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    Field Failures Analysis: Heribert

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    mirosek
    This document provides guidance on implementing a field failure analysis process to analyze defects found after products have been delivered to customers. It recommends establishing standardized processes for inspection, testing, data collection, root cause analysis and corrective actions. The process aims to reduce warranty costs and improve quality through collaboration between OEMs and suppliers. Key elements include planning inspections and tests, systematically analyzing field data, using a problem-solving method like 8D, and continuously improving based on findings. The goal is to gain insights that enhance products and manufacturing processes.

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    © All Rights Reserved
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    Field Failures Analysis: Heribert

    Uploaded by

    mirosek
    498 views17 pages
    This document provides guidance on implementing a field failure analysis process to analyze defects found after products have been delivered to customers. It recommends establishing standardized processes for inspection, testing, data collection, root cause analysis and corrective actions. The process aims to reduce warranty costs and improve quality through collaboration between OEMs and suppliers. Key elements include planning inspections and tests, systematically analyzing field data, using a problem-solving method like 8D, and continuously improving based on findings. The goal is to gain insights that enhance products and manufacturing processes.

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    This document provides guidance on implementing a field failure analysis process to analyze defects found after products have been delivered to customers. It recommends establishing standardized processes for inspection, testing, data collection, root cause analysis and corrective actions. The process aims to reduce warranty costs and improve quality through collaboration between OEMs and suppliers. Key elements include planning inspections and tests, systematically analyzing field data, using a problem-solving method like 8D, and continuously improving based on findings. The goal is to gain insights that enhance products and manufacturing processes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    498 views17 pages

    Field Failures Analysis: Heribert

    Uploaded by

    mirosek
    This document provides guidance on implementing a field failure analysis process to analyze defects found after products have been delivered to customers. It recommends establishing standardized processes for inspection, testing, data collection, root cause analysis and corrective actions. The process aims to reduce warranty costs and improve quality through collaboration between OEMs and suppliers. Key elements include planning inspections and tests, systematically analyzing field data, using a problem-solving method like 8D, and continuously improving based on findings. The goal is to gain insights that enhance products and manufacturing processes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 17

    QMS

    Qualitts-Management-Systeme

    Key Points Regarding

    Field Failures Analysis


    If you have further questions let us know.
    We are ready to help.

    Heribert Nuhn

    8D

    QMS
    Qualitts-Management-Systeme
    Germany
    D-56587 Strassenhaus
    Deutschland
    Tel.: ++ 49 2634 9560 71
    Fax.: ++ 49 2634 9560 72
    Mobil: + 49 171 315 7768
    eMail: [email protected]
    Version 2009.1

    5y
    Wh

    FMEA
    RGA/ A

    ISO/ TS
    1
    Schadteilanalyse

    PQ P

    6 949

    P
    DV
    A
    VD

    P
    PA
    P
    /
    2

    Inte

    rn

    tor
    i
    d
    u
    al A

    Field Failures Analysis


    A Common Quality Management
    within the Supply Chain

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    Field Failure Analysis


    Initial Situation:
    "Within the automotive industry
    expenses for Warranty and Policy
    account for two to four percent of all
    cost per vehicle, thus exceeding the
    US$ 30 Billion estimated by industry
    experts."

    Source:

    Version 2009.1

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    June 19th, 2006

    enduser/
    repair shop

    Scope
    customer
    complaint
    request for
    warranty

    OEM
    supplier

    repair shop
    process

    claims
    process

    warranty
    process

    exchange
    of parts

    Quality
    process:
    Field Failure
    Analysis

    agreement
    invoice

    - NTF Version 2009.1

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    Process of Field Failure Analysis


    Goal: Added Value for OEM and Supplier
    OEM

    Supplier

    introduction of a
    planning process for
    field failure analysis
    precise definition of intial
    inspection (standard
    inspection and testing
    and functional testing)
    initial definition of NTFProcess
    NTF-Process is basis for
    audits related to field
    failure analysis
    Version 2009.1

    foundation for the planning process


    regarding field failure analysis
    precise and economic approach for
    inspection and testing
    an approach for OEMs, i.e.
    identical and uniform terms and
    definitions
    approach for the entier supply
    chain
    improved cooperation with OEMs
    regarding field failure analysis

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    Field Failure Analysis Process


    Continuous Improvement Process

    Field Failure Analysis Process


    no

    evaluation

    standard
    inspection
    and testing
    mutually
    agreed
    inspections
    and tests

    ok
    after
    standard
    inspection

    not ok.
    acc. to standard inspection

    functional
    testing
    1. evidence of
    defect:
    defect oriented
    2. acc. to agreed
    inspection

    ?
    Criteria
    for release
    are met
    yes
    ?

    NTF-Process
    collecting
    data

    Exchange of Info. & Parts as agreed

    Warranty Parts

    inspection of
    systems

    and
    ok
    after
    functional
    testing

    not ok.
    acc. to functional testing

    evaluating
    data

    evaluation of
    processes

    not ok
    acc. to systems and/ or processes

    Root Cause Analysis and Defect Elimination Processes


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    Evaluation
    Stand. Inspection
    and Testing

    Functional Testing

    yes

    mutually agreed
    and defined Inspecevidence
    tion & Testing
    of

    mutually
    agreed

    no

    defect
    oriented
    mutually
    agreed

    defect

    Test S.1
    Test S.2

    Test S.n

    no
    n. ok
    according
    to standard
    inspection

    Test F/B.1

    Test D/F.1

    Test F/B.2

    Test D/F.2

    Test F/B.n

    Test D/F. n

    n.ok
    according
    functional
    testing

    no

    criteria
    for
    release
    ?
    NTFcustomer
    Process
    complaint
    feasible
    ?
    yes

    yes

    ? customer complaint feasible ?

    not ok according to functional testing

    Version 2009.1

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    ok
    acc. to
    evaluation

    Criteria for Release


    Examples:
    large number of "ok according to evaluation"
    new product or part (after market launch or production part
    approval process)
    new launch for
    vehicle/ component/ system
    importance of defect to customer
    field failure/ vehicle at reduced capacity
    new or frequent complaints (dealer/ customer statement)
    If NTF-Process is not initiated efective parts will be disposed of
    according to agreement (if no agreement has been made this will
    be done four weeks after completion and documentation of
    evaluation).
    Version 2009.1

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    NTF-Process
    Collecting and Evaluating Data:
    it is a prerequisite that both parties continuously
    evaluate the data in their field of responsibility
    initially only data and information readyly available
    is evaluated during the NTF-Process the objective
    being to attain further information in the future
    if collecting and evaluating data generates new
    findings the NTF-Process must continue by
    inspecting systems and/ or evaluating processes

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    NTF-Process
    Finalization of NTF-Processes:
    Where a problem was identified during the NTF-Process
    problem solving will be carried out according to the
    agreed problem solving process.
    Where a problem was not identified during the NTFProcess the initiator will decide if further analyses are
    promising.
    Where further analyses are not promising positive
    results the finalization of the NTF-Process must be
    documented.

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    10

    Problem Solving Process


    Problem Analysis:
    Problem analysis identifies the root cause of failure for
    the defect that has been confirmed in the NTF-Process.
    The defect identified represents the problem description
    or problem definition for the subsequent problem solving
    process.
    Typically the automotive industry uses the
    8D-Methodology for problem solving.

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    11

    Planning the Field Failure Analysis Process


    The field failure analysis process must be implemented in the
    organisation.
    Process description and ressources must be avilable.
    Areas for logistics, data management, standard inspection and
    testing, functional testing and NTF-Process must be clearly
    defined.
    On the basis of this VDA-Manual a product-specific approach
    must be implemented for each product.
    Sections for data collection and data evaluation, system
    inspection and process evaluation must be part of a NTFProcess.
    Detailed planning for newly developed products.
    Control plans must developed for standard inspection and
    testing and functional testing.
    Criteria for releasing the NTF-Process must be defined.
    Control plan and criteria for releasing the NTF-Process must
    be established during the RGA-Process.
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    12

    Planning the Field Failure Analysis Process


    As a minimum this subject is covered in Quality Assurance Process
    (RGA) Checklist 4.2.5 under "Claims Management".

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    13

    Guideline
    A guideline must be established for the NTF-Process
    for groups of product and
    to assure a systematic and methodical implementation
    Prerequesits for procedures and work instructions must be met.
    Criteria for release must be defined.
    Requirements for inspection and test documentation and
    equipment must be met.
    A cost effective planning of capacities and estimate of
    expenditure must be performed.
    Results from the Field Failure Analysis Process are part of the
    Production Part Approval Process (VDA 2/ PPAP).
    Changes in respective control plans or changes by steps for
    inspections and tests are subject to applicable approval
    procedures.
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    14

    Continuous Improvement Process (CIP)


    Continuous Improvement Process
    Planning of inspections
    and tests needed
    for defective
    part analysis

    Implement field
    failure analysis
    process according
    to planning

    Eliminate
    identified
    deviations and
    introduce
    measures to
    improve the defect
    part analysis process

    Check Plan/ Actual


    to iIdentify
    differences and
    potential for
    improvement

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    15

    Interfaces and Exchange of Information


    Reporting
    The reporting system for the field failure analysis
    process should have a uniform format within an
    organisation.
    Inspection and Testing Report
    8D-Report
    Quality Report
    overview of core areas of defects
    improvement of product quality
    contribution of implemented action
    submit upon request
    NTF-Report must provide diagrams
    Version 2009.1

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    16

    Interfaces and Exchange of Information


    Reporting
    Standard Elements
    Stratification Diagram
    Pareto Diagrams
    Defect and Action Plan
    Report of Effectivness

    Version 2009.1

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    17

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