About the speaker: John Lindland has 35 years of applied experience in failure mode and effects analysis, quality methods, applied statistics, and root cause analysis.  ASQ has awarded John with two Cecile C Craig Awards.  The first was for The Dynamic Cost of Quality Model.  The second was for defining Error-proofing and Mistake-proofing.  Error-proofing/mistake-proofing became the basis for The Seven Failure Modes 7FM which was his first book (2007).  John worked at Ford Motor Company.  He was a Director of Quality over a multi-facility plastics supplier to the OEM.  Then he spent 21 years as an international consultant with Ford, GM, Chrysler, Samsung, Dow Chemical, Lockheed Martin, the US Army, The National Science Foundation, The FAA, and a large number of the other top companies as his clients.  John returned to industry to by joining Fiat Chrysler Automobiles as a Master Black Belt and the Global DFMEA lead.  7FM became their global approach.  Their first full vehicle that went through 7FM was the 2017 Chrysler Pacifica.  It launched in 3 year (concept to validation) at a 60% lower problem rate than any competitor.  The launch included the electrified PHEV powertrain.  It is the most award winning vehicle in its class four years since it launched.  John was on FCA’s Functional Safety Steering committee and working group for four years.  He was a senior principle quality engineer with Raytheon, a Director of Functional Safety and Quality with TuSimple (Level 4 Autonomy).  He currently returned to consulting and is proud to be the VOC chair with the Phoenix ASQ chapter.

This 7FMEA topic was an applied systems level design and covered:

  • The hierarchy of functions (super system, system, assembly, component)
  • Categories of physical functions
  • Categories of micro controller functions
  • The physics of the function
  • The 7FM Functional Block Diagram: How to model the system
  • The seven failure modes
  • The Temporal Fault State Map: Adding the failure modes to the 7FM Functional Block Diagram
  • A brief overview of
    • Prevention-Cause,
    • Failure Mode-Fault Detection,
    • Effects, and Detection
  • A brief overview of Severity, Occurrence, and Detection
  • An overview of Matrix FMEA
    • Inputs
    • Design Elements
    • Causes and Degradation Factors
    • Functions – Intended Outputs
    • Primary Failure Modes
    • Effects – Unintended Outputs
    • How to prioritize the design
    • How to prioritize function-based testing, fault injection testing, and failure-based testing
    • How to prioritize design changes
    • Matrix FMEA as a living document

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At the October meeting, the discussion topic was Ishikawa (Fishbone) Diagrams, a type of cause and effect diagram. Common areas of focus include:

  • Human Factors or People
  • Methods or Processes
  • Environment
  • Measurement
  • Materials
  • Machines/Tools and Maintenance

Discussion included how leadership, policy, and biases play a role as causes. Have you ever used an Ishikawa Diagram to prevent a problem rather than react to a problem?