least one potential cause of failure and at least
one potential effect of failure. In an embodiment, the initial CMRC
may be revised based on an initial occurrence value associated with
the combination of the at least one potential cause of failure and
the at least one potential effect of failure. The initial
occurrence value is revised based on an execution of at least one
prevention control associated with the combination of the at least
one potential cause of failure and the at least one potential
effect of failure. Further, the current CMRC is based on a current
severity value, and a current occurrence value associated with a
combination of at least one potential cause of failure and at least
one potential effect of failure. The current severity value and the
current occurrence value is based on an execution of at least one
recommended action associated with the combination of the at least
one potential cause of failure and the at least one potential
effect of failure. Further, the forecast CMRC is based on a
forecast severity value, and a forecast occurrence value associated
with a combination of at least one potential cause of failure and
at least one potential effect of failure. The forecast severity
value and the forecast occurrence value is based on a presumption
execution of at least one recommended action associated with the
combination of the at least one potential cause of failure and the
at least one potential effect of failure.
[0163] As illustrated in FIG. 44, the developing module 110 may
enable the FMEA analysts to view a report from the risk chart. The
FMEA analyst may select any cell within the CMRC to view
information associated with all the combinations of cause and
effect under that cell and other sequential order of elements
associated with that combination, as illustrated in user interface
window 4400. The information may include one or more of an item, or
process step, requirements associated with item or process step
output, potential failure modes associated with the item or
process, an initial severity value, an initial occurrence value and
an initial detection value associated with the combination cause
and effects, prevention or detection controls associated with the
combination cause and effects, a validation identification of the
FMEA project, recommended actions associated with the combination
of the cause and effects, of failure, a forecasted severity value,
a forecasted occurrence value and a forecasted detection value
associated with the combination of the cause and effects, a current
severity value, a current occurrence value and a current detection
value associated with the combination of the cause and effects, the
FMEA analysts assigned for an execution of the one or more
prevention or detection controls and the recommended actions, and a
start date, target completion state associated with the prevention
or detection controls and the recommended actions. In an
embodiment, the sequential order of elements in the report may also
include visual descriptors associated with the elements. The visual
descriptors provide a status or issues associated with the
elements.
[0164] In an embodiment, the display module 202 provides a path in
the report to view and edit the information associated with the
elements of the sequential order of elements. In an embodiment, the
FMEA analyst may select any element in the report and may double
click that to view the edit information page corresponding to that
element. For example, the FMEA analyst may want to revise the
initial occurrence value for a combination of cause and effect and
thus double click the corresponding cell under the initial
occurrence column to view the edit cause information page. In an
embodiment, the display module 202 may provide a path on the report
to export the report in XML format or any other required format
known in the art In an embodiment of the disclosure, the PRRC is
based on a timeline for risk mitigation during the FMEA project and
a Dealer Repair Frequency (DRF). The DRF is a correlation of an
occurrence value and an ability to predict that occurrence after
the validation. The calculation of DRF is done for each failure
mode and cause combination in the FMEA project. Specifically, the
PRRC is based on the timeline for risk mitigation and a mean DRF.
The mean DRF is a failure rate spread for a limited time-period in
a product lifecycle.
[0165] As illustrated in a user interface window 4500 in FIG. 45,
the PRRC is plotted between a mean DRF and the timeline for risk
mitigation. The PRRC further includes a design DRF, a glide-path
DRF, a capability DRF, a target DRF, a current DRF, a history DRF,
a carryover DRF and a projection DRF. The PRRC is developed either
for a single FMEA project or for a validation project or for a
combination of validation projects.
[0166] The target DRF is based on a specified target timeline
provided by the one or more FMEA analysts for the risk mitigation.
The target DRF is provided by the one or more FMEA analysts on the
user interface. As illustrated in a user interface window 4600 in
FIG. 46, a target DRF may be provided, by the FMEA analyst, for the
FMEA project in the "Coverage table" under the "Overview" tab.
Similarly, as illustrated in a user interface window 4700 in FIG.
47, a target DRF may be provided for a validation project. Also, a
carryover/block load DRF is also provided for adding NPI/CPI DRF
values if the same is not included in the individual FMEA projects.
Further, as illustrated in the user interface window 4700, system,
subsystem may be selected and provided by the FMEA analyst. The
user interface window 4700 also displays the various FMEA or
validation projects associated with the PRRC.
[0167] In an embodiment, when an initial DRF calculation is
performed using an initial occurrence value within the FMEA
project, it is termed as Designed in the DRF. Thus, the design DRF
is determined based on an initial occurrence value associated with
a combination of at least one potential effect of failure and at
least one potential cause of failure. The glide-path DRF is based
on a completion of prevention and detection controls and
recommended actions within a required target date of completion.
The glide-path DRF enables the FMEA analyst to track the risk
mitigation timeline during the product development cycle. In an
embodiment, a history of the glide-path DRF is recorded in a
pre-determined time range to track a progress of the risk
mitigation for the FEMA project during the product development
cycle. The capability DRF is based on a lowest occurrence value
associated with a combination of at least one potential effect of
failure and at least one potential cause of failure. The current
DRF is based on an initial revised occurrence value on a successful
execution of the prevention and detection controls associated with
a combination of at least one potential effect of failure and at
least one potential cause of failure.
[0168] The present disclosure (i.e., Graphic User Module 110, any
part(s) or function(s) thereof) may be implemented using hardware,
software or a combination thereof, and may be implemented in one or
more computer systems or other processing systems. However, the
manipulations performed by the present disclosure were often
referred to in terms, such as comparing or checking, which are
commonly associated with mental operations performed by a human
operator. No such capability of a human operator is necessary, or
desirable in most cases, in any of the operations described herein,
which form a part of the system. Rather, the operations are machine
operations. Useful machines for performing the operations in the
system may include general-purpose digital computers or similar
devices.
[0169] In an embodiment of the present disclosure, the present
system is directed towards one or more computer systems capable of
carrying out the functionality described herein.
[0170] The computer system 4800 includes at least one processor,
such as a processor 4802. The processor 4802 is connected to a
communication infrastructure 4804, for example, a communications
bus, a cross over bar, a network, and the like. Various software
embodiments are described in terms of this exemplary computer
system 4800. After reading this description, it will become
apparent to a person skilled in the relevant art(s) how to
implement the system using other computer systems and/or
architectures.
[0171] The computer system 4800 includes a display interface 4806
that forwards graphics, text, and other data from the communication
infrastructure 4804 for display on a display unit 4808.
[0172] The computer system 4800 further includes a main memory
4810, such as random access memory (RAM), and may also include a
secondary memory 4812. The secondary memory 4812 may further
include, for example, a hard disk drive 4814 and/or a removable
storage drive 4816, representing a floppy disk drive, a magnetic
tape drive, an optical disk drive, etc. The removable storage drive
4816 reads from and/or writes to a removable storage unit 4818 in a
well-known manner. The removable storage unit 4818 may represent a
floppy disk, magnetic tape or an optical disk, and may be read by
and written to by the removable storage drive 4816. As will be
appreciated, the removable storage unit 4818 includes a computer
usable storage medium having stored therein, computer software
and/or data.
[0173] In accordance with various embodiments of the system, the
secondary memory 4812 may include other similar devices for
allowing computer programs or other instructions to be loaded into
the computer system 4800. Such devices may include, for example, a
removable storage unit 4820, and an interface 4822. Examples of
such may include a program cartridge and cartridge interface (such
as that found in video game devices), a removable memory chip (such
as an erasable programmable read only memory (EPROM), or
programmable read only memory (PROM)) and associated socket, and
other removable storage units 4820 and interfaces 4822, which allow
software and data to be transferred from the removable storage unit
4820 to the computer system 4800.
[0174] The computer system 4800 may further include a communication
interface 4824. The communication interface 4824 allows software
and data to be transferred between the computer system 4800 and
external devices. Examples of the communication interface 4824
include, but may not be limited to a modem, a network interface
(such as an Ethernet card), a communications port, a Personal
Computer Memory Card International Association (PCMCIA) slot and
card, and the like. Software and data transferred via the
communication interface 4824 are in the form of a plurality of
signals, hereinafter referred to as signals 4826, which may be
electronic, electromagnetic, optical or other signals capable of
being received by the communication interface 4824. The signals
4826 are provided to the communication interface 4824 via a
communication path (e.g., channel) 4828. The communication path
4828 carries the signals 4826 and may be implemented using wire or
cable, fiber optics, a telephone line, a cellular link, a radio
frequency (RF) link and other communication channels.
[0175] In this document, the terms "computer program medium" and
"computer usable medium" are used to generally refer to media such
as the removable storage drive 4816, a hard disk installed in hard
disk drive 4814, the signals 4826, and the like. These computer
program products provide software to the computer system 4800. The
disclosure is directed to such computer program products.
[0176] Computer programs (also referred to as computer control
logic) are stored in the main memory 4810 and/or the secondary
memory 4812. Computer programs may also be received via the
communication interface 4804. Such computer programs, when
executed, enable the computer system 4800 to perform the features
of the present disclosure, as discussed herein. In particular, the
computer programs, when executed, enable the processor 4802 to
perform the features of the present disclosure. Accordingly, such
computer programs represent controllers of the computer system
4800.
[0177] In accordance with an embodiment, where the system is
implemented using a software, the software may be stored in a
computer program product and loaded into the computer system 4800
using the removable storage drive 4816, the hard disk drive 4814 or
the communication interface 4824. The control logic (software),
when executed by the processor 4802, causes the processor 4802 to
perform the functions of the system as described herein.
[0178] In another embodiment, the system may be implemented
primarily in hardware using, for example, hardware components such
as application specific integrated circuits (ASIC). Implementation
of the hardware state machine so as to perform the functions
described herein will be apparent to persons skilled in the
relevant art(s). In yet another embodiment, the system is
implemented using a combination of both the hardware and the
software.
INDUSTRIAL APPLICABILITY
[0179] Generally, in FMEA project, various FMEA analysts are
required to complete one or more tasks associated with sequential
order of elements. Conventionally, the FMEA analysts use
spreadsheets to fill the information and then the various
spreadsheets are collated to track the progress of the FMEA project
during a product development cycle. Also, the FMEA analysts need to
perform various calculations such as value of RPN manually to find
out the possible combination of causes and effects that needs risk
mitigation.
[0180] In an embodiment, the user interface 112 provides a solution
to the various FMEA analysts to track the progress of risk
mitigation in the FMEA project during the product development
cycle. As illustrated in FIG. 49, process 4900 details out the
steps of facilitating the FMEA project. At step 4910, the GUI
module 110 displays information pages on the user interface 112 to
the various FMEA analysts, assigned to the particular FMEA project.
The information pages may include placeholders for including
information associated with the sequential order of elements. The
information may include name of item or process, requirements
associated with those items or process, potential failure modes,
potential causes and effects associated with the failure modes, one
or more controls and recommended actions associated with the
various causes and failure mode combinations.
[0181] At step 4920, the GUI module 110 receives textual inputs
from the FMEA analysts to be filled in the information pages.
Conventionally, the FMEA analyst may only be able to provide the
basic information regarding the sequential order of elements. In an
embodiment, the user interface 112 enables the FMEA analyst to
provide additional information associated with each of the
sequential order of elements. Further, the user interface 112 also
enables the FMEA analysts to upload attachments associated with the
sequential order of elements and to link one or more other projects
that may be related to the current FMEA project. The user interface
112 further enables the FMEA analyst to link NPI/CPI projects with
the current FMEA project. Conventionally, the FMEA analysts use to
manually calculate the RPN values based on the occurrence value,
severity value and detection value. In an embodiment, the user
interface 112 enables the FMEA analysts to view the RPN value
associated with each possible combination of cause and failure
mode. The user interface 112 automatically calculates an initial
RPN and a current RPN once the required information such as initial
and current values of occurrence, severity and detection is
received from the FMEA analysts and thus, eliminating the risk of
human errors.
[0182] At step 4930, the GUI module 110 represent the sequential
order of elements in a tree structure format on the user interface
112. The user interface 112 includes the "FMEA Navigator" 710,
which displays the sequential order of elements in the tree
structure format. The first node in the tree structure includes the
name of item or process step. Subsequently, the next node includes
the one or more requirements/process step output associated with
the item or process step. The next node includes one or more
failure modes associated with the requirements or process step
output. The subsequent node includes the one or more effects and
causes associated with each of the failure modes. The subsequent
mode includes the various controls or recommended actions
associated with the cause and failure mode combination. The tree
structure enables the FMEA analysts to view the association of
sequential order of elements with each other. The tree structure
also enables the FMEA analyst to navigate any element from the
sequential order of elements by selecting the element to view the
information associated with the element or double clicking the
element to view an editable information page associated with the
element.
[0183] In an embodiment, the GUI module 110 displays a real time
status of the FMEA project in the user interface 112. The FMEA
analysts may view the real time status of the FNEA project under
the "Summary" tab in the user interface 112 and may also run a
report to access pending executions of controls and recommended
actions associated with the sequential order of elements. The
status of the FMEA also includes visual indicators such as, but not
limited to, flags, watch symbols, star symbol with either pending
or overdue execution of controls or recommended actions. Further,
the user interface 112 may provide a path on the status to view
and/or edit the information associated with the sequential order of
elements.
[0184] The user interface 112 may also enable the FMEA analyst to
view one or more tasks assigned to the particular FMEA analyst on
controls or recommended actions. In an embodiment, the FMEA analyst
having a team leader or a project manager role may access the
progress of the various tasks assigned to several other team
members (FMEA analysts assigned to the project) in a particular
FMEA project. In an embodiment, the FMEA analysts may also track
the progress of the FMEA project through "DVP&R" tab which
includes an execution status of various control and/or recommended
actions associated with the sequential order of elements. In
various embodiments, the FMEA analysts may export the status
reports for the FMEA project in one or more formats such as XML
spreadsheets. The FMEA analysts may import the XML spreadsheet into
the user interface 112 and may update the status of the FMEA
project in the user interface 112 based on the information included
in the imported XML spreadsheets.
[0185] Further, at step 4940, the GUI module 110 develops risk
charts to enable the FMEA analyst to visually track the risk
mitigation progress in the FMEA project during the product
development cycle. In an embodiment, GUI module 110 develops the
risk chart for a single FMEA project or for a validation project
that includes multiple FMEA projects. The GUI module 110 may
develop two types of charts: Criticality Matrix Risk Chart (CMRC)
and Proactive Reliability Risk Chart (PRRC).
[0186] In one embodiment, the CMRC may be used to visually present
a criticality of potential failure modes and the risks associated
with those failures. The CMRC is based on a correlation of severity
values associated with potential effects of failure, and occurrence
values associated with potential causes of failures. The CMRC is
formed as a grid which is divided in three different zones: a risk
mitigation zone 4210, a probable risk mitigation zone 4220 and a
risk free zone 4230. The CMRC is divided in the three zones 4210,
4220, and 4230 based on the severity and occurrence values for each
combination of cause and effect in the FMEA project or the
validation project. Each cell with in the grid includes a total
number of cause and effect combinations from the FMEA project
corresponding to the occurrence and severity values plotted in the
CMRC. In an embodiment, the three zones 4210, 4220, and 4230 in the
grid may be populated based on industry standards, such as an AIAG
standard.
[0187] In an embodiment, the risk mitigation zone 4210 includes all
such combination of potential causes of failure and potential
effects of failure that have a correlation of the severity value
and the occurrence value greater than a predetermined threshold.
Each of the cause and effect combinations in the risk mitigation
zone may include one or more recommended actions from the FMEA
analyst to mitigate the risk associate with those cause and effect
combinations. The criticality of the risk associated with a
cause/effect combination is based on the severity value and the
occurrence value of the effect and the cause respectively. In an
embodiment, the probable risk mitigation zone 4220 includes all
such combination of potential causes of failures and potential
effects of failure that have a correlation of the severity value
and the occurrence value greater than a predetermined threshold.
Each of the cause and effect combinations in the probable risk
mitigation zone 4220 may include one or more controls such as
prevention controls or detection controls. Further, in an
embodiment, if any combination of potential causes of failure and
potential effects of failure in the probable risk mitigation zone
4220 has an RPN value greater than a pre-determined value, then all
those combinations have one or more recommended actions. The RPN is
based on a correlation between the severity value, the occurrence
value and the detection value. The detection value is associated
with each combination of the potential causes of failure and the
potential effects of failure. In an embodiment, the detection value
is taken as a predetermined number to calculate the RPN if no
inputs are provided by the FMEA analyst for the detection value. In
an embodiment, the risk free zone 4230 includes all such
combination potential causes of failure and potential effects of
failure that have a correlation of the severity value and the
occurrence value lesser than a predetermined threshold. Each of the
cause and effect combinations in the risk free zone 4230 may not
need any controls or recommended actions. In various embodiments,
the three zones 4210, 4220 and 4230 may be visually separated from
each other by color codes, a hatch pattern or the like. However, it
will be apparent to a person skilled in the art that the three
zones may be visually separated by using any other method known in
the art.
[0188] In an embodiment, the FMEA analyst may track a progress of
the risk mitigation in the FMEA project by comparing the initial
CMRC and the current CMRC. The initial CMRC is based on an initial
severity value and an initial occurrence value associated with a
combination of at least one potential cause of failure and at least
one potential effect of failure. In an embodiment, the initial CMRC
may be revised based on an initial occurrence value associated with
the combination of the at least one potential cause of failure and
the at least one potential effect of failure. The initial
occurrence value is revised based on an execution of at least one
prevention control associated with the combination of the at least
one potential cause of failure and the at least one potential
effect of failure. Further, the current CMRC is based on a current
severity value, and a current occurrence value associated with a
combination of at least one potential cause of failure and at least
one potential effect of failure. The current severity value and the
current occurrence value is based on an execution of at least one
recommended action associated with the combination of the at least
one potential cause of failure and the at least one potential
effect of failure. Further, the forecast CMRC is based on a
forecast severity value, and a forecast occurrence value associated
with a combination of at least one potential cause of failure and
at least one potential effect of failure. The forecast severity
value and the forecast occurrence value is based on a presumption
execution of at least one recommended action associated with the
combination of the at least one potential cause of failure and the
at least one potential effect of failure.
[0189] In an embodiment of the disclosure, the PRRC is based on a
timeline for risk mitigation during the FMEA project and a Dealer
Repair Frequency (DRF). The DRF is a correlation of an occurrence
value and an ability to predict that occurrence after the
validation. The calculation of DRF is done for each failure mode
and cause combination in the FMEA project. Specifically, the PRRC
is based on the timeline for risk mitigation and a mean DRF. The
mean DRF is a failure rate spread for a limited time-period in a
product lifecycle.
[0190] While aspects of the present disclosure have been
particularly shown and described with reference to the embodiments
above, it will be understood by those skilled in the art that
various additional embodiments may be contemplated by the
modification of the disclosed machines, systems and methods without
departing from the spirit and scope of what is disclosed. Such
embodiments should be understood to fall within the scope of the
present disclosure as determined based upon the claims and any
equivalents thereof.
* * * * *