The Story of FMEA Implementation
Advance FMEA implementation and Problem Solving process in Indonesia Chemi-con
Introduction
Indonesia Chemi-con is an electronic part manufacturing which more focus on capacitor production. This company is own by Japan Chemi-con which speciality on electronics parts mostly capacitor. Indonesia Chemi-con was establish in jan 1993 for production of electrolytic capacitors.
Indonesia Chemi-con was certified company to IATF 16949 which the implementation of FMEA and problem solving become mandatory. The input from management is focus on how to make FMEA become a living document and linked to the problem solving for the capability on reduce the occurences.
The Advance FMEA and Problem-Solving Workshops
FMEA basically risk management process which the risk is measured by RPN (Risk Priority Number) . RPN is consist of severity, occurrences and detection.
The main activities of the workshops is to reduce the occurrences and identify the failure, cause of failure, and error which leading to the failure which affecting the number of occurrences. The workshops is more focus in Gemba to learning to understand the failure, the causes and the error that lead the causes.
The workshops were learning on how to use stratification in Gemba, such as simply identify the problem, stratify the problem based on machine, parts and other analysis lead such as which spindle contribute more, which sub process contribute more, which area could be more affected. All these activities are done directly in the machine.
The problem solving continue with identify the suspected causes by using fish bone diagram. The analysis will lead to what causes /factors and how to verify that the causes is significantly affecting the effect.
On the other side, the RPN also could be reduce by implementing the detecting process. The best detection method is to detect the error before product is made, where the least favorable method is to detect the reject after leaving the station.
Finally, the workshops is close by development the problem solving report, and team learning more deeper on finding the root cause and how to update the action result on the FMEA document