Step 1: Identify the potential causes of failures using the inputs from an input-output diagram and import them into the FMEA tool. Avoid any initial prioritization of inputs such as through a cause-and-effect matrix, to ensure that all possible failure modes are included in the COPQ analysis. Include only controlled factors (inputs) in the analysis. This is important, as existing costs for uncontrolled factors cannot be calculated with confidence.
Step 2: After importing the inputs, review the list with the team to ensure all potential failures are identified. Include every possible failure even if the process has not experienced it. If there is a risk for failure, the team must identify it and include the potential cost of failure in the COPQ calculation.
Step 3: Perform the risk prioritization calculation for each individual potential failure mode by using the FMEA tool. Record the Risk Priority Number values as a calculation of severity, occurrence and detection scores as follows:
Risk Priority Number = Severity x Occurrence x Detection
Step 4: Using team inputs and any available estimation tools, calculate the average cost to resolve (ACR) for each potential cause of failure. The cost will be a multiple of estimated effort hours to resolve (EHR) and the average cost per effort hour (ACH). Note that the estimation in this step tends to have a 90- to 95-percent confidence level, which is an acceptable level for isolating the COPQ.
ACRi = EHRi x ACHi
Where: ACRi = Average cost to resolve incident i
EHRi = Effort hours to resolve incident i
ACHi = Average cost per hour for incident i
i = 1 to n (n being the total number of failures)
Step 5: Calculate the average effort cost required to resolve a random incident by using the weighted average of time to resolve the failure weighted by the risk priority of each failure.
Weighted Average Cost to Resolve (WACR) =
Step 6: Calculate the COPQ for the project by multiplying the random incident cost and the potential reduction in incidents (per year) as identified in the project charter.
COPQ = WACR x Reduction in Events Due to the Project
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skill9641 (威望:1) (上海 普陀) 石油化工 总监
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Step 1: Identify the potential causes of failures using the inputs from an input-output diagram and import them into the FMEA tool. Avoid any initial prioritization of inputs such as through a cause-and-effect matrix, to ensure that all possible failure modes are included in the COPQ analysis. Include only controlled factors (inputs) in the analysis. This is important, as existing costs for uncontrolled factors cannot be calculated with confidence.
Step 2: After importing the inputs, review the list with the team to ensure all potential failures are identified. Include every possible failure even if the process has not experienced it. If there is a risk for failure, the team must identify it and include the potential cost of failure in the COPQ calculation.
Step 3: Perform the risk prioritization calculation for each individual potential failure mode by using the FMEA tool. Record the Risk Priority Number values as a calculation of severity, occurrence and detection scores as follows:
Risk Priority Number = Severity x Occurrence x Detection
Step 4: Using team inputs and any available estimation tools, calculate the average cost to resolve (ACR) for each potential cause of failure. The cost will be a multiple of estimated effort hours to resolve (EHR) and the average cost per effort hour (ACH). Note that the estimation in this step tends to have a 90- to 95-percent confidence level, which is an acceptable level for isolating the COPQ.
ACRi = EHRi x ACHi
Where: ACRi = Average cost to resolve incident i
EHRi = Effort hours to resolve incident i
ACHi = Average cost per hour for incident i
i = 1 to n (n being the total number of failures)
Step 5: Calculate the average effort cost required to resolve a random incident by using the weighted average of time to resolve the failure weighted by the risk priority of each failure.
Weighted Average Cost to Resolve (WACR) =
Step 6: Calculate the COPQ for the project by multiplying the random incident cost and the potential reduction in incidents (per year) as identified in the project charter.
COPQ = WACR x Reduction in Events Due to the Project