You are an engineer reviewing the production line for a great new smoke alarm. The following...
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You are an engineer reviewing the production line for a great new smoke alarm. The following is an extract of the FMEA that has been conducted on the product and you have been tasked with reviewing production costs and the safety of the product. System Subsystem Component Design Lead ore Team Item/Function Sensor A Alarm component Alarm housing Design Verification Process Shay Isaac See Project III R1 Report Potential Failure Mode(s) Not correctly calibrated Insufficien t volume Alarm cover breaks at first removal Potential Fifact(s) of Fallure Faulty fire KHTIXOT Faulty fire sensor Potential Cause(s) Mechanism(s) of Failure 9 thuman error Sev 8 Faulty component Replacement 3 Incorrectly housing required cast housing Potential Failure Mode and Effects Analysis (Design FMEA) Key Dute Occ Current Design Controls 1 Training and verification of tasting 1 Inspection Det 3 4 4 Inspection 2 RPN Recommende d Action(s) 54 Purchase specialised calibration tool 45 Investigate alternative alarm component 24 Negotiate quality with supplier Responsibility & Target Completion Dute Your investigations have led to 2 options for improving the products FMEA Number Project III Prepared By Sylvia Wu FMEA Date Revision Date Currently the product has the following (simplified) cost and revenue components: • The wholesale price of each sensor is $75 • The company has a contract to sell 24 000 units per year. • The company spent $350 000 to design this particular mechanism. They invested $1 million in setting up for production. . The production cost is $62 per unit Page 1 Actions Takan 22/10/2020 21/08/2021 Action Results New Sev New Occ New Det New RPN Your investigations have led to 2 options for improving the products Option A: You source a calibration unit for Sensor A which costs $235 000 and will increase the rate at which you detect the problem. You believe this will reduce the "Detection" value in the FMEA analysis for the Sensor A to a value of 2. Option B: You can change the manufacturer of the alarm housing to one with better quality casting. This will reduce the "Occurrence" of the problem of the alarm housing breaking at first removal to a a value of 3 but will cost an additional $0.50 per unit. Answer the following questions: 1. For Option A, how long will it take to break even? (Answer in years to 2 decimal places) 2. For Option A, what is the new RPN for the Sensor A failure listed? 3. For Option B, how long will it take to break even? (Answer in years to 2 decimal places) 4. For Option B, what is the new RPN for the Alarm housing failure listed? 5. Which option will you suggest to your manager? (A or B) Justify your answer (You can consider the costs, revenue, breakeven, the FMEA, improved safety etc. for your answer but you must to select one of the options and give a justification for this based on the factor you think is most significant as an engineer giving a recommendation.) You are an engineer reviewing the production line for a great new smoke alarm. The following is an extract of the FMEA that has been conducted on the product and you have been tasked with reviewing production costs and the safety of the product. System Subsystem Component Design Lead ore Team Item/Function Sensor A Alarm component Alarm housing Design Verification Process Shay Isaac See Project III R1 Report Potential Failure Mode(s) Not correctly calibrated Insufficien t volume Alarm cover breaks at first removal Potential Fifact(s) of Fallure Faulty fire KHTIXOT Faulty fire sensor Potential Cause(s) Mechanism(s) of Failure 9 thuman error Sev 8 Faulty component Replacement 3 Incorrectly housing required cast housing Potential Failure Mode and Effects Analysis (Design FMEA) Key Dute Occ Current Design Controls 1 Training and verification of tasting 1 Inspection Det 3 4 4 Inspection 2 RPN Recommende d Action(s) 54 Purchase specialised calibration tool 45 Investigate alternative alarm component 24 Negotiate quality with supplier Responsibility & Target Completion Dute Your investigations have led to 2 options for improving the products FMEA Number Project III Prepared By Sylvia Wu FMEA Date Revision Date Currently the product has the following (simplified) cost and revenue components: • The wholesale price of each sensor is $75 • The company has a contract to sell 24 000 units per year. • The company spent $350 000 to design this particular mechanism. They invested $1 million in setting up for production. . The production cost is $62 per unit Page 1 Actions Takan 22/10/2020 21/08/2021 Action Results New Sev New Occ New Det New RPN Your investigations have led to 2 options for improving the products Option A: You source a calibration unit for Sensor A which costs $235 000 and will increase the rate at which you detect the problem. You believe this will reduce the "Detection" value in the FMEA analysis for the Sensor A to a value of 2. Option B: You can change the manufacturer of the alarm housing to one with better quality casting. This will reduce the "Occurrence" of the problem of the alarm housing breaking at first removal to a a value of 3 but will cost an additional $0.50 per unit. Answer the following questions: 1. For Option A, how long will it take to break even? (Answer in years to 2 decimal places) 2. For Option A, what is the new RPN for the Sensor A failure listed? 3. For Option B, how long will it take to break even? (Answer in years to 2 decimal places) 4. For Option B, what is the new RPN for the Alarm housing failure listed? 5. Which option will you suggest to your manager? (A or B) Justify your answer (You can consider the costs, revenue, breakeven, the FMEA, improved safety etc. for your answer but you must to select one of the options and give a justification for this based on the factor you think is most significant as an engineer giving a recommendation.)
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1 For Option A how long will it take to break even Answer in years to 2 decimal places Th... View the full answer
Related Book For
Managerial Decision Modeling with Spreadsheets
ISBN: 978-0136115830
3rd edition
Authors: Nagraj Balakrishnan, Barry Render, Jr. Ralph M. Stair
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