Of course, carrying out PFMEA does not end work on the development of the process. An obligation is, for example, to conduct risk analysis reviews. The article discusses the most important elements of the little-known RPFMEA method.
Reverse PFMEA is still a little known analysis in Poland, the name of which is usually translated as reversed PFMEA. The course itself has not yet received standardized international descriptions (e.g. authorized by ISO or IATF), but its conduct can be based on the QSB + standard issued by GM and PSA.
The primary goal of RPFMEA is to reassess the topicality of the previously conducted process analysis. During the RPFMEA, errors, causes, effects, preventive and control actions as well as SOD scores are confirmed as defined in the PFMEA. It is, like the regular PFMEA analysis, the work of an interdisciplinary team, which is based on the observation of the production line and the so-called related documents such as: process flow diagram, job instructions, process monitoring records, etc.
The essence of the RPFMEA analysis can be checked up to four points:
An important principle of conducting the RPFMEA analysis is the participation of at least one “external” person, ie a person who was not involved in the PFMEA of the examined process and may not even know it. The role of such a person is to identify new risks to “fresh”, which is to lead to an even better “sealing” of individual phases of the process. The role of the maintenance department representative cannot be overestimated (employees of the Maintenance Office, also outside RPFMEA, are more and more often involved in risk analyzes ) – he is to ensure that the team does not damage the process equipment during the experiments.
And the last feature of working with Reverse PFMEA – because it is a form of audit, it should also look like organizational. The QSB + standard referred to at the beginning requires a detailed schedule of RPFMEA analyzes to be developed, ensuring that all processes will be audited within a specified period. In order to standardize the approach, a checklist should also be developed, thanks to which all the questions that are important from the point of view of risk analysis assessment will be asked each time – this document, after being completed, later acts as a report, so important for each audit.
Mikołajczyk J., The use of FMEA analysis in the modern concept of maintenance – RCM, “Zeszyty Naukowe Politechniki Poznańskiej” 2013, No. 61.
Tomasz Greber [PROQUAL]