You are an engineer reviewing the production line for a great new smoke alarm. The following is an extract of the FMEA that has been conducted on the product and you have been tasked with reviewing production costs and the safety of the product. Design Verification Process System Subsystem Component Potential Failure Mode and Effects Analysis (Design FMEA) FMEA Number Project III Prepared By Sylvia Wu FMEA Date 22/10/2020 Revision Date 21/08/2021 Design Lead Key Dute Shay Isaac See Project Ill R1 Report Core Team Page of 6 Action Results Item Function Potential Filc( of Failure Faulty fire Card Design Controls Occ Sev a Potential Causes Mechanism of Failure 9 Human error Det RPN Actions Taken Recommende d Actions Potential Failure Models Not Correctly calibrated Responsibility & Target Completion Date New Det New RPN Sensor A 1 Training and 3 verification of testing 4 Alarm component Insufficien t volume Faulty fire Sensor 54 Purchase specialised calibration tool 45 lavestigate alternative alarm component 8 Faulty 1 Inspection 4 component Alarm housing Alarm cover Replacement housing required 3 Incorrectly cast housing 4 Inspection 2 24 Negotiate quality with supplier breaks at first removal Currently the product has the following (simplified) cost and revenue components: The wholesale price of each sensor is $75 The company has a contract to sell 24 000 units per year. The company spent $350 000 to design this particular mechanism. They invested $1 million in setting up for production. The production cost is $62 per unit Your investigations have led to 2 options for improving the products Your investigations have led to 2 options for improving the products Option A: You source a calibration unit for Sensor A which costs $235 000 and will increase the rate at which you detect the problem. You believe this will reduce the "Detection" value in the FMEA analysis for the Sensor A to a value of 2. Option B: You can change the manufacturer of the alarm housing to one with better quality casting. This will reduce the "Occurrence of the problem of the alarm housing breaking at first removal to a a value of 3 but will cost an additional $0.50 per unit. Answer the following questions: 1. For Option A, how long will it take to break even? (Answer in years to 2 decimal places) 2. For Option A, what is the new RPN for the Sensor A failure listed? 3. For Option B, how long will it take to break even? (Answer in years to 2 decimal places) 4. For Option B, what is the new RPN for the Alarm housing failure listed? 5. Which option will you suggest to your manager? (A or B) Justify your answer (You can consider the costs, revenue, breakeven, the FMEA, improved safety etc. for your answer but you must to select one of the options and give a justification for this based on the factor you think is most significant as an engineer giving a recommendation.) You are an engineer reviewing the production line for a great new smoke alarm. The following is an extract of the FMEA that has been conducted on the product and you have been tasked with reviewing production costs and the safety of the product. Design Verification Process System Subsystem Component Potential Failure Mode and Effects Analysis (Design FMEA) FMEA Number Project III Prepared By Sylvia Wu FMEA Date 22/10/2020 Revision Date 21/08/2021 Design Lead Key Dute Shay Isaac See Project Ill R1 Report Core Team Page of 6 Action Results Item Function Potential Filc( of Failure Faulty fire Card Design Controls Occ Sev a Potential Causes Mechanism of Failure 9 Human error Det RPN Actions Taken Recommende d Actions Potential Failure Models Not Correctly calibrated Responsibility & Target Completion Date New Det New RPN Sensor A 1 Training and 3 verification of testing 4 Alarm component Insufficien t volume Faulty fire Sensor 54 Purchase specialised calibration tool 45 lavestigate alternative alarm component 8 Faulty 1 Inspection 4 component Alarm housing Alarm cover Replacement housing required 3 Incorrectly cast housing 4 Inspection 2 24 Negotiate quality with supplier breaks at first removal Currently the product has the following (simplified) cost and revenue components: The wholesale price of each sensor is $75 The company has a contract to sell 24 000 units per year. The company spent $350 000 to design this particular mechanism. They invested $1 million in setting up for production. The production cost is $62 per unit Your investigations have led to 2 options for improving the products Your investigations have led to 2 options for improving the products Option A: You source a calibration unit for Sensor A which costs $235 000 and will increase the rate at which you detect the problem. You believe this will reduce the "Detection" value in the FMEA analysis for the Sensor A to a value of 2. Option B: You can change the manufacturer of the alarm housing to one with better quality casting. This will reduce the "Occurrence of the problem of the alarm housing breaking at first removal to a a value of 3 but will cost an additional $0.50 per unit. Answer the following questions: 1. For Option A, how long will it take to break even? (Answer in years to 2 decimal places) 2. For Option A, what is the new RPN for the Sensor A failure listed? 3. For Option B, how long will it take to break even? (Answer in years to 2 decimal places) 4. For Option B, what is the new RPN for the Alarm housing failure listed? 5. Which option will you suggest to your manager? (A or B) Justify your answer (You can consider the costs, revenue, breakeven, the FMEA, improved safety etc. for your answer but you must to select one of the options and give a justification for this based on the factor you think is most significant as an engineer giving a recommendation.)
