【Dell的FMEA教材失效模式影响分析】（DOC36页）

FailureModeEffectsAnalysis失效模式影响分析Objectives课程目标Bytheendofthetraining,youwillbeableto:在本堂课程结束时,您将能够:1.Compareandcontrastthedifferenttypesoffailuremodeeffectsanalysis(FMEA).比较与对照不同类别的失效模式影响分析(FMEA).2.CharacterizethedifferencesinquestionsaskedincompletingeachtypeofFMEA.区分在完成不同类别的FMEA过程中所提出问题的特性.3.DefinedesignFMEAandprocessFMEA.定义设计FMEA与流程FMEA.4.DescribehowtoapplyFMEAtoaprocessmap.了解如何将FMEA运用于流程图.5.ListthestepsandcomponentsusedinbuildinganFMEA.将建立FMEA的步骤与要件列出.6.Demonstratehowtoassesslevelofrisk.展示如何评估风险等级.7.Prioritizeriskassessmenttodrivecorrectiveactions.排定风险评估优先级以推动矫正措施.FEMAandWhatisit?什么是失效模式影响分析FMEACouldthesehavebeenavoided?TheBhopaltragedyTheValujetaircrashThecontaminationofmeatatHudsonFoodsTheY2Kproblem下列事件原本是否可以避免呢?印度波布尔化工厂毒气外泄惨剧美国Valujet航空公司坠机意外美国Hudson食品公司肉品污染事件千禧虫问题WhatisFMEA?什么是失效模式影响分析Disciplinedapproachtostudyingfailuresin-Product-System-Process-Service-Pluscausesandeffects有系统的研究下列各种失效-产品-系统-流程-服务-原因与结果Methodthatquantifieslevelofrisk用量化评估风险等级的一种方法.RequirementofQS9000QS9000品管系统要求条件之一.Tooltouseonneworexistingproducts,processes,services,etc.用于新的或现有的产品,流程,服务,等等的工具.WhenFMEA’sShouldBeConducted何时该做FMEALifeCycleCost生命週期成本StagesinProduct/ServiceLifeCycle產品/服務生命週期之各個階段FMEAExerciseFMEA练习FMEAExercise1FMEA练习一Considerthepagerasacommunicationdevice.Answerthefollowingquestions:将呼叫器当做一个通讯工具.回答下列问题:1.Identifythemostseriousfailurethatcanoccurwithapager.列出呼叫器可能发生最严重的失效状况(故障)._______________________________________________________________________________________________________________________________________________________________________________________2.Whatcouldbethe“worstcase”effectofthisfailure?这个失效状况所能导致的最糟结果是什么?___________________________________________________________________________________________________________________________________________________________________________________________________________________________3.Identify5causesthatleadtosuchfailure,andrankinorderofpriorityforcorrectiveaction.列出五个导致这个失效状况的原因,并将它们矫正措施的优先等级列出.Cause原因Rank等级FMEAExercise1,ContinuedFMEA练习一,续前页Pointstoconsider:Whatwasthebasisforallottingtheranksyoudid?Howsuredidyoufeelaboutwhatyouweredoing?Doyouthinkyourrankingwillagreewithmostotherpeopleintheclass?Why?Wouldateameffortbebetterorworse?考虑以下各点:您分配优先等级的参考依据是什么?您对您的结论有多大的信心?您认为这个班里大部份的学员会同意您的评比等级吗?为什么?小组合作的结果会更好或更差?FailureModeEffectsAnalysis,ContinuedFMEA分析,续前页ProbabilityofOccurrence–Cause发生机率–原因Veryrare,maybeoncein10yrs.,or1ppb1非常罕见,每＋年才可能发生一次,或小于十亿分之一Rare,maybeoncein5yrs.,orX00ppb2罕见,每五年才可能发生一次,或大约为十亿分之数百Couldoccursomewhatfrequently,morethanonce/2yrs.,or100ppm3发生频率略高于每两年一次,或小于百万分之一百Couldoccur1to3times/yrorbetween100and1000ppm4每年发生一至三次,或介于百万分之一百至百万分之一干Definitelymorethanoneoccurrenceperquarter,orabove1000ppm5发生频率多于每季一次,或高于百万分之一千Severity–Effect严重性–影响Minorinconvenienceinpersonal/worklife1对个人生活与工作稍有不便Noticeableimpacttoworkschedule/personalplans2对个人与工作计划稍有影响Affectsrelationshipswithboss/familymembers3对上司/家人之间的关系有影响Lossofrevenue,relationships,andorreputation4对收入,关系,或名誉有损失Couldresultininjury,/othersafetyissues5导致受伤或其它安全事故Detection–FailureMode(orCause)侦测能力–失效模式(或原因)Failureoritscauseisreadilyorselfevident1失效本身或其原因显而易见或自行彰显Manualinspectionortestcaneasilydetectfailure/cause2人工检验或测试可以轻易侦测到失效或其原因Failureishardtodetect,specialinstrumentsortrainingreq.3失效不易侦测,必须要有特殊仪器或训练Failuredetectionwilldestroytheunit4失效侦测过程会损毁产品Failurecanslipbyunnoticed5无法侦测到失效CompletethefollowingFMEARatingWorksheetfortheprobleminExercise1.将练习一的问题排定FEMA优先等级并填入下表.Productorfeature产品或特性Failuremode失效模式Effect影响SCause原因OCurrentcontrols现行管制DRPN风险系数Rank等级FailureModeEffectsAnalysis,ContinuedFMEA分析,续前页CommontypesofFMEAFMEA的一般类型Design/Product–Focusonproduct,system,sub-system,orcomponentpart设计/产品–重点在产品,系统,次系统,或零附件.Process–Focusprocess.Outputusuallyaproduct流程–重点在流程本身.其输出通常为产品.Service–Focusonprocess,butoutputisservice服务–重点在流程.但其输出为服务.Design/ProductFMEA设计/产品FMEABenefits:IncreasesrobustnessofdesignsIdentifiesfailuremodesEnablesprioritysettingforcorrectiveactionSupportsfailurediscussionbetweendifferentgroupsProvidesaframeworkforcontinuousimprovementofdesignsIdentifiesoftenmissedfailuremodeswhenusedatsystemslevelCustomers:Enduser,manufacturing,assembly,serviceand…好处:更完善的产品设计找出失效模式得以设定矫正措施的优先级支持不同工作小组之间的失效案例讨论提供设计持续改善的工作架构找出在系统阶层经常遗漏的失效模式客户:最终用户,制造,组装,服务,与…ProcessFMEA流程FMEABenefits:IncreasesrobustnessofprocessIdentifieshighriskprocessstepsIdentifiesprocessvariablescontrolsSupportsfailurediscussionbetweendifferentgroupsDocumentsresultsofprocessProvidesframeworkforcontinuousimprovementofprocesses……Customers:Enduser,downstreammanufacturing/assemblyprocesses,serviceoperationsand…好处:更完善的流程设定找出高风险的流程步骤找出流程变量的控制办法支持不同工作小组之间的失效案例讨论经由纸上作业制订流程提供流程持续改善的工作架构……客户:最终用户,下游制造,组装流程,服务作业,与…FailureModeEffectsAnalysis,ContinuedFMEA分析,续前页ServiceFMEA服务FMEABenefits:ReducesprobabilityofservicenotmeetingexpectationsIdentifiesfailuremodesEnablesprioritizationforcorrectiveactionPinpointshighriskstepsinserviceprocessIdentifieshighestvaluecontrolstepsCustomers:Enduser,downstreamprocessowners,and….好处:降低服务不良的