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Quality Planning (AQP) Process Failure Mode Effects Analysis (PFMEA) Statistical Process Control (SPC), Process Capability Analysis, and Measurement Systems Analysis (MSA) Workplace Organization and Occupational Safety |
Products Technical presentation slides and accompanying notes as pdf files, some with supplementary material such as Excel spreadsheets.
Modified DD2977: A Simple Alternative to FMEA $50 (single user license) This is a 65 slide overview of adaptation of the Army's DD2977, Deliberate Risk Assessment Worksheet, to process failure mode effects analysis (PFMEA); it is essentially "FMEA for people who don't want to do FMEA and are not required to do so." DD2977 itself is in the public domain as a publication of the U.S. Government, and the instructions and risk table occupy only two pages. DD2977 can be adapted to reflect the prevention and detection controls that are cited by traditional PFMEA, and the risk table does not have the drawbacks of the risk priority number (RPN) which is the product of three ordinal numbers. DD2977 does, like FMEA, require actions to reduce identified risks along with documentation of the actions taken. This makes DD2977 a viable alternative to PFMEA for applications of relatively low complexity when contractual and regulatory requirements do not require a formal PFMEA. Process Failure Mode Effects Analysis and Control Plan $75 (single user license) This is a 93 slide overview of advances in process failure mode effects analysis (PFMEA) per the Automotive Industry Action Group's (AIAG's) and German Association of the Automotive Industry (VDA) and also of control plans that can be appended to PFMEAs to create dynamic control plans. The new seven step process is logical and straightforward, and includes major advances over the previous method. (1) The Occurrence rating is now
based on the nature of the Prevention controls (administrative or
engineering controls, also known as behavioral and technical controls,
with the latter being superior) that disable the failure cause
(formerly known as the failure mechanism).
(2) The Risk Priority Number (RPN) has the serious drawback of being the product of three ordinal numbers. Consider for example two failure modes, one with Severity 4, Occurrence 5, and Detection 10, and the other with S=10, O=5, and D=4. The first will occur relatively frequently but can, at most, annoy customers. The second will occur less frequently but can kill customers, so the second's priority far outweights the first's even though both have RPN=200. The RPN has been replaced by an Action Priority of High, Medium, or Low which depends on the Severity, Occurrence, and Detection ratings with Severity having the greatest weight and Detection the least. An Occurrence rating of 1 (best possible, the failure mode cannot happen) earns an Action Priority of Low regardless of the other two ratings. Complete utlization of this material requires the tables in the AIAG/VDA manual which must be purchased from AIAG. Recommended reference for prevention and detection controls: Shingo, Shigeo. 1986. Zero Quality Control: Source Inspection and the Poka-Yoke System. . Statistical Process Control (SPC), Process Capability Analysis, and Measurement Systems Analysis (MSA) Process Capability and Process Performance $50 (single user license) This is a 47 slide presentation (in pdf format with accompanying notes) on process capability and process performance assessment. It adds the consideration of Ppk calculation for non-normal distributions, a topic that is rarely covered in traditional references. An Excel spreadsheet contains the data used in the examples so purchasers can try it in their own statistical software packages. Workplace Organization and Occupational Safety 6S: 5S + Safety $50 (single user license) 5S is the workplace organization program that comes from the Japanese words for clearing up, arranging, neatness, discipline, and ongoing improvement. The 6th S adds workplace safety and supports the ISO 45001 standard for occupational health and safety (OH&S) standard. This downloadable set of PowerPoint slides and notes (pdf format, includes slides from an online webinar presented by Levinson Productivity Systems plus accompanying notes and references) provides an overview of 6S 5S_preview ISO 45001 Overview $50 (single user license) ISO 45001:2018 is an international standard for occupational health and safety (OH&S) management systems. This is a pdf copy of a 1-hour PowerPoint overview including the slides and accompanying notes, and an appendix on the Army’s Hazard Identification and Risk Assessment (HIRA) process. Levinson Productivity Systems P.C. |