10 Steps to Conduct a PFMEA(不看后悔)全英文版

10StepstoConductaPFMEAStep1Reviewtheprocess—Useaprocessflowcharttoidentifyeachprocesscomponent.Step2Brainstormpotentialfailuremodes—Reviewexistingdocumentationanddataforclues.Step3Listpotentialeffectsoffailure—Theremaybemorethanoneforeachfailure.Step4AssignSeverityrankings—Basedontheseverityoftheconsequencesoffailure.Step5AssignOccurrencerankings—Basedonhowfrequentlythecauseofthefailureislikelytooccur.Step6AssignDetectionrankings—Basedonthechancesthefailurewillbedetectedpriortothecustomerfindingit.Step7CalculatetheRPN—SeverityXOccurrenceXDetection.Step8Developtheactionplan—Definewhowilldowhatbywhen.Step9Takeaction—ImplementtheimprovementsidentifiedbyyourPFMEAteam.Step10CalculatetheresultingRPN—Re-evaluateeachofthepotentialfailuresonceimprovementshavebeenmadeanddeterminetheimpactoftheimprovements.--------------------------------------------------------------------------------Step1:ReviewtheProcessReviewtheprocesscomponentsandtheintendedfunctionorfunctionsofthosecomponents.Useofadetailedflowchartoftheprocessoratraveler(orrouter)isagoodstartingpointforreviewingtheprocess.ThereareseveralreasonsforreviewingtheprocessFirst,thereviewhelpsassurethatallteammembersarefamiliarwiththeprocess.Thisisespeciallyimportantifyouhaveteammemberswhodonotworkontheprocessonadailybasis.Thesecondreasonforreviewingtheprocessistoidentifyeachofthemaincomponentsoftheprocessanddeterminethefunctionorfunctionsofeachofthosecomponents.Finally,thisreviewstepwillhelpassurethatyouarestudyingallcomponentsoftheprocesswiththePFMEA.Usingtheprocessflowchart,labeleachcomponentwithasequentialreferencenumber.ThesereferencenumberswillbeusedthroughouttheFMEAprocess.Themarked-upflowchartwillgiveyouapowerfulvisualtorefertothroughoutthePFMEA.Withtheprocessflowchartinhand,thePFMEAteammembersshouldfamiliarizethemselveswiththeprocessbyphysicallywalkingthroughtheprocess.Thisisthetimetoassureeveryoneontheteamunderstandsthebasicprocessflowandtheworkingsoftheprocesscomponents.Foreachcomponent,listitsintendedfunctionorfunctions.Thefunctionofthecomponentisthevalue-addingrolethatcomponentperformsorprovides.Manycomponentshavemorethanonefunction.Returntotop--------------------------------------------------------------------------------Step2:BrainstormPotentialFailureModesInStep2,considerthepotentialfailuremodesforeachcomponentanditscorrespondingfunction.Apotentialfailuremoderepresentsanymannerinwhichthecomponentorprocessstepcouldfailtoperformitsintendedfunctionorfunctions.UsingthelistofcomponentsandrelatedfunctionsgeneratedinStep1,asateam,brainstormthepotentialfailuremodesforeachfunction.Don’ttakeshortcutshere;thisisthetimetobethorough.Prepareforthebrainstormingsession.Beforeyoubeginthebrainstormingsession,reviewdocumentationforcluesaboutpotentialfailuremodes.Returntotop--------------------------------------------------------------------------------Step3:ListPotentialEffectsofFailureDeterminetheeffectsassociatedwitheachfailuremode.Theeffectisrelateddirectlytotheabilityofthatspecificcomponenttoperformitsintendedfunction.Aneffectistheimpactafailurecouldmakeifitoccurred.Somefailureswillhaveaneffectonthecustomersandothersontheenvironment,thefacility,andeventheprocessitself.Aswithfailuremodes,usedescriptiveanddetailedtermstodefineeffects.Theeffectshouldbestatedintermsmeaningfultoproductorsystemperformance.Iftheeffectsaredefinedingeneralterms,itwillbedifficulttoidentify(andreduce)truepotentialrisks.Returntotop--------------------------------------------------------------------------------Step4:AssignSeverityRankingsAssignaseverityrankingtoeacheffectthathasbeenidentified.Theseverityrankingisanestimateofhowseriousaneffectwouldbeshoulditoccur.Todeterminetheseverity,considertheimpacttheeffectwouldhaveonthecustomer,ondownstreamoperations,orontheemployeesoperatingtheprocess.Theseverityrankingisbasedonarelativescalerangingfrom1to10.A“10”meanstheeffecthasadangerouslyhighseverityleadingtoahazardwithoutwarning.Conversely,aseverityrankingof“1”meanstheseverityisextremelylow.Therankingscales(forseverity,occurrence,anddetection)aremissioncriticalforthesuccessofaPFMEAbecausetheyestablishthebasisfordeterminingriskofonefailuremodeandeffectrelativetoanother.ThesamerankingscalesforPFMEAsshouldbeusedconsistentlythroughoutyourorganization.ThiswillmakeitpossibletocomparetheRPNsfromdifferentFMEAstooneanother.SeeFMEAChecklistsandFormsforanexamplePFMEASeverityRankingScale.Thebestwaytocustomizearankingscaleistostartwithastandard,genericscaleandthenmodifyittobemoremeaningfultoyourorganization.Asyouaddexamplesspecifictoyourorganization,consideraddingseveralcolumnswitheachcolumnfocusedonatopic.Onetopiccouldprovidedescriptionsofseveritylevelsforoperationalfailures,anothercolumnforcustomersatisfactionfailures,andathirdforenvironmental,health,andsafetyissues.SeeFMEAChecklistsandFormsforanexamplesofCustomPFMEARankingScales.(Examplesofcustomscalesforseverity,occurrence,anddetectionrankingsareincludedinthisAppendix.)Returntotop--------------------------------------------------------------------------------Ste