Excel Sheet Download 28021

Partial file snippet.

Sheet 1: FWI

	
	
	
	
		
		Author:
Insert company logo by replacing this logo.
		

		Reverse FMEA
		

	
	
		

		[DOCMENT CODE/ REVISION]
		

	
	
		

		Form work instruction
		

	
	
		

		

		

	
	
		

		0. General
		

	
	
		

		

		

	
	
		

		The goal of this form is to facilitate the implementation of R FMEA by follwing the following steps:
		

	
	
		

		Plan your study
		

	
	
		

		Realize analysis
		

	
	
		

		Prepare analysis - review operations list, prepare questionaires by using actual identified failure modes.
Place: Meeting room
		

	
	
		

		Perform analysis - test the workstation!
Place: Workstation
		

	
	
		

		Perform process observation
Place: Workstation
		

	
	
		

		Debate and conclude
		

	
	
		

		

		

	
	
		

		Report R FMEA Activity
		

	
	
		

		Use activity report to document R FMEA related activities.
		

	
	
		

		R FMEA activity report
		

	
	
		

		

		

	
	
		

		1. Content
		

	
	
		

		

		

	
	
		

		1.1 Planning
		

	
	
		

		This section is used to plan and follow R FMEA implementation.
		

	
	
		

		
 
		
		

	
	
		

		

	
	
		

		

		

	
	
		

		

		

	
	
		

		(1): line identification (workcell, machine or similar)
		

	
	
		

		(2): Planned day
		

	
	
		

		(3): Actual day (when the review was performed)
		

	
	
		

		

		

	
	
		

		(1): line identification (workcell, machine or similar)
		

	
	
		

		(2): Planned day
		

	
	
		

		(3): Actual day (when the review was performed)
		

	
	
		

		

		

	
	
		

		By clicking on Line name (for example F1608) you will go to operations list.
		

	
	
		

		

		

	
	
		

		For each line operations are available as dropdown list for planning:
		

	
	
		

		

		

	
	
		

		
 
		
		
	
		

		
	
		

		
	
		

		
	
		

		
	
		

		
	
		

		
	
		

		
	
		

		

		

	
	
		

		When planning or updating status you will need to select the operation - (1).
		

	
	
		

		

		

	
	
		!
		If the line is planned to be stopped R FMEA will be planned for in-station review and not for observation.
		

	
	
		

		

		

	
	
		

		Document your R FMEA team in this section:
		

	
	
		

		R FMEA Local Team
		

	
	
		

		

		

	
	
		

		On-site P FMEA review
		

	
	
		

		

		

	
	
		

		1. check Process FMEA vs. Flow chart in workshop.
		

	
	
		

		Create/ update operations list.
		

	
	
		

		

		

	
	
		

		2. Document actual failure modes from P FMEA
		

	
	
		

		Use Operation CheckList
		

	
	
		

		Check actual controls effectiveness.
		

	
	
		

		Try to indentify new failure modes.
		

	
	
		

		- initial checklist preparation - use brainstorming to find new failures
- go in the process and:
     - check control effectiveness
     - check failure modes
     - try to think about other faillure possibilities
		

	
	
		

		

		

	
	
		

		There are 2 possibilities to work with this form when you prepare and update operation checklist:
		

	
	
		

		(1) - document each operation in a separate sheet
		

	
	
		

		Operation Checklist
		

	
	
		

		(2) - document operation by using Process CheckList (all operations in one sheet)
		

	
	
		

		Process CheckLIst
		

	
	
		

		

		

	
	
		

		(1) Operations checklist
		

	
	
		

		
 
		
		

	
	
		

		(1) - operation number and name
		

	
	
		

		(2) - R FMEA team
		

	
	
		

		(3) - Potentia failure mode analysis
		

	
	
		

		() - identififed failure mode [HOW]: describe here how it can occurs based on workstation review.
		

	
	
		

		() - if it can occurs, defines how it can be detected or prevented, if prevention is installed.
		

	
	
		

		(4) - defines where the failure mode is detected or prevented (at workstation/ downstream or no detection)
		

	
	
		

		

		

	
	
		

		-review in room P FMEA, prepare the preliminary list by thinking about other failure modes (use brainstorming)
		

	
	
		

		- review the workstation, try to find other failure modes then document in the list
		

	
	
		

		

		

	
	
		

		Review results will be transferred as conclusion in work station evaluation.
		

	
	
		

		

		

	
	
		

		(2) Process checklist
		

	
	
		

		

		

	
	
		

		
 
		
		
	
		

		
	
		

		

		

	
	
		

		The logic is same as for (1) Operations checklist. Difference is that all operations are centralized in the same sheet.
		

	
	
		

		

		

	
	
		

		3. Observe the process
		

	
	
		

		With your team go and see the process. Write down your remarks by using:
		

	
	
		

		Observation form.
		

	
	
		

		- see how the process is going
		

	
	
		

		- write what is happening in the workstation by using the form:
		

	
	
		

		

		

	
	
		

		
 
		
		

	
	
		

		

	
	
		

		

	
	
		

		(2) - workstation and line/ process
		

	
	
		

		(3) - FMEA study
		

	
	
		

		

		

	
	
		

		(4) - Observations/ Time
		

	
	
		

		(4.1) - write what you have remarked during observation of the process
		

	
	
		

		(4.2) - time (duration in seconds or other time unit)
		

	
	
		

		(5) - count each occurence with | 
		

	
	
		

		(6) - total count of occurences
		

	
	
		

		(7) - number of observed cycles
		

	
	
		

		

		

	
	
		

		Results of observations will be transferred as conclusion in work station evaluation.
		

	
	
		

		

		

	
	
		

		4. Final conclusions
		

	
	
		

		Discuss your remarks during a short meeting then document your conclusions in the final form.
		

	
	
		

		Rank the operation accordingly following matrix:
		

	
	
		

		

		

	
	
		

		
 
		
		

	
	
		

		Use the following sections according your implementation:
		

	
	
		

		- workstation assesment
		

	
	
		

		- process view:  check list assesment
		

	
	
		

		

		

	
	
		

		Template by:
		
	
		

		This free template comes without any warranty for the user.
		

	
	
		

		If there are software modules, functions, classes used it comes without any warrany for the user.
		

	
	
		

		
 
		
		

	
	
		

		

	
	
		

		

	
	
		

		

	
	
		

		

	
	
		

		according GNU GPL V3 license
		

	

 
 
 




Sheet 2: Planning

	
	
	
	
	
		
 
		
		

		Planning| Reverse FMEA (Automotive Process Lines)
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		

		

		[DOCUMENT NUMBER]/[REVISION]
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		

		

		

		Company name:
		

		

		Site:
		

		

		Date:
		Monday, March 01, 2021
		

		

		P
		Planned
		

		

		E
		Realized
		

		

		S
		Line stopped
		

		

		R    Replanificat
	
	
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		A se nota motivul în câmpul observații.
	
	
		Team
		
		Author:
Click pentru a accesa secțiunea operații
		Line/
		2021
Weeks >>
		WK1
		WK6
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		Observatii
	
	
		Operation
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		L
		M
		M
		J
		V
		
	
		Local Team
		Line
		Operation >>
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Injection
		Planned
		

		P
		P
		P
		P
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Realized
		

		E
		E
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		
	
		Local Team
		Line
		Operation >>
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Assembly
		Planned
		

		

		

		

		

		

		

		

		P
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Realized
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		
	
		Local Team
		Line
		Operation >>
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Machining
		Planned
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Realized
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		
	
		Local Team
		Line
		Operation >>
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		General
		Planned
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

	
	
		Realized
		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		



Sheet 3: OperationsList

	
	
	
	
	
	
	
	
	
	
		

		

		

		

		

		

		

		

		

	
	
		

		R FMEA Planning|Operations List(Process steps)
		

		

	
	
		

		

		

		

		

		

		

		

		

	
	
		

		[PLANT] Processes
		
	
		

		Injection
		Assembly
		Machinining
		
		Author:
Replace it with your own process.
		Generic process
		
	
		

		Number
		Description
		Number
		Description
		Number
		Description
		Number
		Description
	
	
		

		10
		Raw material incoming inspection
		10
		

		10
		

		10
		Operation 1
	
	
		

		20
		Raw material stockage& identification in Warehouse
		20
		

		20
		

		20
		Operation 2
	
	
		

		30
		Mould preparation &setting parameters
		30
		

		30
		

		30
		Operation 3
	
	
		

		40
		Injection
		40
		

		40
		

		40
		Operation 4
	
	
		

		50
		Packaging
		50
		

		50
		

		50
		Operation 5
	
	
		

		60
		Products transfer in warehouse
		60
		

		60
		

		60
		Operation 6
	
	
		

		..
		..
		70
		

		70
		

		70
		Operation 7
	
	
		

		

		

		

		

		

		

		

		

	
	
		

		

		Go to CheckList

The words contained in this file might help you see if this file matches what you are looking for:

...Sheet fwi author insert company logo by replacing this reverse fmea form work instruction general the goal of is to facilitate implementation r follwing following steps plan your study realize analysis prepare review operations list questionaires using actual identified failure modesplace meeting room perform test workstation place process observationplace debate and conclude report activity use document related activities content planning section used follow line identification workcell machine or similar planned day when was performed clicking on name for example f you will go each are available as dropdown updating status need select operation if be stopped instation not observation team in local onsite p check vs flow chart workshop create update modes from checklist controls effectiveness try indentify new initial preparation brainstorming find failures control think about other faillure possibilities there with a separate all one number potentia mode identififed describe here how...

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Author: Insert company logo by replacing this logo.	Reverse FMEA
	[DOCMENT CODE/ REVISION]
	Form work instruction

	0. General

	The goal of this form is to facilitate the implementation of R FMEA by follwing the following steps:
	Plan your study
	Realize analysis
	Prepare analysis - review operations list, prepare questionaires by using actual identified failure modes. Place: Meeting room
	Perform analysis - test the workstation! Place: Workstation
	Perform process observation Place: Workstation
	Debate and conclude

	Report R FMEA Activity
	Use activity report to document R FMEA related activities.
	R FMEA activity report

	1. Content

	1.1 Planning
	This section is used to plan and follow R FMEA implementation.




	(1): line identification (workcell, machine or similar)
	(2): Planned day
	(3): Actual day (when the review was performed)

	(1): line identification (workcell, machine or similar)
	(2): Planned day
	(3): Actual day (when the review was performed)

	By clicking on Line name (for example F1608) you will go to operations list.

	For each line operations are available as dropdown list for planning:










	When planning or updating status you will need to select the operation - (1).

!	If the line is planned to be stopped R FMEA will be planned for in-station review and not for observation.

	Document your R FMEA team in this section:
	R FMEA Local Team

	On-site P FMEA review

	1. check Process FMEA vs. Flow chart in workshop.
	Create/ update operations list.

	2. Document actual failure modes from P FMEA
	Use Operation CheckList
	Check actual controls effectiveness.
	Try to indentify new failure modes.
	- initial checklist preparation - use brainstorming to find new failures - go in the process and: - check control effectiveness - check failure modes - try to think about other faillure possibilities

	There are 2 possibilities to work with this form when you prepare and update operation checklist:
	(1) - document each operation in a separate sheet
	Operation Checklist
	(2) - document operation by using Process CheckList (all operations in one sheet)
	Process CheckLIst

	(1) Operations checklist

	(1) - operation number and name
	(2) - R FMEA team
	(3) - Potentia failure mode analysis
	() - identififed failure mode [HOW]: describe here how it can occurs based on workstation review.
	() - if it can occurs, defines how it can be detected or prevented, if prevention is installed.
	(4) - defines where the failure mode is detected or prevented (at workstation/ downstream or no detection)

	-review in room P FMEA, prepare the preliminary list by thinking about other failure modes (use brainstorming)
	- review the workstation, try to find other failure modes then document in the list

	Review results will be transferred as conclusion in work station evaluation.

	(2) Process checklist




	The logic is same as for (1) Operations checklist. Difference is that all operations are centralized in the same sheet.

	3. Observe the process
	With your team go and see the process. Write down your remarks by using:
	Observation form.
	- see how the process is going
	- write what is happening in the workstation by using the form:




	(2) - workstation and line/ process
	(3) - FMEA study

	(4) - Observations/ Time
	(4.1) - write what you have remarked during observation of the process
	(4.2) - time (duration in seconds or other time unit)
	(5) - count each occurence with \|
	(6) - total count of occurences
	(7) - number of observed cycles

	Results of observations will be transferred as conclusion in work station evaluation.

	4. Final conclusions
	Discuss your remarks during a short meeting then document your conclusions in the final form.
	Rank the operation accordingly following matrix:


	Use the following sections according your implementation:
	- workstation assesment
	- process view: check list assesment

	Template by:
	This free template comes without any warranty for the user.
	If there are software modules, functions, classes used it comes without any warrany for the user.





	according GNU GPL V3 license


R FMEA Planning\|Operations List(Process steps)

[PLANT] Processes
Injection		Assembly		Machinining		Author: Replace it with your own process. Generic process
Number	Description	Number	Description	Number	Description	Number	Description
10	Raw material incoming inspection	10		10		10	Operation 1
20	Raw material stockage& identification in Warehouse	20		20		20	Operation 2
30	Mould preparation &setting parameters	30		30		30	Operation 3
40	Injection	40		40		40	Operation 4
50	Packaging	50		50		50	Operation 5
60	Products transfer in warehouse	60		60		60	Operation 6
..	..	70		70		70	Operation 7

	Go to CheckList

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