Effective Fmeas Achieving Safe Reliable And Economical Products And Processes Using Failure Mode And Effects Analysis 1st Edition Carl S Carlson - Solutions

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16.3When selecting software for doing FMEAs, it is important to consider (select all that apply):1. Ease of performing basic FMEA functionality.2. Ability to access all FMEAs in the database.3. Linkage to other quality and reliability processes.4. Users ’ familiarity with spreadsheet - based
16.2The reasons to move from use of spreadsheet - based FMEA software to a relational database include (select all that apply):1. Comprehensive query functions across FMEAs.2. The FMEA team will save in meeting and administrative time when doing multiple FMEAs.3. Multiuser environment with login
16.1A relational database is a type of database that (indicate true of false):1. Is the same as Microsoft Excel ® .2. Stores data in “ relations ” which (to the end user) are in tables with rows and columns.3. Allows data to be easily accessed from other projects that are in the same
15.11FMMEA is different from traditional FMEA in the following ways. (Select all that apply.)1. FMMEA requires each failure mode be analyzed for the underlying failure mechanism.2. FMMEA can be used to prioritize failure mechanisms for PoF models.3. FMMEA has the same output as a traditional
15.10Software FMEA procedure advises the use of precedence guidelines for solutions to software problems: (1) design out the failure mode, (2) use redundancy to achieve fault tolerance, (3) go into fail - safe mode (e.g., the ability to “ limp home ” ), (4)implement early prognostic warning,
15.9When defi ning the functions in a software FMEA, the procedure says the software should always go to the “ desired state ” no matter what causes the software to malfunction, and further says if a desired state is not identifi ed in the specifi cation, the software should always go into fail
15.8Identify which of the following statements are true about software FMEAs. (Select all that apply.)1. Many of the preparation steps for software FMEA are similar to regular FMEAs.. 2. As in traditional FMEAs, each function is analyzed for what can go wrong with the function.3. Software FMEAs
15.7Some of the possible objectives for software FMEA include . . . (Select all that apply.)1. Identifying missing software requirements.2. Writing the software code.3. Analyzing a system ’ s behavior as it responds to a request that originates from outside of that system.4. Replacing the
15.6Review the section on “ All-Terrain Bicycle Trade - off Analysis ” in Appendix C.What concept FMEAs could be done and how would these concept FMEAs help with the concept trade - off decision for the all - terrain bicycle?
15.5Review Hazard Analysis example 1 on a pressure cooker (Section 15.2.3 ), including the PHA worksheet. Answer the following questions.1. What column is missing in the PHA worksheet?2. What additional corrective or preventive measures might be considered to address the burn hazard, caused by
15.4A Hazard Analysis is . . . (Select one.)1. In reality, the same as a System FMEA.2. A Design FMEA that focuses only on high severity and high occurrence.3. A type of FMEA that focuses on safety and has its own set of scales.4. A type of FMEA that focuses on safety and uses the same scales
15.3Review the gas insulated switchgear RCM project covered in Section 15.1.7 . One of the concerns from the FMEA was SF 6 gas contamination. What failure effect consequence was identifi ed from the decision diagram? What tasks were proposed in the PM program to address this concern?
15.2Identify which of the following statements about RCM are true or false.1. A well - done equipment FMEA or series of equipment FMEAs is at the core of an RCM analysis.2. The output of an RCM project is input to an FMEA project.3. Run to failure is a valid RCM strategy in which equipment is
15.1One of the primary purposes of RCM is . . . (Select one.)1. To determine the reliability of equipment.2. To determine PM requirements and other actions needed to ensure safe and cost - effective operations of a system.3. To improve the manufacturing process.4. To develop highly reliable
14.3Review the FTA in Figure 14.4 , “ Bicycle does not stop in time, ” and answer the following questions.Question 1On the left side of the FTA there is an intermediate event “ Bicycle being ridden with misadjusted brake cable. ” If the brake cable was misadjusted at factory and the user
14.2FTA should be used . . . (Select all that apply.)1. Instead of FMEA when the team has limited time.2. When the FMEA team is analyzing a complex failure mode with many causes and would like a visual tool to show graphically the complex set of causes.3. When the FMEA team would like to
14.1In describing FTA, which of the following are true? (Select all that apply.)1. FTA begins with an already identifi ed unwanted event.2. An event is a logic symbol used in FTA that represents the relationship between fault inputs and outputs.3. The top level of the FTA is the root cause of
13.8Review Case Study 1 and Figure 13.8 , “ DRBFM worksheet of rack boot subassembly,” in Section 13.6 . One of the concerns being discussed by the DRBFM team was the hardness of the Rack Boot (with the thermoplastic elastomer) increasing from 50 to 95 Hs. The authors said, “ Participants
13.7The three elements of GD 3 are Good Design, Good Discussion, and Good Dissection.What is Change Point Analysis and where does it fi t into the GD 3 process?
13.6The analysis portion of DRBFM procedure calls for two separate steps, with the fi rst step being performed by the responsible engineer and the second step by the expert team. Which specifi c columns are fi lled out by the responsible engineer and which portion of the DRBFM procedure is done by
13.5Intentional and incidental changes need to be considered when performing DRBFM.Which of the following are within the scope of incidental changes? (Select all that apply.)1. The list of modifi cations that are being proposed to the current design2. Differences in the usage environment
13.4The following changes should be considered when doing Change Point Analysis.(Select all that apply.)1. Changes to the supplier process2. Changes to the usage environment3. Changes to the DRBFM review team4. Changes to component interfaces
13.3In DRBFM, the essence of Good Design is . . . (Select one.)1. To properly prepare for the DRBFM project.2. To examine the results of testing.3. To begin with a proven and reliable design.4. To identify and eliminate risk due to changes in design.
13.2Which of the following are good practices when doing a DRBFM project? (Select all that apply.)1. Ideally, the DRBFM project is based on a well - done FMEA, with the focus on changes and interfaces.2. The DRBFM should look at actual physical parts when discussing the changes to the
13.1Which of the following statements are true about DRBFM? (Select all that apply.)1. DRBFM uses same set of risk ranking scales as FMEA, for severity, occurrence, and detection.2. The DRBFM worksheet is identical to an FMEA worksheet, without the risk ranking scales.3. After preparation for a
12.4Perform quantitative criticality analysis on a bicycle brake lever.Input data:The brake lever has an expected life of 5 years. The bicycle reliability engineer says the brake lever will have an estimated 0.5 failures in 5 years based on failure distributions, and so on.There are two failure
12.3Mode Criticality is the product of which three factors? (Select the correct answer.)1. Severity, probability of occurrence, and probability of loss2. Expected failures, mode ratio of unreliability, and item criticality3. Failure probability, mode ratio of reliability, and expected
12.2When doing a Criticality Analysis for a FMECA, keep in mind the following (select all that apply):1. A Criticality Analysis is the same as a Risk Priority Number (RPN) calculation in FMEA procedure.2. Quantitative Criticality Analysis calculation uses the mode ratio of unreliabilityfor each
12.1The following are statements about FMECAs (select all that are true):1. FMECA adds a Criticality Analysis to FMEA, along with a different set of scales.2. There is no difference between an FMEA and a FMECA.3. FMECA is no longer used by companies as the original standard has been
11.6FMEAs can be linked to other quality and reliability tools to increase their value.Which of the following statements are true about the linkage of FMEAs to other tools? (Select all that apply.)1. Design FMEAs may identify shortcomings in the manufacturing Process Control Plans.2. Process
11.5This is the same scenario as an End of Chapter problem in Chapter 4 , with a different question at the end.The Incredible Bike Company ( IBC ) has system design, system integration, and system assembly responsibilities for the new all - terrain bicycle. They decide to use FMEAs to ensure the
11.4The following are statements relating to the question how to deal with supplier parts.(Select all that are true.)1. All supplier FMEAs should be reviewed and approved by the FMEA team according to the FMEA Quality Objectives.2. Suppliers of critical parts (deemed high risk by the project
11.3Scenario: An FMEA audit is under way. The FMEA team has omitted recommended actions for several high - risk issues in the FMEA. The FMEA auditor should . . . (Select all that apply.)1. Make note of the omission, recommend the team develop effective actions for the high - risk issues, and
11.2The following are statements about management reviewing FMEA issues. (Select all that are true.)1. It is important for management to review all failure modes, causes, and recommendations on a regular basis.2. Management should review the high - risk issues from FMEAs on a regular
11.1Management has many important roles in the successful implementation of FMEAs in their company. Which of the following are key roles for management in implementing a successful FMEA process? (Select all that apply.)1. Provides agreement on FMEA strategy and supports needed
10.9When should brainstorming be used in an FMEA? List two examples showing which elements of an FMEA that could receive benefi t from brainstorming and the circumstances that would generate the brainstorming technique for both examples.
10.8Scenario: You are assigned to facilitate a Design FMEA; however, due to heavy workload and unavailability of subject - matter experts, you have been told to do the FMEA with the design engineer. What should you do?
10.7The FMEA team has a few members who are not contributing during a discussion about potential recommended actions for a high - risk issue. What are three probing questions that the nonparticipating team members can be asked to solicit their input?
10.6The hallmarks of a good consensus process include . . . (Select all answers that apply.)1. One person who disagrees cannot hold up the team.2. Many ideas are shared.3. No one pushes a predetermined solution.4. The team compromises to get agreement.
10.5Scenario: The FMEA team is having trouble understanding the difference between a failure mode and a cause. The meeting is dragging on and on. You should . . . (Select all that apply.)1. Refer to the FMEA training material and review the defi nitions of failure mode and cause with the team.
10.4Scenario: Two people in the group you are facilitating begin shouting at one another and generally acting rude. You should . . . (Select all that apply.)1. Use your active listening skills as you know that confl ict is good and there may be important ideas being communicated, even if
10.3Scenario: You are facilitating an FMEA meeting and the group is having trouble developing effective recommended actions for a known cause. The best facilitation tool to address this scenario is . . . (Select all that apply.)1. Use confl ict management techniques to fi nd and address the
10.2Scenario: you are facilitating an FMEA meeting and two attendees are having a side conversation. You should . . . (Select all that apply.)1. Out of courtesy, allow the side conversation to continue until the two attendees have fi nished their conversation.2. Interrupt the two people who are
10.1A facilitator is one who . . . (Select all that apply.)1. Contributes structure and process to groups.2. Effectively solves the problems brought forward by the group.3. Supports the group to achieve exceptional performance.4. Acts as a tiebreaker when the group cannot come to a decision.
8.10Power Steering (Use of Design FMEA at System, Subsystem, and ComponentLevels)Review the three Design FMEA excerpts from Figure 8.25 of Section 8.10 . Although these three FMEAs are example excerpts only, with sanitized data and recommendations, they can be used as teaching examples. Answer the
8.9Resin Lever (Use of FMEA and DRBFM)Review the Resin Lever case study in Section 8.9 and the improved FMEA in Figure 8.23 . Identify two positive attributes in this FMEA.
8.7Projector Lamp (Use of Design FMEA)Study the Projector Lamp FMEA in Figure 8.17 of Section 8.7 . Analyze the FMEA in terms of quality, completeness, and adequacy. Note three specifi c defi ciencies and suggest improvements. Compare results to the teaching analysis.Case Study Problem 8.8All -
8.6Space Shuttle Challenger O - Ring Failure (Use of FMEA to Study O - Ring Failure)Review the Space Shuttle Challenger O - Ring Failure case study in Section 8.6 . Use the O - ring failure on the space shuttle Challenger as an example to practice identifying function, failure mode, effect,
8.5DC - 10 Cargo Door Failure (Use of FMEA to Study Cargo Door Failure)Review the DC - 10 Cargo Door Failure case study in Section 8.5 . Use the door latch pin failure on DC cargo door latching subsystem as an example to practice identifying function, failure mode, effect, cause, and controls based
8.4Flashlight (Use of Design FMEA with FTA)Review the Flashlight case study in Section 8.4 and the fl ow of information from FTA to FMEA in Figure 8.16 . Although this FMEA is a truncated excerpt to show the transfer of information from FTA to FMEA, it can be used as a teaching example. Suggest two
8.3Motorola Solutions “ Press - to - Talk ” Feature (Use of Design FMEA)Review the Motorola Solutions “ Press - to - Talk ” case study in Section 8.3 and the FMEA single - line excerpt in Figure 8.10 . For teaching purposes, brainstorm two other hypothetical failure modes for the PTT
8.2Strudel Pastry Manufacturing (Use of Hazard Analysis and FMEA)Review the Strudel Pastry Manufacturing case study in Section 8.2 and the FMEA/Hazard Analysis table in Figure 8.7 . Suggest two improvements that can made to this FMEA/Hazard Analysis.
8.1Shock Absorber Assembly (Use of Process FMEA)Review the Shock Absorber case study in Section 8.1 and the Process FMEA in Figure 8.2 . Suggest three improvements that can made to this PFMEA.
7.9Refer to the following example of a Process FMEA recommended action from Chapter 3 :Process Step: Apply lubrication to O - ring using lubricant gun Function: Lube O - ring with ABC lubricant, using XYZ specifi cation Failure Mode: Insuffi cient lubrication Effect: Gas leak at fi tting, with
7.8What are “ single - point failures? ” How can an FMEA team identify and address single - point failures?
7.7An FMEA team is considering how to address a high severity and high occurrence issue. Some of the team members want to reduce the severity risk with action strategies such as fail - safe and early warning. Other team members want to signifi -cantly reduce the occurrence risk using a robust
7.6Which of the following are true statements about management ’ s role in ensuring the execution of FMEA recommended actions? (Select all that apply.)1. Management needs to stay directly involved in the approval, status, and execution of all FMEA recommended actions for high severity and high
7.5Which of the following are characteristics of well - written FMEA recommended actions? (Select all that apply.)1. The name of the person on the FMEA team who recommended the action.2. The name of the person who is responsible for execution of the recommended action.3. A brief description (no
7.4Which of the following are action strategies to reduce the occurrence risk? (Select all that apply.)1. Make the design fault tolerant.2. Introduce redundancy to the design.3. Reduce stress – strength interference.4. Increase the design margin.
7.3Which of the following are action strategies to reduce the severity risk? (Select all that apply.)1. Make the design fault tolerant.2. Introduce redundancy to the design.3. Reduce stress – strength interference.4. Increase the design margin. Item/Function Potential Potential Effects)
7.2Which of the following is important input to prioritization of corrective actions?(Select all that apply.)1. All high RPN issues, regardless of whether severity is high or low2. All high severity issues, regardless of whether RPN is high or low3. All low severity issues4. All low RPN issues
7.1Figure 7.7 is an excerpt from the Brake Cable Design FMEA, with the recommended actions omitted. Study the FMEA, including severities and RPNS, and prioritize issues for corrective action. Use the Causes numbers (1, 2, 3, 4) to identify the priority sequence.
6.12An example of a function from the System FMEA of the all - terrain bicycle stated,“ The bicycle must provide safe and reliable transportation, including safe stopping distances and safe operation under all customer usage conditions as defi ned in the all - terrain technical specifi cation.
6.11Scenario: In 2011, a vehicle manufacturer announced a recall of certain models for improper routing of the vehicle ’ s power steering hose, which could lead to melting of the hose due to its close proximity to the catalytic converter. The safety concern was that the melted hose could drip
6.10A Process FMEA is being done on a pump assembly station. Widget “ A ” is a supplier part that is assembled into the pump. One of the operations being analyzed is“ inspect the length of widget ‘ A ’ to print dimension 123. ” The Process FMEA team has identifi ed the primary function
6.9Hypothetical scenario: a manufacturer of air conditioning (AC) systems is concerned about potential failures introduced during installation of the AC system at commercial or residential sites. From an FMEA standpoint, how can this concern be addressed?
6.8An FMEA is being done on a projector lamp, with a function “ Provide reliable light for image transfer at a minimum of 1000 lumens for 2000 hours of operation. ”One possible failure mode is “ lamp burns out prematurely. ” Brainstorm one other possible failure mode.For the failure mode
6.7Interfaces must be covered in the scope of an FMEA. One way to do this is to include interfaces in the FMEA Function column. Chapter 6 includes an example of an interface - type function for the interface between the all - terrain handlebar subsystem and hand brake subsystem.What document
6.6It is important to identify the primary functions in the Function column of an FMEA. There are a number of different types of functions. List three function types.
6.5Which of the following statements are true about failure mechanisms? (Select all that apply.)1. Understanding the underlying failure mechanism will help to generate effective recommendations to resolve the problem and improve the design.2. Understanding the underlying failure mechanism does
6.4Which of the following apply to prevention - type design controls? (Select all that apply.)1. Prevention - type design controls are part of the basis for determining the detection ranking.2. Prevention - type design controls describe how a cause or failure mode can be prevented based on newly
6.3FMEA teams sometimes get confused between failure mode, effect, and cause in an FMEA. Which of the following are true statements about a failure mode, effect, and cause in an FMEA? (Select all that apply.)1. The “ cause ” is the cause of the effect.2. The “ cause ” is the cause of the
6.2Which of the following is an example of an effect in the Hand Brake Subsystem Design FMEA? (Select all that apply.)1. Bicycle wheel does not slow down when the brake lever is pulled, potentially resulting in accident.2. Cable binds due to inadequate lubrication or poor routing.3. Provide the
6.1Hypothetical Scenario: A System FMEA is planned for the all - terrain bicycle.Which of the following should be included within the scope of the all - terrain System FMEA? (Select all that apply.)1. The interfaces between the bicycle subsystems2. The interactions between the bicycle and the
5.12Refer to the “ Operating Conditions ” table in Appendix C, “ All - Terrain Bicycle Documents. ” How should information like this be used in FMEA applications?
5.11Scenario: You are preparing to lead a System FMEA on the all - terrain bicycle.Review the section titled “ All - Terrain Bicycle Functional/Technical Specifi cations ”in Appendix C, “ All-Terrain Bicycle Documents. ” Answer these questions:The Front suspension has a requirement: “
5.10A Process FMEA will be done on the assembly of a fl ashlight. List six examples of information that should be gathered prior to the fi rst meeting with the FMEA team.
5.9Draw an FMEA Block Diagram for the fl ashlight. Be sure to include physical connections and energy transfers as well as interfaces.
5.8A Design FMEA will be done on the design of a fl ashlight. List six examples of information that should be gathered prior to the fi rst meeting with the FMEA team.
5.7Which of the following are important elements of good FMEA preparation? (Select all that apply.)1. The company organization structure2. Technical specifi cations of the item being analyzed with FMEA3. Schematics of all subsystems outside the scope of the FMEA4. Field history of similar items
5.6The FMEA facilitator is trying to determine when to begin holding the FMEA meetings with the subject - matter expert team. (Select all that are true.)1. Begin holding FMEA meetings as soon as the decision to do the FMEA is made.2. Begin holding FMEA meetings as soon as all the preparation
5.5The purpose of an FMEA Block Diagram is (select all that are true):1. To document the primary functions of the item.2. To document the primary failure modes of the item.3. To visually show the scope of the FMEA, including interfaces.4. To visually show the timing of the FMEA.
5.4Which of the following would usually be part of a System FMEA team? (Select all that apply.)1. Design engineer2. System engineer3. Manufacturing engineer4. Reliability or quality representative5. Director over department of items being analyzed6. System test engineer7. Service or fi eld
5.3Reference Figure 5.7 “ System FMEA block diagram example — all - terrain bicycle. ”Name three missing elements from the System FMEA Block Diagram.
5.2Which of the following are true statements about FMEA preparations? (Select all that apply.)1. Past FMEAs should be easily accessible to the FMEA team.2. Warranty, recalls, and other fi eld history are part of Failure Review and Corrective Action System ( FRACAS ) but not needed in preparation
5.1In an FMEA, which of the following are true statements about the severity, occurrence and detection scales? (Select all that apply.)1. The scales from the selected FMEA standard must be used exactly as is, without any modifi cation.2. In using the detection scale, the higher the rating on the
4.5The Incredible Bike Company ( IBC ) has system design, system integration, and system assembly responsibilities for the new all - terrain bicycle. The bicycle seat is made of a new material for comfort and durability, and the seat design is considered critical based on Preliminary Risk
4.4In the example of Preliminary Risk Assessment for the all - terrain bicycle project, one of the risk criteria columns is “ Risk identifi ed by System FMEA. ” What does this mean?
4.3Which of the following statements about the timing of Design FMEA projects are true? (Select all that apply.)1. Design FMEAs should be started before a design concept has been identifi ed and completed before product design has begun.2. Design FMEAs should be started shortly after a design
4.2Which of the following risk criteria should be considered when deciding which FMEAs to do on a given project? (Select all that apply.)1. The degree of new technology in the design.2. The cost of the piece part.3. The degree of fi eld failures on similar parts.4. The availability of potential
4.1Which of the following statements supports the rationale for FMEA selection?(Select all that apply.)1. In order to reduce risk, FMEAs must be done on every subsystem, component, and part.2. FMEAs are time intensive and should be done on items that are selected based on defi ned risk
3.10Perform the following steps as part of a hypothetical Design FMEA on an inexpensive wooden pencil:1. Assuming “ pencil system ” is the highest level of the system hierarchy, Identify and write down two additional items from the wooden pencil system hierarchy.2. For the item “ Pencil
3.9Using the AIAG (4th ed., 2008) severity scales (reference Figures 3.2 and 3.3 ), select an appropriate severity ranking for the following examples of effects:1. Item: Power steering pump Function: Delivers hydraulic power for steering by transforming oil pressure at inlet [ xx psi ] into
3.8In an FMEA, which of the following is true about “ RPN ” ? (Select the best answer.)1. An “ RPN ” is the sum of Severity, Occurrence, and Detection rankings.2. An “ RPN ” is the product of Severity and Occurrence rankings.3. An “ RPN ” is the product of Severity, Occurrence,
3.7In an FMEA, which of the following is true about a “ control ” ? (Select all that apply.)1. A “ control ” is the specifi c recommendation by the FMEA team to control the risk associated with the cause of failure.2. A “ control ” needs to be taken to the level of root cause of the
3.6In an FMEA, which of the following is true about an “ effect ” ? (Select all that apply.)1. An “ effect ” is the specifi c reason for the failure.2. An “ effect ” is the potential consequence or impact of the failure to the system or end user.3. An “ effect ” is the manner in
3.5In an FMEA, which of the following is true about a “ failure mode ” ? (Select all that apply.)1. A “ failure mode ” is the specifi c reason for the failure.2. A “ failure mode ” is the manner in which the item or assembly could fail to meet the intended function and its
3.4In an FMEA, which of the following is true about a “ function ” ? (Select all that apply.)1. A “ function ” is what the item is intended to do, without respect to any standard of performance.2. A “ function ” is what the item is intended to do, usually to a given standard of
3.3Indicate whether each statement about the application of FMEA is true or false.1. One of the uses of FMEA is to improve the reliability of the product.2. One of the uses of FMEA is to improve the safety of the product.3. FMEAs can be used to improve the quality of the manufacturing
3.2Hypothetical scenario: A hydraulic pump company is developing a new line of hydraulic pumps that has a new material for the pump piston never before used in hydraulic pumps. (Answer True or False for each of the following.)1. The current hydraulic test procedures should be used. The FMEA should

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Effective Fmeas Achieving Safe Reliable And Economical Products And Processes Using Failure Mode And Effects Analysis 1st Edition Carl S Carlson - Solutions

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