Failure Mode Effect Analysis
The FMA process used by IN-RDVS uses familiar industry standard tools and documentation covering: Quality History Analysis, Boundary Diagrams, Interface Analysis, P Diagrams, Reliability and Robustness Analysis and FMEA. This group of tools is used to identify and quantify potential failure modes and their effects. Using this information actions are generated to avoid or eliminate the potential failure mode occurring. Documenting this design failure mode analysis feeds into the validation test and quality history documentation. Frequently significant and critical characteristics identified via the FMEA are cascaded to our prototyping and production manufacturing processes. We use this systematic approach to formalise thoughts and design considerations engineers have whilst developing our designs.
Quality History Documentation: Many of our designs have evolved and have versions tailored to customer requirements, with each having a level of quality history in order to continuously improve the core design. By recording issues and improvements found during the development phase on quality history documentation we have a wealth of experience to review when commencing a new project or major modification to a core design.
Boundary Diagrams and Interface Analysis: Typically components and subsystems work fine on the bench but when integrated in to the vehicle system intermittent failures occasionally occur. We have found that by documenting the design on a boundary diagram the type and characteristics of interface can be identified. Owners of “both ends” of each interface agree the specification thus avoiding system interface issues, which can often be incorrectly described as component failures. The boundary diagram is also used within IN-RDVS to help the FMEA team focus on the scope of the FMEA i.e. where an interface crosses the boundary. Often FMEA teams can go off track diving too deeply inside the boundary or considering failure modes in adjacent systems not related to the design.
P Diagrams: P Diagrams are used to define the Inputs and Outputs of the primary function under consideration in the FMEA. Noise factors developed through experience of the vehicle system and through historical data are also recorded on the P Diagram. Design controls document applicable industry standards and also IN-RDVS design processes. P Diagrams are then used to feed into the FMEA and robustness analysis.
Failure Mode Effect Analysis: A variety of FMEAs are generated within RDVS. We have experience of Concept FMEAs and Design FMEAs from PCB component level to Vehicle System FMEAs. FMEAs are documented in Byteworx or in the customer preferred format. We have worked with several OEMs generating FMEAs on HEV functions and other new vehicle technologies.