【導讀】許多的小部件失效。一個可靠性的計劃？顧客滿意意味著：決不要說對不起！

　　

【正文】 7日星期二 | 42 RPN : Acceptance threshold ? S = 5 (reduced performance + degradation) ? O = 5 ( approximately %) ? D = 5 (may detect prior to shipment) Generally, RPN 125 may be a good threshold to use ie for RPN 125 = corrective action is needed. But there are exceptions 。 SxOxD RPN 125 S O D Description Action? 10 1 1 Failure unlikely to reach user 1 10 1 Frequent Minor, detectable failure 1 1 10 Minor defect reaches user infrequently 10 10 1 Serious and frequent failure 1 10 10 Frequent minor defect reaches user 10 1 10 Serious defect reaches user 10 10 10 IN TROUBLE!!! H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 43 Step 5 Establish Actions and Responsibilities 1. What has to be improved : change of design life test contact with supplier control point build in, in production process etc. 2. Who is responsible 3. When is it finished H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 44 RPN acceptable? Corrective actions DO New RPN1 Acceptable? End Yes No No Yes RPN acceptable? Corrective actions DO New RPNn Acceptable? End Yes No No Yes H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 45 Choice of Corrective Actions Unlikely to be effective Preferred choices * Increase inspection * Pokayoke (foolproofing) * Additional test * Process change * Additional check * design change * Retrain operators * Automation * Rewrite SOP * Computerisation * Robotics H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 46 S u b j e c t : D a t e : No P r oc e s s s t e p / P ur po s e P ot e nt i a l Fa i l ur e M od eP ot e nt i a l E f f e c t on Fa i l ur eS P ot e nt i a l c a us e s on Fa i l ur eO C ur r e nt C on t r olD R P N G r a v i t y Fa c t orR e c om m e nd e d A c t i onO w ne r C om pl e t i on D a t eA c t i on T a k e n / R e s ul tE v ol ut i on Fa c t or1 M o u n t a c t u a t o r a n d i n s t a l l s p r i n g c l i p = H o l d a c t u a t o r i n p l a c eD i f f i c u l t y i n a s s e m b l i n g s p r i n g c l i p~ L o n g c y c l e t i m e 8 ~ H a n d l i n g r e q u i r e d t o o r i e n t a t e c l i p 8 ~ P r o d u c t i o n M o n i t o r i n g C h a r t , O p r s k i l l c h a r t4 2562 C u t L D G U , M o u n t L D G U t o l i n e p e n h o u s i n g = A s s e m b l e L D G UL e n s a n d g r a t i n g c o n t a m i n a t i o n~ F a i l G r a t i n g A d j u s t m e n t8 ~ H a n d l i n g 4 ~ R e j e c t a t a d j u s t m e n t s t n1 32~ C u t t i n g m a c h i n e d i r t y3 ~ W e e k l y m a i n t e n a n c e4 963 M o u n t a n d s e c u r e f l e x a s s y = A s s e m b l e F l e x A s s yE S D L D G U d a m a g e b y c o n t a c t a f f e c t i n g l o n g / s h o r t t e r m r e l i a b i l i t y8 H a n d l i n g b y o p e r a t o r2 ~ R e j e c t a t a d j u s t m e n t s t n8 1284 S o l d e r a c t u a t o r amp。 L D G U t o F l e x A s s y = C o n n e c t a c t u a t o r , L D G U a n d F l e xF a il u r e M o d e amp。 E f f e c t A n a ly s is P r o c e s sH Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 47 Corrective Action Preference Hierarchy The intent of any remended corrective action is to improve the RPN rating by reducing Severity, Occurrence, Detection or all 3 together. Emphasis should be on prevention, . reducing Occurrence. Should prevention be impossible, the following Hierarchy of preference should be used: 1. Prevention, or potential cause elimination 2. Detection, as early in the product life cycle as possible: best ……… at the design stage next best ……… prior to mass production then ……… prior to shipment and, as last resort ……… in the field, prior to catastrophic failure 3. Impact reduction, . reduce Severity Generally, to reduce any of the three rating O, D, S process and/or design changes/modification are required H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 48 FMEA is is not * structured * a showpiece * systematic * a number game * rigorous * a guessing game * prehensive * a documentation exercise * scientific * a selfconsolation exercise * a discipline .. * preventive .. * customerfocused .. * a team effort .. * a crossfunctional exercise .. * a living document .. * a continuous process * a oneoff exercise H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 49 Real Life FMEA Exercise H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 50 3 PRODUCT DFMEA H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 51 Process FMEA vs Product DFMEA * PFMEA does not rely on product design changes to overe process weaknesses, but it does take into consideration a product?s design characteristics * DFMEA does not rely on process controls to overe design weaknesses, but it does take the technical/physical limitations of the manufacturing process (. the process capability) into consideration. Process step Purpose Piecepart or subassy Function Process FMEA Product FMEA H Philips CFT Asia Pacific Innovation amp。 Industrial Support CZB698000006| 2020年 7月 7日星期二 | 52 Process FMEA v