Table of Contents for Power of Deduction : Failure Modes and Effects Analysis for Design


List of Figures and Tables
viii
Preface xi
Chapter 1 Important Ideas About DFMEA
1(14)
Some Basic Vocabulary
1(2)
A Bit of History
3(2)
Typical Approaches
5(10)
The First Common Problem: Forcing DFMEA without Supporting the Method
5(4)
The Second Common Problem: Adopting a "Form" Mentality
9(2)
The Third Common Problem: Blaming Manufacturing for Everything
11(1)
The Fourth Common Problem: After-the-Fact Detection
11(4)
Chapter 2 The Right Way to Use DFMEA
15(26)
The Basic Methodology: Inputs
16(4)
The Basic Methodology: The Process
20(1)
The Basic Methodology: Outputs
21(2)
The Story of the Wright Brothers
23(4)
The Chain of Verification: FMEA and Design Systems
27(9)
The Apollo I Accident
36(5)
Background
36(1)
The Capsule
37(1)
The Accident and the Aftermath
38(3)
Chapter 3 Step 1---Define the Project
41(26)
Starting Out---Understanding Scope
42(3)
Creating Block Diagrams
45(11)
A Short Block Diagram Example: The Clamshell Phone
46(5)
An Even Shorter and Less Complex Example: Suspension Trailing Arm
51(3)
Special Team Issues: Alignment with Project Complexity
54(2)
Developing "Fit for Use" Statements of Function: Robustness and P-Diagrams
56(9)
Starting the Main Worksheet
65(2)
Chapter 4 Step 2---Understanding Function
67(20)
The Language of Function
69(3)
Putting the Pieces Together: The Deductive Interface Matrix
72(12)
Developing Skill with Interface Matrix Techniques
80(2)
Creating Boundary Diagrams
82(2)
Specification Development
84(3)
Chapter 5 Step 3---Deduce Failure Modes
87(14)
Foundational Assumptions
87(2)
Definition of "Failure Mode"
89(2)
Developing Failure Mode Descriptions: The Failure Mode Worksheet
91(5)
Looking at an Example: The Trailing Arm Weldment
96(1)
A Few Good Tips: Getting Better Results
97(4)
Chapter 6 Step 4---Effects and Severity
101(18)
Understanding Effects---and Cause-and-Effect Relationships
102(4)
Don't Let Complexity Overwhelm Analysis
106(4)
"Customer Dissatisfied" Is Not an Acceptable Effect
110(1)
Another Pitfall: Too Much "What If" Thinking
111(1)
Technique Considerations for Effect-Severity Analysis
112(1)
Understanding and Rating Severity
113(3)
Summing Up: Step 4
116(3)
Chapter 7 Step 5---Causes and Occurrences
119(20)
Dealing with Multiple Causal Factors
122(3)
Understanding Occurrence
125(5)
Self-Deception About Occurrence
130(3)
Techniques for Cause and Occurrence Analysis
133(3)
Summing Up: Step 5
136(3)
Chapter 8 Step 6---Controls and Detection
139(12)
Why Prevention Controls Are Important
141(5)
Rating Detection
146(1)
Techniques for Control and Detection Analysis
147(1)
Summing Up: Step 6
148(3)
Chapter 9 Step 7---Assessing and Addressing Risk
151(18)
Risk Priority Number
152(2)
Classification and Characteristics Designation
154(4)
Classification
154(2)
Identification and Designation of Characteristics
156(2)
Recommended Actions
158(4)
Reducing Severity
158(2)
Reducing Occurrence
160(1)
Improving Detection
161(1)
Action Planning
162(3)
Summing Up: Step 7
165(4)
Chapter 10 Using DFMEA Constructively
169(18)
Special Characteristic Listings
169(2)
Designated Characteristics in Validation and Process Control
171(3)
Recording Action Plan Results
174(1)
Legal and Ethical Issues
175(6)
"Living Document" Issues
181(3)
Updating DFMEA Worksheets
181(1)
Creating a DFMEA Template Library
182(1)
Using DFMEA As an Aid in Problem Solving
183(1)
Final Thoughts
184(3)
Bibliography 187(2)
Index 189