The FMEA Role on Knowledge Retention and Diffusion. Christiane Bischof dos Santos, MSc Ricardo Sales Gomes Robert Bosch Ltda.

Transcrição

1 Subsystem 1 Component A Customer System Subsystem 2 Component B Requires durability. Comply with environmental legislation. Contains green items Easy replacement possibility Component C Quebra do produto em uso. Non-durable Goods Crystalline structure unstable Component D Subsystem 3 Component E Made with recyclable plastic Material unsuitable Failure Effect Causes Failure mode Christiane Bischof dos Santos, MSc Ricardo Sales Gomes Robert Bosch Ltda. 1

2 Introduction Professionals who leave the company - much of the essential knowledge for the organization is inside the professional head, not documented neither explained. Challenge >> knowledge management resource field. On innovation projects, the volume of generated knowledge is very significant. Only a small part is properly retained. FMEA is a method that helps knowledge retention. It works based on multidisciplinary meetings, if properly moderated, can lead to a result quite rich in terms of learning and knowledge acquisition. 2

3 The knowledge on Organizations (1/2) Two distinct categories for sources of knowledge in organizations Explicit Knowledge Includes all tangible items that we call know-how, taking the form of procedures, models, algorithms, analysis and documents. Tacit Knowledge It is structured or not, the intangible elements that are inherent to individuals or community to which they belong. Coletive Coletive Individual - Knowledge embedded in models, behavior predictable and regular. - Knowledge formalized in documents or databases. - Knowledge included in systems management, design, production. - Personal skills - Talents - Knowledge of the company and contexts of decision - Knowledge of the environment (customers, competitors and socioeconomic) 3

4 The knowledge on Organizations (2/2) Nonaka suggested a model for the conversion of knowledge: From/To Tacit Explicit Tacit Socialisation Externalisation Explicit Internalisation Combination Premise: Learning is a social action. People interaction is essential to learn. 4

5 The FMEA (Failure Mode and Effect Analysis) AIAG Manual definition: It is the analytical methodology to ensure that potential problems are considered and treated during the development of products and processes. It is believed that between 70 to 80% of all potential failures could be identified already at the stage of development through its effective use. FMEA achieve excellence when they can condensate all knowledge (know-how or individual skills) that adds value to the process. A FMEA must be performed by a heterogeneous team. Risk analysis is a important result of FMEA. 5

6 Choice of Innovation Project and Methodology One of the most important limits to the generation of innovation by companies, countries and regions is the non-sharing of knowledge that remain specific and non-transferable. Lemos, C. As a case of study were used a System FMEA performed by four participants in a multidisciplinary approach, plus moderator. The chosen project is a innovation in the automotive industry. To evaluate historical data and performance were used a similar product as a comparison. This project is a significant innovation because it effectively introduces a new concept for the organization and end users. 6

7 Implementation of FMEA (1/5) Start: Preparation Definition o scope and targets Team build Product Development Eng. Validation Eng. Sales Eng. Product Design Eng. FMEA moderator, skilled and experienced Phase 1: Structural Analysis Phase 2: Functional Analysis Phase 3: Failure Analysis Phase 4: Action Analysis Phase 5: Optimization 7

8 Implementation of FMEA (2/5) Phase 1: Structural Analysis Subsystem 1 Component A Component B Customer System Subsystem 2 Component C Component D Subsystem 3 Component E 8

9 Implementation of FMEA (3/5) Phase 2: Functional Analysis Subsystem 1 Component A Component B Customer Requires durability. Comply with environmental legislation. System Contains green items Subsystem 2 Easy Recycle replacement is possible possibility Component C Component D Subsystem 3 Component E Made with recyclable plastic More detail to ensure the final quality to the customer. 9

10 Implementation of FMEA (4/5) Phase 3: Failure Analysis Subsystem 1 Component A Customer Requires durability. Comply with environmental legislation. Do not comply with env. Quebra regulations do produto em uso. System Subsystem 2 Contains green items Easy Recycle replacement is possible possibility Non-durable Item not green Goods Crystalline Recycle structure is not possible unstable Component B Component C Component D Subsystem 3 Component E Made with recyclable plastic Material unsuitable Failure Effect Failure mode Causes 10

11 Implementation of FMEA (5/5) Phase 4: Action Analysis Actions that could avoid the cause, or in case of occurrence, how to detect it. Actions to detect a failure, during development phase. Phase 5: Optimization Evaluation of actions and evaluation of risks. Can be done into the FMEA form with phase 4. In this phase discussions are fundamental. Moderator must point the critical risks and evaluate proposed actions. It is fundamental that all participants have a general view of the evaluated process. In order to propose effective actions, preventive focus. 11

12 Results Socialization and Combination are present in all phases of FMEA Team integration is mandatory for a good knowledge diffusion and retention Skilled moderator is the key to make the team go deep into analysis Externalization were also present during Actions and Optimization phases of FMEA Team became multi competent. Internalization of discussed subjects allowed them to get knowledge of other fields of knowledge. Combination of documents provided explicit knowledge presentation. This result is not measurable. 12

13 Conclusion Systematic utilization of FMEA allows its utilization as a efficient tool to help on decision process. FMEA is an important source of knowledge for the future users. FMEA application can be used in all stages of a innovation project. The techniques of knowledge management may be appropriate for the development stages of FMEA with this condition be properly conducted by experienced moderator who follow a system that allows uniform application as is suggested by VDA guideline. 13