Introduction_FMEAChineseversion

11“Makingtodaybetterthanyesterday”IntroductiontoFMEA2CarmelGlobalSummitMeeting,Sep20133WhatIsLean?Producingqualityproductwithminimalresources(Materials,Utilities,Labour,MachineandTime)tofulfillcustomerdemand&requirement.(Quantity,QualityandDelivery)4CarmelGlobalSummitMeeting,Sep20135LEAN–SIGMASYNERGY:LSS6Contents什么是FMEAFMEA的目标何时应用FMEAFMEA的步骤FMEA小提示7LearningObjectives学习目标Aftercompletingthismodule,youwillbeableto…完成这一单元，你能够，1.识别出FMEA需求IdentifytheneedforFMEA2.使用流程图做FMEA分析UsetheProcessMaptodevelopanFMEA3.使用FEMA识别高失效风险和失效原因UseFMEAtoidentifyhighpriorityfailuremodesandcausesoffailure4.识别可以降低失效风险的建议措施Identifyrecommendedactionstoreducetheriskoffailure7JohnsonControls,Inc.©Sept.2002W2FMEA.ppt8WhatisFMEA?什么是FMEA•失效模式和影响分析是一组系统化的行动，目的在于：–识别和评估潜在失效及其影响–识别出可以降低和消除失效机会的方案–记录分析发现8JohnsonControls,Inc.©Sept.2002W2FMEA.ppt9HowisFMEAused如何使用FMEA•FMEA输入是流程图•FMEA是一个分析过程isananalyticalprocess.•FMEA输出是失效模式和失效原因优先等级outputisprioritizedfailuremodesandcausesoffailure.FMEA流程图失效模式和失效原因优先等级输入过程输出10WhentoUseFMEA何时应用FMEA•FMEA是用来预防失效的发生，避免内外部客户的投诉。•isdesignedtopreventfailuresfromoccurringorfromgettingtointernalandexternalcustomers.•因此，对于可能产生失效并且失效影响会带来潜在严重后果的情形下，应用FMEA是必不可少的。•Therefore,FMEAisessentialforsituationswherefailuresmightoccurandtheeffectsofthosefailuresoccurringarepotentiallyserious.11FourCommonClassesofFMEA•SystemFMEA•系统FMEA–关注系统间相互作用是如何失效的；Focusesonhowinteractionsamongsystemsmightfail.•设计FMEADesignFMEA–关注于产品设计中是如何失效Focusesonhowproductdesignmightfail.•过程FMEAProcessFMEA–关注于过程如何导致的产品可能失效Focusesonhowprocessesthatmaketheproductmightfail.•机械FMEAMachineryFMEA–关注于机械过程如何导致的可能失效Focusesonhowmachinerythatperformprocessesmightfail.12AIAGModelforQualityPlanning质量策划的AIGI模式13UnderstandingofFailureSequence理解失效顺序14FMEAInformationLinkage15FMEAStepsFMEA步骤1.填写表头信息Fillintheheaderinformation.2.填写过程步骤Fillintheprocesssteps.3.对每一步骤/过程，列出要求Foreachprocessstep,listrequirements.4.对每一要求列出失效模式Foreachrequirement,listthefailuremode.5.对每一失效模式，列出失效影响Foreachfailuremode,listtheeffectoffailure.6.对每一失效影响，评估严重程度Foreacheffectoffailure,estimatetheseverity.7.对米易失效模式，列出各种原因Foreachfailuremode,listcauses.8.对每一失效原因，评估发生概率Foreachcauseoffailure,estimatethelikelihoodofoccurrence.9.对每一失效原因，列出当前过程控制措施Foreachcauseoffailure,listthecurrentprocesscontrols.10.对每一过程控制，评估可侦测性，Foreachprocesscontrol,estimatethedetection.11.对每一失效原因，及时RPN(风险优先值）Foreachcauseoffailure,calculatetheRiskPriorityNumber.12.Forhighprioritycausesoffailureand/orfailuremodes,developrecommendedactions.16FMEAStep11.Fillintheheaderinformation.SIXSIGMA-FailureMode&EffectsAnalysis(FMEA)ProcessDescription:FMEANumber:BlackBelt:Page:ofTeamMembers:Preparedby:FMEADate:RevisionDate:ProcessStepRequirementsPotentialFailureModePotentialEffect(s)ofFailureSeverityPotentialCause(s)/Mechanism(s)ofFailureOccurrenceCurrentProcessControlsDetectionRPNRecommendedAction(s)Responsibility&TargetCompletionDateActionsTakenSevOccDetRPNActionResultsA.DescribetheprocessB.NumbertheFMEAC.IdentifytheBlackBeltD.IdentifypagenumbersE.ListteammembersF.NamethepreparerG.EntertheFMEAdateH.Entertherevisiondata17FMEA-Step22.Fillintheprocesssteps.AddallvalueaddedprocessstepsfromtheprocessmaptotheFMEAform.StartEndStep2AStep2BStep2CStep1WeldNuttoPedestalGood?ReworkYesNoProcessStepRequirementsWeldNuttoPedestalVANVANVA18FMEA-Step33.Foreachprocessstep,listrequirements.Requirementscanbespecifications,ifavailable,orstatementsofwhattheprocessstepshouldaccomplish.ProcessStepRequirementsWeldNuttoPedestalNutPresentNutWeldedSecurelyInternalThreadsingoodcondition19FMEA-Step44.Foreachrequirement,listthefailuremode.ProcessStepRequirementsPotentialFailureModeWeldNuttoPedestalNutPresentNutnotpresentNutWeldedSecurelyNutweldedinsecurelyInternalThreadsinInternalthreadsgoodconditiondamaged20IdentificationofFailureMode21FMEATipsaboutStep44.Foreachrequirement,listthefailuremode.TipsaboutStep4:Failuremodesarenegativestatementsofrequirements.Failuremodesarenotcauses.“Operatorfailstoloadweldnut”isnotafailuremode.Itisacauseofthefailuremode,“Nutnotpresent.”Thiscolumniseasy-ifyouavoiddiscussingcauses!Justwait.Everyonecandiscusscausesinstep7.22FMEA-Step55.Foreachfailuremode,listtheeffectoffailure.ProcessStepRequirementsPotentialFailureModePotentialEffect(s)ofFailureWeldNuttoPedestalNutPresentNutnotpresentCannotassembleseatbeltrestrainttopedestalNutWeldedSecurely(110lbs.min.Tensiletest)NutweldedBoltbreaksweldnutinsecurelyloosewhenseatbeltrestraintisassembledInternalThreadsinInternalthreadsSeatbeltrestraintisgoodconditiondamagedassembled,butthreadsarestripped.Assemblyisweak.23FMEATipsaboutStep55.Foreachfailuremode,listtheeffectoffailure.TipsaboutStep5:Listonly“worstcase”effectsoffailure(that’sallyouneedtoestimateseverity).Capturewhatactuallyhappenswhenthefailuremodeoccurs.Avoidgeneralstatementslike,“Partisrejected”or“Customercomplaint.”Bybeingspecificinthiscolumn,latersteps(estimatingseverity&listingcauses)willgomucheasier.24FMEA-Step66.Foreacheffectoffailure,estimatetheseverityProcessStepRequirementsPotentialFailureModePotentialEffect(s)ofFailureSeverityWeldNuttoPedestalNutPresentNutnot