Failure Mode and Effects Analysis 失效模式及后果分析（FMEA手册培训） .ppt

Welcome 欢迎进入,Failure Mode and Effects Analysis失效模式及后果分析,Course Purpose课程目标,Define what an FMEA is,list the benefits and distinguish between three types of FMEAs 定义什么是FMEA，定义FMEA的益处，以及三种类型的FMEA之间的区别Describe how to use Path/Step 1 of the FMEA Working Model in order to complete/review Design FMEAs描述如何使用FMEA工作模式的路径/步骤1，以便完成/评审设计FEMA。Learn new robustness methodologies学习新的，稳健的方法Explain how FMEAs fit into Fords quality strategies,FPDS timings and FPS strategies说明FMEA如何符合福特的质量战略，FPDS的时间进度和FPS战略。,Participants will be able to function as effective FMEA team members by being able to:学员通过掌握以下知识可以有效的完成FMEA小组成员的工作：,Participant Materials学员材料,FMEA HandbookFMEA手册Participant Guide学员指导书,Page Number页码,FMEA-An IntroductionFMEA-简介,Why Do FMEAs?为何进行FMEA？Definition,Purpose,Benefits,TypesFMEA的定义，目的，益处，类型FMEA Working ModelFMEA的工作模式Generating/Managing产生/管理Team Approach小组法,FMEA DefinitionFEMA-定义,Identify potential failure modes识别潜在的失效模式Identify and prioritize actions确定措施，并排列其有限顺序Document the process对过程进行文件化,Structured group of activities which.FEMA是一组结构化的活动，这些活动：,Why Do FMEAs?为何进行FMEA？,To ensure that all potential risks are identified and addressed确保已经识别并说明所有的潜在风险Significant savings in engineering time-reduction in changes immediately before and after Job 1有效的节约工程时间-减少Job 1之前和之后的即时变化。,FMEA PurposesFMEA的目的,Failures 失效,Time 时间进度,Timing&Qualityof Potential Failures潜在失效的时间进度和质量,JOB 1,FMEA,FMEA PurposesFMEA的目的,VDS/SDS,Design and Process Orientation设计和过程导向,Customer Orientation顾客导向,Campaign Background活动的背景,CAMPAIGN RESPONSIBLE ORGANIZATIONS活动的相关组织,0%,20%,40%,60%,80%,100%,Ford PD 福特PD,Supplier 供方,Ford Mfg 福特制造商,ORGANIZATION 组织,Best Practice FMEAFMEA的最好练习,RELIABILITY NOISE FACTORS可靠性的噪音因素,0%,20%,40%,60%,80%,100%,System系统间的相互作用,Deterioration退化,Environment环境,Mfg Variation制造变差,Customer顾客使用,NOISE FACTOR 噪音因素,FMEA TypesFMEA-类型,Design/ProcessConceptFMEA设计/过程FMEA的概念,Component 部件,DesignFMEA设计FMEA,System 系统,Sub-System 子系统,ProcessFMEA过程FMEA,Assembly装配,Manufacturing制造,MachineryFMEA机械 FMEA,Change Point Approach变化点的处理,New design or process is planned计划了新的设计或过程Modification to a component,process or system is planned,including those due to Global 8D计划了部件，过程或系统的更改，包括8D过程的更改Component is to be used in new environment,location,or application部件将要用于新的环境，现场，或应用。,FMEAs are living documents,and are updated when.FMEA是动态文件，在以下情况下进行更新,Benefits/Uses-Concept FMEAsFMEA概念的益处/用法,Helps select optimum concept帮助选择最适宜的概念Helps set targets for the concept帮助制定概念的目标Identifies testing requirements识别试验要求Helps determine if hardware system redundancy is required帮助决定是否需要,Design 设计,Process 过程,Concept 概念,Benefits/Uses-Design FMEAs设计FMEA-益处/用法,Aids in evaluating requirements and alternatives帮助评价要求和可供选择的方法Aids in initial design for DFM,DFA,DFS,and DFR帮助DFM，DFA，DFS和DFR的初始设计Helps plan thorough and efficient development and validation programs 帮助进行项目的完整策划，有效开发和确认。Develops a prioritized list for actions开发一份按优先顺序排列的措施清单Helps identify potential special characteristics帮助识别潜在的特殊特性Helps validate DVPs and SDSs帮助确认DVP和SDS,Process 过程,Concept 概念,Design 设计,Benefits/Uses-Process FMEAs过程FMEA-益处/用法,Assesses Effects on all customers评估所有顾客的效果Identifies potential Manufacturing and Assembly causes to focus controls on reducing occurrence and/or increasing detection识别潜在的制造和装配原因，对降低发生率和/或提高探测度进行重点控制Develops a prioritized list for actions开发一份按优先顺序排列的措施清单Documents the results of the manufacturing or assembly process文件化制造或装配过程的结果Identifies confirmed special characteristics requiring special controls识别确定的，需要特别控制的特殊特性,Design 设计,Concept 概念,Process 过程,Former FMEA Process,Targets,Cross-Functional Team,History,FMEA,Robustness Tools are not specified,FMEA(with Robustness Linkages)ProcessFMEA（有稳健联系的）过程,FMEA(withRobustnessLinkages)FMEA（有稳健联系的）,Qualifies and clarifies the relationships between Systems鉴定并说明系统之间的关系,Identifies and quantifies the strength of System Interactions识别并量化系统之间的相互作用,Identifies Noise and Control Factors and Error States识别噪音，控制因素和误差状态,Summarizes Error States,Noise Factors,and associated Design Controls总结误差状态，噪音因素和相关设计控制图,FMEA Working ModelFMEA 工作模式,Path/Step 1路径/步骤1,Path/Step 2路径/步骤2,Path/Step 3路径/步骤3,Generating FMEAsFMEA的产生,FMEAs,Who initiates?由谁发起的？,Failure Mode and Effects Analysis失效模式和后果分析,Who prepares?由谁准备？,Who updates?由谁更新？,Who is FMEA customer?谁是FMEA的顾客？,When started and updated?何时开始？何时更新？,Relationshipto FPDS?与FPDS的关系？,When is FMEA complete?什么时间完成FMEA？,How is FMEA documented?如何对FMEA进行文件化？,When to discard?何时废止？,Who initiates an FMEA?谁执行FMEA,CFMEA:CFMEA:Scientific Research Labs(SRLs),Research Vehicle Technology(RVT),Advanced Manufacturing,or program team科学研究试验室（SRLs），车辆研究技术（RVT），先期制造，或项目小组DFMEADFMEAResponsible Engineer or Supplier相应的工程师和供应商PFMEAPFMEAResponsible Engineer or Supplier相应的工程师和供应商,When can FMEA documents be discarded?什么时候可以处理掉FMEA文档,FMEA Documents must be retained in accordance with Global Information Standards Record Retention Schedule:FMEA必须按照全球信息记录保持时间标准对这些文档进行保存DFMEAs:Last use+10 yearsDFMEs：最终使用后+10年PFMEAs:Last use+5 yearsPFMEAs：最终使用后+10年,How is an FMEA documented?FMEA怎样文件化,On Industry Standard compliant(SAE J1739)Forms产业标准表格（SAE J1739）,When is an FMEA complete?何时FMEA才算完成了？,An FMEA is a living documentFMEA是动态的文档The FMEA is complete when matched with a released/signed-off product or process:FMEA“完成”是在与已发布/批准的产品或过程相符时CFMEA:when the System Design Specifications are frozen and the design functions are defined.CFMEA：当系统设计规范冻结和设计功能确定时DFMEA:when the product design is released for production.DFMEA：当产品设计发布用于生产时PFMEA:when all operations have been considered,all Special Characteristics have been addressed,and the Control Plan has been completed.PFMEA：当所有的生产都被考虑到，所有的特殊特性都被适当安排，以及控制计划完成时,Who prepares an FMEA?谁来准备FMEA？,An individual is usually responsible for the preparation of an FMEA:个人通常对FMEA的准备负责任：Ford:responsible engineer福特：相应的工程师Supplier:Supplier engineer供应商：供应商处的工程师All input should be a team effort.所有的输入必须是小组的努力结果。For proprietary designs(black/gray box),suppliers are responsible.The Ford design responsible activity approves the accuracy and thoroughness of suppliers FMEAs.对于私人设计（黑/灰匣子），由供应商负责。福特相应的工程师对供应商的FMEA的精确性进行批准。,Who updates an FMEA?谁更新FMEA？,FMEAs are updated by the responsible System,Product,or Manufacturing/Assembly EngineerFMEA由相应的系统、产品或制造/装配工程师进行更新。Suppliers are responsible to keep their own FMEAs up to date.供应商负责对他们自已的FMEA进行更新。,Who is the FMEA Customer?谁是FMEA的顾客？,All FMEAs:所有的FMEAs:End User最终用户Service activities售后服务CFMEA and DFMEA:CFMEA和DFMEA：Design responsible activities与设计有关的行动Manufacturing process activities 与制造有关的过程PFMEA:PFMEA：subsequent or downstream manufacturing or assembly operations下一工序或下游的制造或装配,When is an FMEA started or updated?FMEA什么时候起动或更新,DFMEAInitiated before or at finalization of design concept 在设计概念前或决定时起动Updated throughout the phase of product development 在产品开发的各个阶段进行更新Fundamentally completed before the production drawings are released for tooling 基本上，在生产用图纸正式发放用于模具开发前应完成PFMEAInitiated before or at the feasibility state 在可行性分析前或开始时起动Fundamentally completed prior to tooling for production基本上，在生产用工装制造前完成,FMEAs and Systems EngineeringFMEA和系统工程,DFMEA,PFMEA,Self AssessmentIntro,Design FMEA-An Introduction设计FEMA-简介,Identify DFMEA Team 成立DFEMA小组Establish Scope确定范围Describe Function功能描述Brainstorming头脑风暴Function Trees功能树Practice Exercise 1实践练习1,Design FMEA Team设计FMEA-小组,Design FMEA Scope设计FMEA-范围,Is the boundary or extent of the analysis defines what is included and excluded 分析的界限或程度是否确定包含什么，不包含什么？Scope incorrectly done:不正确的范围会：Lengthens analysis延长分析Misses target analysis偏离目标分析Identifies wrong team membership错误地识别小组成员,Design FMEA Scope设计FMEA-范围,Create a boundary diagram创建界限图Identify the boundary for analysis确定分析界限Confirm composition of support team确定支持小组的成员,Once core team is established.一旦成立了核心小组,Constructing Boundary Diagrams创建界限图,Boundary Diagram Example界限图-范例,Headlamp Assembly前灯装配,Boundary Diagram Example界限图-范例,垂直调整片的装配,Reflector反光镜,Vehicle BodyUpper CrossMember,Hood(Clearance)车蓬（清洁）,AdjusterSocket调节器插座,User用户,Clips 2夹具2,Service服务,Vibration 振动,Boundary Diagram Example界限图-范例,Assembly装配,Lateral Location Screw侧面定位螺丝钉,Practice Exercise 1,Interface Matrix接口矩阵,Recommended robustness tool that acts as an input to a Design FMEA接口矩阵是推荐的作为设计FEMA输入的稳健工具Identifies and quantifies the strength of system interactions by:接口矩阵可以通过以下方式识别并鉴定系统的相互作用：Showing whether the relationship is necessary or adverse显示系统间的关系是互利的还是不利的Identifying the type of relationship确定关系的类型,Example Interface Matrix接口矩阵的范例,Example Interface Matrix,Practice Exercise 2,P-Diagram P图,Recommended structured tool to identify intended inputs and outputs for a functionP图是推荐的，用于识别某一功能的预期输入和输出的结构化的工具Describes noise factors,control factors,ideal function,and error states描述噪音因素，控制因素，理想的功能和误差状态Assists in the identification of:有助于识别：Potential Causes for failure 潜在的失效原因Failure Modes 失效模式Potential Effects of failure 潜在的失效后果Current Controls 目前的控制方法Recommended Actions 建议的措施,Example P-DiagramP图的范例,Practice Exercise 3,Header Information表头信息,Complete each field完成每一区域：System,Subsystem or Component Name and Number系统、子系统或零件名称和编号Model Years/Program(s)车型 年份/项目Team 小组成员Design Responsibility 设计责任人Key Date.关键时间FMEA Number FMEA编号Prepared By 准备人FMEA Date FMEA日期,Determine Function确定功能,What is Function?功能是什么？,Design intent or engineering requirement设计意图或工程要求Written in verb-noun measurable format书面的，可以测量的动名词格式Representation of all wants,needs and requirements,both spoken and unspoken for all customers and systems描述所有顾客和系统的所有需要，需求和要求，可以是口头描述的，也可以是非口头描述的,Generate产生Control控制Dispense分配Retain保持Prevent,Describe Function功能描述,Light照明Speed速度Fuel燃料Seat Track座椅调节轮Rust生锈,Item Function Worksheet 零件功能工作清单,Brainstorming 头脑风暴,Exercise in creative thinking Method to generate ideas通过创造性思维找到解决办法的练习,Function Trees 功能树,Provide an organized approach to identify the essential features of a product(or process sometimes)提供一种结构化的方法，用于识别产品（或过程）必要的特征Help ensure that unspoken and spoken requirements are defined有助于确保“口头”和“非口头”的要求已经确定Provide a graphical representation of functions to ensure clear,total team understanding提供功能的图示描述，以确保全体小组清楚地理解,Constructing Function Trees建立功能书,AdjustHeadlamp调整前灯,Vertical Trimmer Function Tree 垂直调整片的功能树,Guidelines 指南,Brainstorm all functions(VERB-NOUN)Document individual functions by asking“HOW is function achieved?”通过提问“如何达到功能？”文件化各自的功能Repeat left to right,until actionable level不断从左到右重复，直至到达可执行的层次Use worksheet to check that actionable level is measurable 使用工作表检查可执行的层次是可以测量的Work right to left and check structure by asking“WHY is function included?”从右到左进行，通过提问“为什么包含此功能”检查功能树的结构,Ford Confidential,Design FMEA Functions设计FMEA的功能,Practice Exercise 4,Section Summary本节摘要,Identify DFMEA Team 确定DFMEA小组Establish Scope,Boundary Diagram确定范围，界限图P-Diagram,Interface MatrixP图，接口矩阵Describe Function功能描述Brainstorming头脑风暴Function Trees功能树Practice Exercises实践练习,Design FMEA Path/Step 1设计FMEA 路径/步骤1,Failure Modes失效模式Effects-Severity 后果-严重度Potential Special Characteristics潜在特殊特性Recommended Actions建议的措施Practice Exercises 实践练习,Design FMEA Path/Step 1设计FMEA-步骤/步骤1,Potential Failure Modes潜在失效模式,Function 1功能1,Function 2功能2,Function 3功能3,Function 4功能4,Function N功能n,Failure Modes-Vertical Trimmer失效模式-垂直调整片,No function 没有起作用No adjustment 没有调整Partial/Over Function/Degraded Over Time Adjustment in one direction 部分/全部的功能降低朝一个方向调整Intermittent functionAdjustment sometimes and 功能的间歇性中断not at others(not in cold)Unintended function有时调整 None known非预期的功能 不知道,Function:Adjust Light Beam X in Both Directions功能：调整所有方向的X光,Failure Mode Type 失效模式的类型 Potential Failure Mode失效模式的类型,Practice Exercise 5,Effects of Failure Modes失效模式的后果,Effects of Failure Modes失效模式的后果,Design FMEA Severity设计FMEA-严重度,Criteria:Severity of Effect 准则：后果的严重度,Ranking 等级,Effect 后果,无,.affects safe vehicle operation and/or government regulation without warning影响车辆安全运行和/或政府法规，失效发生时无警告,10,Hazardous With Warning有警告的严重危害,Hazardous Without Warning无警告的严重危害,.affects safe vehicle operation and/or government regulation with warning影响车辆的安全运行和/或政府法规，失效发生时有警告,9,Low 低,operable at reduced level of performance.Customer experience some dissatisfaction运行性能下降，顾客有些不满意,5,None,No Effect 没有影响,1,Suggested Severity Evaluation Criteria建议的严重度评价准则,Vertical Trimmer/垂直调整片Retains Setting,Potential Effects of Failure 潜在失效后果Part:May be stripped during adjustment(7)零件：可能在调整过程中丢失 Next Higher Assembly:Headlamp cannot be adjusted(6)更高层的装配：前灯不能调整 System:Misaligned lightbeam(8)系统：光束方向偏离 Vehicle:Impaired night/fog performance(7)车辆：夜晚/雾天性能下降 Govt Regs:Non-compliance(10)政府法规：不符合 Customer:Impaired night/fog(7)顾客：减少夜晚/雾天行驶,10,DFMEA Severity Rating ExampleDFMEA严重度等级的范例,SEV,Item 条款,Function 功能,Potential Failure Mode潜在失效模式Does not maintain adjustment不用继续调整,YC,S=9 S=10,Design FMEA 设计FMEA,Identify Potential Special Characteristics识别潜在的特殊特性,DFMEA-Recommended ActionsDFMEA-建议的措施,Practice Exercise 6,Section Summary本节摘要,Failure Modes失效模式Effects-Severity 后果-严重度Potential Special Characteristics潜在的特殊特性Recommended Actions建议的措施Practice Exercises实践练习,Ford Confidential,FMEA-Review Section 1FMEA-评审 第1节,FMEA-Review Section 1FMEA-评审 第1节,FMEA-Review Section 1FMEA-评审 第1节,Potential Effects of Failure Modes:潜在失效模式的后果：Part/Sub-component 零件/分部件Next Higher Assembly 更高层的装配System 系统Vehicle 车辆Government Regulations 政府法规Customer(Internal and End User)顾客（内部的和最终用户）,FMEA-Review Section 1FMEA-评审 第1节,可能出错的地方,Path/Step 2:路径/步骤2：Causes Occurrence原因-发生率Special Characteristics特殊特性Actions 措施 Path/Step 3:路径/步骤3：Design Controls设计控制Assessing Risk评估风险Actions 措施Practice Exercise 3实践练习 3,Design FMEA Paths/Steps 2 and 3设计FMEA 路径/步骤2和3,FMEA No 6,DFMEA Paths/Steps 2&3,Design FMEA Path/Step 2设计FMEA 路径/步骤2,Potential Cause of Failure潜在失效原因,An indication of a design weakness,the consequence of which is the failure mode 潜在失效原因是由设计缺陷引起的，其结果就是失效模式。,What Might Cause Failure?可能导致失效的原因？,Item is manufactured and assembled within engineering specifications工程规范中已经制造并装配的零件Design may include a deficiency that may cause unacceptable variation(misbuilds,errors,etc.)设计中可能包含某种缺陷，这种缺陷可能引起不可接受的变差（错误构造，误差等）,Two Assumptions for Cause.两种假定的原因,Manufacturing Misbuilds 制造的错误构造,Due to Design Deficiencies由设计缺陷引起的,+-,+-,Manufacturing Misbuilds 制造的错误构造,Due to Design Deficiencies由设计缺陷引起的,+-,+-,Use a Fishbone Diagram使用鱼刺图,Causes of Failure失效的原因,No Adjustment没有调整,Thread Seizure,Broken Bracket有故障的支架,Interface not Understood by User用户没有理解接口,Thermostat Geometry,Thread Fusion,Material Propagation,Screw Thread Specification Oversize螺旋的螺纹太大,Support Area too Small支持范围太窄,Causes of Failure-Why Ladder失效原因-,Material cracked,PartBends零件弯曲,Support area too small支持范围太窄,WHY?为什么？,WHY?为什么？,WHY?为什么？,Level 3第3层,Level 2第2层,Level 1第1层,Broken Bracket有故障的支架,Sentencing Technique判断的技巧,Could result in可能导致,Leads to引起,TIME 时间,Due to由于,Sentencing Technique Example判断技巧的范例,No Adjustment没有调整,Could result in可能导致,Due to由于,Leads to导致,TIME 时间,Causes of Failures失效的原因,Function1功能1,Failure Mode 1失效模式1,Failure Mode 2失效模式2,Failure Mode n失效模式n,Design FMEA Occurrence设计FMEA-发生率,Possible Failure Rates可能失效的比率,Ranking 等级,Probability of Failure失效的可能性,9,Very High:Persistent failure很高：持续的失效,10,Moderate:Occasional failures中等：偶尔失效,6,5,4,Remote:Failure unlikely很低：不可能失效,1,Suggested Occurrence Evaluation Criteria建议的发