【文章內(nèi)容簡介】 ally Assess the Performance and Improve ? 對防錯情況進行定期評審及改進 24 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Manufacturing Processes 制造過程 Product Quality 產(chǎn)品質(zhì)量 Process Design 過程設(shè)計 Product Design 產(chǎn)品設(shè)計 What is the Right Time to Error Proof?? 正確的防錯時間是什么時間 ? 100:1 10:1 1:1 As Early As Possible 及早發(fā)現(xiàn) 25 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Why Error Proof Early During New Product Development 為什么在新產(chǎn)品開發(fā)期間防錯 Cost of “Fixing” the Defects “修理”缺陷的成本 Concept Development 觀念開發(fā) Preliminary Design 初步設(shè)計 Detailed Product Design 詳細的產(chǎn)品設(shè)計 Customer Support 客戶支持 Industrialization 產(chǎn)業(yè)化 Production 生產(chǎn) Process Design 過程設(shè)計 Cost of “Fixing” 設(shè)備的花費 Multiplies With Life Cycle Stages 整個過程當中的多項防錯 Stages of Product Life Cycle 產(chǎn)品生命周期中各個階段 26 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Why Error Proof Early During Processing 在處理期間為什么要盡早防錯 Cost of “Fixing” the Defects設(shè)備成本失效 Ining Parts 外協(xié)件 After Completing the Process過程完成之后 At the End of the Line 產(chǎn)品最終離開生產(chǎn)線 After Delivery to Customer 交付給客戶之后 Final Test 最后檢驗 Cost of “Fixing” Increases With Process Steps 隨著程序步驟增長修復(fù)錯誤成本增長 Steps of Product Processing 產(chǎn)品處理的步驟 Reject Return 廢棄件 No Delay沒有拖延 Reject Scrap 廢棄件 廢品 Minor Delay 稍微拖延 Reject Scrap / Rework 廢棄件 廢品 /返工 Reschedule Some Delay進度稍有拖延 Significant Rework / Scrap Add to the Production Schedule Delayed Deliveries 重要的返工 /廢品影響生產(chǎn)進度及產(chǎn)品交付 Warranty Costs Administrative Costs Liabilities Reputation Market Share Loss擔(dān)保成本及管理成本增加 ,導(dǎo)致市場份額損失 27 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Error Proofing Exercise No. 2 防錯訓(xùn)練的第二部分 ? Form Teams of Two ? 兩個一組 ? Discuss and Agree on One Example of Product Design or Manufacturing Process to Analyze ? 討論一個產(chǎn)品設(shè)計或制造工藝的例子 ,并進行分析 ? Identify ? 鑒別 ? Error Proofing Implemented防錯實施 ? Estimate Cost / Quality Impact消除成本 /質(zhì)量影響 OR或者 ? Error Proofing Opportunities Missed喪失防錯良機 ? Estimate the Cost / Quality Impact消除成本 /質(zhì)量影響 ? List Lessons Learned學(xué)到的教訓(xùn)清單 ? Prepare to Present to the Class準備到課堂上展示 ? 20 Minutes ? 20分鐘 28 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Identify Opportunities for Errors 識別防錯的時機 29 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Methods for Identifying Potential Errors 識別潛在的防錯方法 ? Customer Demanded Good Start ? 消費者的需求 良好的開始 ? Internal Quality Results – Reactive ? 內(nèi)部質(zhì)量成效 反應(yīng) ? Past Experience Not Completely Reliable ? 以往經(jīng)驗 不完全可靠 ? Customer 反饋 Too Late ? 消費者的反饋 太遲 ? Systematic Analyses to Identify Potential Errors ? 識別潛在的錯誤需進行系統(tǒng)分析 ? Potential Failure Mode and Effects Analysis (FMEA) ? 潛在的失效模式及效果分析 (FMEA) ? Product FMEA ? 產(chǎn)品 FMEA ? Process FMEA ? 過程 FMEA 30 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Potential Failure Mode and Effects Analyses PFMEA 潛在的失效模式和 效果分析 Overview 總攬 31 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 Key Points of FMEA FMEA的關(guān)鍵部分 ? FMEA Analyses Potential Failures ? FMEA分析潛在失效 ? Fleas Have to Be Done by Multifunctional Teams ? Fleas應(yīng)由多功能組執(zhí)行 ? Design FMEA Should Be Initiated Before or at the Concept Stage ? 設(shè)計 FMEA是在開始之前或者概念形成階段 ? Process FMEA Should Be Initiated Before or at the Feasibility Stage, Prior to Tooling or Equipment Finalization ? 過程 FMEA是在工裝及設(shè)備調(diào)整好開始生產(chǎn)之前或者可研階段 ? FMEAs Should Be Continuously Updated, As Changes in Product Process Designs Take Place ? 應(yīng)該不斷更新 ,比如 FMEAs中的產(chǎn)品 過程設(shè)計 ? FMEAs Are Living Documents ? FMEAs 是活的文件 ? FMEAs Are Never Ending Processes ? FMEAs 是永遠都不會結(jié)束的工藝 32 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 FMEA Type and Levels FMEA的類型和水平 Design FMEA 設(shè)計 FMEA Process FMEA 過程 FMEA Subsystem 子系統(tǒng) Critical Features 關(guān)鍵特性 Components / Parts零件 Subassemblies 分裝 Workstations 工作臺 Operations 加工操作 33 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 F M E A N o .I t e m / P r o c e s s P r o c e s s r e s p o n s i b i l i t y P a g e P a r t N o . / D r g . N o . K e y D a t e P r e p a r e d B yC o r e T e a m : F M E A D a t e ( O r i g )I t e m o rP r o c e s sF u n c t i o nR e q u i r e m e n tP o t e n t i a lF a i l u r e M o d eP o t e n t i a l E f f e c t ( s ) o fF a i l u r eSev e ri t yC l assP o t e n t i a l C a u s e ( s ) /M e c h a n i s m ( s ) o fF a i l u r eO c curC u r r e n t P r o c e s sC o n t r o l sD e te c tR.P.N.R e c o m m e n d e dA c t i o nR e s p o n s i b i l i t y T a r g e tC o m p l e t i o nD a t eP o t e n t i a l F a i l u r e M o d e a n d E f f e c t s A n a l y s i s ( F M E A )General Information (1)總說明 2 3 4 5 6 7 8 10 11 9 12 34 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 FMEA Steps FMEA 的步驟 Design FMEA 設(shè)計 FMEA General Information Details of the Product FMEA ? 信息總說明 產(chǎn)品及 FMEA的詳情 ? Item Function / Requirement ? 項目的功能 /要求 ? Enter All Functions of a Product Item ? 鍵入所有產(chǎn)品的功能 ? Potential Failure Mode ? 潛在的故障模式 ? Describe How a Product Item Could Fail ? 描述產(chǎn)品怎樣失效 ? Use Physical Terms, Not Symptoms ? 使用專用描述詞語 ,不是癥狀 Process FMEA 過程 FMEA General Information Details of the Product FMEA ? 信息總說明 產(chǎn)品的詳細資料和 FMEA ? Process Function ? 過程功能 ? Enter Description Purpose of the Process ? 鍵入過程描述和過程功能 ? Potential Failure Mode ? 潛在失效模式 ? Describe How Process Could Fail to Meet Requirements of Subsequent Operations ? 描述工藝為什么不能滿足分序要求 ? Describe Nonconformance ? 描述不一致性 35 169。 2023 Eaton Corporation. All Rights Reserved. 4/11/03 FMEA Steps FMEA的步驟 Design FMEA 設(shè)計 FMEA Pot