Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Applies to:
SAP QM/PLM Consultants, SAP ECC 6.0.EHP3. For more information, visit the Supply Chain Management homepage.

Summary
Failure Modes and Effects Analysis is an analytical method for locating and preventing possible defects and weak points in products and processes early on. FMEA component provides functions that you can be used to perform a Failure Mode and Effects Analysis. Author: Company: Created on: Phani Kumar Adavi Intelligroup Asia Private Ltd 20 August 2009

Author Bio
Phani Kumar Adavi has Eight years of Experience which includes Four years of Experience in SAP Quality Management QM Module. He has been working as Consultant for SAP QM Module, in SAP SCM Department of Intelligroup Asia Pvt Ltd since September 2008.

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Table of Contents
Introduction ......................................................................................................................................................... 3 Abbreviations Used ......................................................................................................................................... 3 Requirement ....................................................................................................................................................... 3 Integration ........................................................................................................................................................... 3 Structure of the Failure Modes and Effects Analysis .......................................................................................... 3 Structure of the Hierarchy profile & Hierarchy Levels ........................................................................................ 4 Procedure ........................................................................................................................................................... 5 Step 1: Creation of Structure, Function and Defect Networks ........................................................................ 5 Step 2: Assign the Master Inspection Characteristics .................................................................................... 6 Step 3: Create Preventive and Detection Actions........................................................................................... 6 Step 4: Assign FMEA to the Control Plan ....................................................................................................... 7 Step 5: Carry out Action & Risk Analysis by Evaluating the Defect Causes & Actions .................................. 8 Step 6 Print preview of FMEA with Risk Priority Numbers for Defects ........................................................... 9 Summary........................................................................................................................................................... 10 Related Content ................................................................................................................................................ 10 Disclaimer and Liability Notice .......................................................................................................................... 11

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Introduction
FMEA is used in Quality Management to prevent and avoid Defects. Six sigma projects use failure modes and effects analysis to identify the weak points. FMEA component supports different styles of FMEA. For Example System FMEA for products & processes. Every Functional element which is part of FMEA structure is investigated for Defect probabilities, defect causes & effects. Abbreviations Used TC Transaction Code FMEA Failure Modes & Effects Analysis RPN Risk Priority Number

Requirement
To determine the RPN for each possible defect by valuating the effect and weighing this together with the valuation of Probability that the defect will actually cause a malfunction or breakdown. Locating & Preventing possible defects and weak points in products as well as processes early on. FMEA in Quality Management is used to prevent and avoid defects. Six Sigma projects can use the FMEA for identification of weak points.

Integration
FMEA integrates with the following Components: Catalogs (TC: QS41) Inspection Characteristics (TC: QS21)

Structure of the Failure Modes and Effects Analysis

The Function and Defect Network is linked as follows in FMEA. (81) System FMEA Process (80) Functions 800 Function List801 Function (802) Prerequisite (806) Characteristic (803) Defect (804) Reason (8000) Probability of Occurrence (8001) Probability of Detection (805) Result

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Structure of the Hierarchy profile & Hierarchy Levels

S.No. Hierarchy Profile Profile Description List Type/Hierarchy Level 010 1 2 3 4 5 6 7 Description Item Type Item Description

80

Functions

Functions Function Prerequisite Characteristic Defect Cause Characteristic Effect

800 801 802 806 803 804 806 805

Functions List Function Prerequisite Characteristic Defect Reason Characteristic Result

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Procedure
The Creation & Execution of the FMEA majorly involves the following steps: Step 1: Creating Structure, Function & defect Networks (Structure Analysis) Step 2: Assigning Characteristics Step 3: Creating Actions Step 4: Assignment of the Control Plan. Step 5: Evaluating the Defects causes & Actions. (Action & Risk Analysis) Step 6: Print preview of FMEA with Risk Priority Numbers for Defects TC QM_FMEA (FMEA Cockpit) is used for the creation of FMEA. Step 1: Creation of Structure, Function and Defect Networks Enter the FMEA Type & objects pertaining to FMEA type i.e. Material & Process operation. Enter the details like Planned Start Date, finish Date, person responsible & approver. Status of FMEA is to be released for further actions. In the Control Plan Tab system displays the relevant Control Plans to which FMEA is attached. Create the Functions List & assign the Function or Process Operation Step from the Task List that is assigned in the initial step of FMEA Creation Assign the Prerequisites that need to be followed during the Execution of the Process Step/Operation assigned in FMEA. Create & Assign the Probable Defects to the Function or Process Step.

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Step 2: Assign the Master Inspection Characteristics Give the Description for the Characteristic, characteristic type & weighting. Description of the Characteristic should be unique. Assign the Master Inspection Characteristic and plant which is a part of the FMEA.

Step 3: Create Preventive and Detection Actions Create Preventive and Detection Actions with reference to the Defect. Give the Planned Start Date details. Ensure to confirm the Preventive and Detection Actions to update the valuations of Probability of Occurrence & Detection that are required for the Calculation of Risk Priority Number.

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Step 4: Assign FMEA to the Control Plan Create Control Plan for FMEA. Assign FMEA in the FMEA Tab of Control Plan. Transfer of Data takes place from FMEA to Control Plan & vice versa.

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Step 5: Carry out Action & Risk Analysis by Evaluating the Defect Causes & Actions Formula for calculating RPN = Severity X Probability of Occurrence X Probability of Detection. Enter the Severity of Defect along with the Probability of Occurrence & Probability of Detection Ratings. Click on the valuate Tab that triggers the Calculation of Risk Priority Number for the Defects.

Severity (4) X Probability of Occurrence (6) X Probability of Detection (6) = RPN (144)

RPN value in the Defects screen of FMEA

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Step 6 Print preview of FMEA with Risk Priority Numbers for Defects

Note: As the concept is already simulated and executed in the system all the screenshots pertaining to the scenario are referenced here in Change mode of the transaction.

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Summary
In case of Multiple Defects or weak points identified for a process or product, depending on the severity of the defect, system will generate the Risk Priority Number which is directly proportional to severity. Depending upon the Risk Priority Number of Defect, necessary Actions are prioritized to prevent & avoid the defects/non conformities. In FMEA, causes from the Lower level system Element & Effects from the Higher Level system Element are linked to the Defects to establish the Cause Effect Relationship. Thus Actions to reduce the projected risk for the whole system are aimed at the potential defects with the highest risk priority number.

Related Content
For more information, visit the Supply Chain Management homepage. For more information, visit the Supply Chain Management homepage.

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Creation of Functions for Failure Modes & Effects Analysis Generation of Risk Priority Number (RPN)

Disclaimer and Liability Notice

This document may discuss sample coding or other information that does not include SAP official interfaces and therefore is not supported by SAP. Changes made based on this information are not supported and can be overwritten during an upgrade. SAP will not be held liable for any damages caused by using or misusing the information, code or methods suggested in this document, and anyone using these methods does so at his/her own risk. SAP offers no guarantees and assumes no responsibility or liability of any type with respect to the content of this technical article or code sample, including any liability resulting from incompatibility between the content within this document and the materials and services offered by SAP. You agree that you will not hold, or seek to hold, SAP responsible or liable with respect to the content of this document.

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