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Using Process FMEA in an Aeronautical Engineering Technology Capstone Course

Abstract

In the Aeronautical Engineering Technology program at Purdue University, undergraduate students gain experience in performance improvement in the capstone project courses. The performance improvement proposed and implemented by the students must also consider the impact on safety. Process Failure Modes and Effects Analysis (PFMEA) is one tool used in the aerospace industry to identify risks in products or processes, and to take action to mitigate or eliminate the risks. Using the SAE standard for PFMEA, students use a structured method to analyze the process steps and the associated risks. The capstone courses are a two-course senior capstone experience. In the first semester, the students prepare a proposal to redesign either a process or product for measurable, dramatic improvement. The projects affect real manufacturing and airport processes and products. In the second semester, students redesign and implement the improved process or product. The goal of the process redesign projects is typically to dramatically reduce process set-up time or process run time. Moreover, students must be made aware that process improvement must not decrease safety; rather the students must improve safety while improving other process performance measures. While there are many inclusions of product redesign in papers discussing capstone courses, this paper focuses on the use of PFMEA in capstone design, build, test and implement projects.

Constraints on time and resources are a reality for student projects. These constraints help prepare students for projects in their future careers. Using the PFMEA standard, students may concentrate improvement efforts on the high priority process steps. By considering process improvements that also include risk elimination or mitigation actions, the students improve the process performance and safety. Through this process, students have a greater understanding of process improvement techniques that lead to measureable improvements, and a greater understanding of the importance of using standards. This paper introduces PFMEA, presents the PFMEA method, and discusses PFMEA inclusion in senior aeronautical engineering technology courses.

Introduction

The Aeronautical Engineering Technology program at Purdue University is an ABET TAC accredited program. Undergraduate students take courses in aircraft sciences and systems, manufacturing processes, and general education topics prior to the senior year. The senior year has multiple capstone courses. This paper discusses the use of Process Failure Modes and Effects Analysis (PFMEA) in two capstone courses where students gain experience in proposing and conducting performance improvement projects.

The performance improvement projects proposed and implemented by the students must also consider the impact on safety. PFMEA is one tool used in the aerospace industry to identify risks in processes, and to take action to mitigate or eliminate the risks. Using the SAE standards for PFMEA, students use a structured method to analyze the process steps and the associated risks.

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Johnson, M. (2010, June), Using Process Fmea In An Aeronautical Engineering Technology Capstone Course Paper presented at 2010 Annual Conference & Exposition, Louisville, Kentucky. 10.18260/1-2--16670