【正文】 auses of failures 防止失效原因的措施 ? Actions to detect failure modes 發(fā)現(xiàn)失效模式的措施 ? History of actions and Responsibilities 措施和責任人的記錄 17 FMEA ? Design 設(shè)計 – Components 元件 – Elements 設(shè)計要素 Design FMEA looks at physical failure modes of ponents and design elements 設(shè)計 FMEA著眼于 元件及設(shè)計要素 的物理失效模式 18 FMEA Rules of Process FMEA 過程 FMEA規(guī)則 ? Tool for process engineers and project team to improve the manufacturing process in a preemptive manner 是工藝工程師和項目小組的工具 ,用來提高製造工藝的前瞻性 ? Used to prioritize actions to ensure attention to critical processes that effect customers 用與區(qū)分先後順序以確保那些影響客戶的重要工藝 ? Used to document process improvements 用於工藝改進 ? Dynamic document for continuous improvement 持續(xù)改進的動態(tài)文件 19 FMEA Purpose of Process FMEA 過程 FMEA的用途 ? Assists in the analysis of new manufacturing process 幫助分析新的製造工藝 ? Establishes the bases for manufacturing process instructions and control sheets 建立製造工藝文件和控制文件的基礎(chǔ) ? Identifies new manufacturing process needs 確定新製造工藝的需求 ? Helps evaluate the risk of process changes 幫助評估工藝更改的風險 20 FMEA ? Process 過程 – Manufacturing 制造 – Assembling 裝配 Process FMEA looks at product failures caused by the process failing to meet requirements 過程 FMEA著眼于因加工 過程 不符合要求所造成的 產(chǎn)品 失效 21 FMEA FMEA Team 小組 ? Team approach is necessary. 需要團隊的方式 ? Responsible for Design FMEA – Design Engineer 設(shè)計工程師負責設(shè)計 FMEA ? Responsible for Process FMEA – Manufacturing Engineer 製造工程師負責過程 FMEA ? Remended representatives: 推薦人選 : – Design / 設(shè)計 – Manufacturing Engineers / 製造工程師 – Quality Engineers / 質(zhì)量工程師 – Reliability / 可靠性 – Materials / 原材料 – Suppliers / 供應(yīng)商 22 FMEA Definition of Terms 術(shù)語 ? Failure Mode – The way in which a specific input requirement fails and if not detected, corrected or removed will cause an Effect to occur. 失效模式 – 一個特殊的輸入要求失敗的方式或者由於未被發(fā)覺 ,糾正或消除而帶來的後果 ? Effect – Impact on customer requirements 後果 – 對客戶要求的影響 23 FMEA Definition of Terms 術(shù)語 ? Cause – Source(s) of process variation that causes the Failure Mode to occur. 原因 – 造成失效模式發(fā)生的過程變差的起源 ? Current Control (proposed controls) 當前的控制 (建議的控制 ) – Design elements that ensure function 確保功能的設(shè)計要素 – Mistake proofing, automated controls, set up instructions, gauges 防錯 ,自動化控制 ,機器設(shè)定指導書 ,量具 – Audits, checklists, inspections, PM, etc.. 稽核 ,檢查表 ,檢驗 ,設(shè)備維護 ,等 24 FMEA Linking Failure Modes to Effects 失效模式和後果之間的聯(lián)繫 Failure Mode 1 Failure Mode 2 Effect 1 Failure Mode 1 Effect 2 Effect 1 Failure Mode 1 Failure Mode 2 Effect 1 Note that the relationship between the Failure Mode and Effect is not always 1to1 請注意失效模式和後果之間的關(guān)係不總是一對一 Effect 2 25 FMEA Risk Priority Number 風險序數(shù) ? The output of a FMEA is the “Risk of Priority Number” RPN 一個 FMEA的輸出是 “ 風險序數(shù) ” RPN ? The RPN is a calculated number based on information provided regarding RPN是根據(jù)下面的資料計算出來的 – The potential failure modes, 潛在失效模式 – The effects, and 後果 – The current or planned ability to detect the failure before it reaches the customer 現(xiàn)有的和已計劃的能力可以在影響客戶前覺察失效 26 FMEA Risk Priority Number 風險序數(shù) ? It is calculated as the product of three quantitative rating 它是用三個級數(shù)計算出來的 RPN = Severity * Occurrence * Detection 風險序數(shù) = 嚴重度 * 發(fā)生頻度 * 探測度 ? The RPN is not sacred RPN不 是神聖的 ? Scaling for Severity, Occurrence, and Detection are locally developed嚴重度 ,發(fā)生頻度 ,探測度的尺度由自己制定 ? Other categories may be added to suit need 根據(jù)需要可以加上其他類型 ? High Risk Priority Numbers are significant to the success of the product design actions must be taken to prevent failures 高風險序數(shù)對產(chǎn)品設(shè)計的成功來講很重要 需要採取措施來防止失效 27 FMEA Definition of RPN Terms RPN術(shù)語 ? Severity (of effect) – Importance to customer, may involve function, safety, reliability, or life of product (1= not severe, 10 = very severe) 嚴重度 (後果的 ) – 對客戶的重要程度 , 可包括功能 ,安全 ,可靠性 , 產(chǎn)品壽命等方面 . (1=不嚴重 , 10=很嚴重 ) ? Occurrence (of cause) – Frequency with which a given Cause may occur (1= not likely to occur, 10= very likely to occur) 發(fā)生頻度 (原因的 ) – 一個特定的原因可能發(fā)生的頻度 (1= 不可能發(fā)生 , 10= 很可能發(fā)生 ) ? Detection (Capability of current or planned Controls) – Ability to detect the cause (1= likely to be detected, 10= not likely to be detected) 探測度 (現(xiàn)有的或已計劃的控制能力 ) – 覺察原因的能力 (1= 有可能發(fā)覺 , 10= 不可能發(fā)覺 ) 28 FMEA Rating Scales 評分尺度 Rating得分 Degree of Severity/ 嚴重程度 1 Customer will not notice the adverse effect or it is insignificant/客戶不會注意到或該不利後果不重要 2 Customer will probably experience slight annoyance/可能對客戶有輕微的影響 3 Customer will experience annoyance due to the slight degradation of performance/由於輕微的性能下降可能給客戶帶來麻煩 4 Customer dissatisfaction due to reduced performance/由於性能下降使客戶不滿意 5 Customer is made unfortable or their productivity is reduced by the continued degradation of the effect/客戶不滿意或受持續(xù)降級的影響使他們的生產(chǎn)力降低 6 Warranty repair or significant manufacturing or assembly plain/保修或者重大的製造或組裝的投訴 7 High degree of customer dissatisfaction due to ponent failure without plete loss of function. Productivity impacted by high scrap or rework levels/零件雖未完全失去功能但引起客戶較大的不滿 。 Take electrical systems as examples. 以電氣系統(tǒng)為例 。 識別每一種失效模式的原因和後果 – Prioritizes the failure modes (using the RPN)。應(yīng)當儘量避免失效，而不是等著顧客提出申訴！ 5