DFMEA---失效模式與后果分析

1、DFMEA-失效模式與后果分析(Design Failure Mode &Effect Analysis)Marian(Shenzhen)Co.,Ltd編制 ： 曹喜元 Formation By： Jack Cao 日期： Date： 1-Feb-2013主要內(nèi)容Main content1.DFMEA 介紹 4.DFMEA 關(guān)鍵參數(shù)DFMEA Presentation DFMEA Key Parameter2.DFMEA 職責(zé) 5.DFMEA 表單填寫說明DFMEA Responsibility DFMEA Form Filling Explanation3.DFMEA 制作流程 6.

2、DFMEA 案例DFMEA Make Process DFMEA Example一、DFMEA 的介紹DFMEA Presentation DFMEA 是FMEA 中的一種，F(xiàn)MEA分為：DFMEA 和PFMEADFMEA is in the FMEA one type, FMEA Contain :DFMEA & PFMEADFMEA 是由負(fù)責(zé)設(shè)計的工程師或小組，在產(chǎn)品設(shè)計階段盡可能的范圍內(nèi)預(yù)估產(chǎn)品在設(shè)計上可能發(fā)生的缺點.DFMEA is Engineer or group to responsible scheme, As far as possible within the sc

3、ope of the estimated product design on the possible faults in the product design stage.PFMEA 是由負(fù)責(zé)制造裝配的工程師或小組，預(yù)估產(chǎn)品在生產(chǎn)過程階段或之前可能會發(fā)生的缺點.PFMEA is PE or group to responsible scheme , As far as possible the estimated product possible faults in the productive process or before.本章節(jié)重點講述DFMEAThis chapter focus

4、es on DFMEA.DFMEA 的形成DFMEA FormationDFMEA 是由負(fù)責(zé)設(shè)計的工程師或小組，在盡可能的范圍內(nèi)預(yù)估產(chǎn)品在設(shè)計上可能發(fā)生的缺點，衡量該項缺點或可能造成的影響，并擬定為防止或檢測該缺點應(yīng)改善的設(shè)計控制，并推動其標(biāo)準(zhǔn)化作業(yè)，且必須配合設(shè)計發(fā)展之程序反復(fù)執(zhí)行.DFMEA is Engineer or group to responsible scheme, As far as possible within the scope of the estimated product design on the possible faults in the product d

5、esign stage, Measure the faults or can cause influence, and plan to prevent or testing the defect should be improved design control, and promote the standardized operation, and must fit in with the development of design program and implementation.最終成品及其所有相關(guān)的系統(tǒng)、子系統(tǒng)都應(yīng)納入評估.DFMEA是設(shè)計小組，即公司工程，運(yùn)用設(shè)計，工程經(jīng)驗或分析

6、方法等而形成的.The final and all related system, subsystem should be included in assessment. DFMEA is the design team, namely the company project, the use of design, engineering experience or analysis methods and form.DFMEA 必備條件DFMEA Essential Condition 確認(rèn)已知及潛在的失效模式； Confirm the known and the potential fai

7、lure mode. 確認(rèn)每一個失效模式的效應(yīng)和原因； Confirm each failure mode effect and reasons. 風(fēng)險優(yōu)先評估（嚴(yán)重性、發(fā)生頻率、難檢度）； Risk priority evaluation (severity, occurrence frequency and difficult to check degree) 提供問題的數(shù)據(jù)及改善行動； Provide problem of data and improvement action. DFMEA 的動態(tài)鏈DFMEA Trends CatenationDFMEA 是個循環(huán)過程，在設(shè)計方案最終形

8、成之時或之前開始.DFMEA is a cyclic process, the design scheme of final form or before the start.在產(chǎn)品開發(fā)各階段中，當(dāng)設(shè)計有變化或得到其他信息時，應(yīng)及時，不斷地修改，最終在產(chǎn)品加工圖樣完成之前全部結(jié)束。In every stage of product development, when the design change or get other information, should be prompt, constantly modified, finally, in product processing p

9、attern until all over.二、DFEMA 職責(zé)DFMEA Responsibility 工程經(jīng)理：DFMEA 總體負(fù)責(zé)人，負(fù)責(zé)組建DFMEA 團(tuán)體，提出 DFMEA 實施計劃，并組織召開DFMEA 會議，分配團(tuán)隊人員任務(wù) 組織DFMEA 評審，DFMEA 審核. Project manager: general manager, responsible for DFMEA, this paper puts forward a DFMEA group DFMEA implementation plan, and organize a DFMEA meeting, distrib

10、ution team personnel task Organization DFMEA review, DFMEA audit. 工程師：負(fù)責(zé)主導(dǎo)DFMEA文件編寫、修改和升級. Engineer: responsible for leading DFMEA document preparation, modification and upgrade.二、DFEMA 職責(zé)DFMEA Responsibility 工程助理：負(fù)責(zé)客戶投訴問題，研發(fā)、試產(chǎn)、量產(chǎn)中問題 的收集，及 時反饋到DFMEA團(tuán)體負(fù)責(zé)人處，并參與O,S,D 參數(shù)評估，提供量 產(chǎn)CPK 數(shù)據(jù). Project assistan

11、t: responsible for customer complaint problem, research and trial production, the quantity of collection, and render When the feedback to DFMEA group place, and participate in O, S,D parameter evaluation, Supply volume production CPK data. 試樣工程師：負(fù)責(zé)研發(fā)產(chǎn)品測試過程 中所出現(xiàn)問題點的收集并及時 反饋到DFMEA負(fù)責(zé)人處，參與O,S,D參數(shù)評估. Sam

12、ple engineer: responsible for research and development in the process of product testing problems point collection and timely feedback to the DFMEA chief place, participate in O, S, D parameter evaluation.二、DFEMA 職責(zé)DFMEA Responsibility CQE：負(fù)責(zé)客戶需求信息歸納整理，DFMEA建議措施監(jiān)督實施、追 蹤，實施效果反饋，根據(jù)DFMEA和客戶需求等信息制定控制計劃，

13、 并參與 O,S,D 參數(shù)評估. CQE: Be responsible for the customer demand information summary, DFMEA suggested measures supervision and implementation, tracking and effect feedback, according to the DFMEA and requirements for information such as control plan, and participate in O, S, D parameter evaluation.三、DFM

14、EA 制作流程DFMEA Make process 注：團(tuán)隊制定目標(biāo)，使團(tuán)隊清楚新產(chǎn)品或以改善為 目標(biāo)，并需要了解客戶需求。 Note: The team set goals, make the team clear new products or to improve as the goal, and need to understand customer needs. 使用方法；Method of application. 客戶要求的設(shè)計/工程SPEC；Customer requested project & Engineering SPEC. 產(chǎn)品信賴；Product Trust

15、. 制程、生產(chǎn)、裝配 要求；Process, Production Assemble of Requirement. 品質(zhì)目標(biāo). Quality Destination.組成DFMEA團(tuán)隊Constitute DFMEA Team確定目標(biāo)Confirm Destination三、DFMEA 制作流程DFMEA Make process 產(chǎn)品設(shè)計及類似產(chǎn)品設(shè)計的問題及原因； Product design and similar product design problems and reasons 制造工藝及類似產(chǎn)品制程中常及的不良原因； Manufacturing process and si

16、milar products in process and bad reason. 類似產(chǎn)品的制程能力及原因； Similar products of process capability and the reason. 類似產(chǎn)品的客訴及原因； Similar products of customer complaint and the reason. 類似產(chǎn)品的依賴性失效及原因； Similar products the dependence of the failure and the reason. 類似產(chǎn)品的管理性問題； Similar products of managerial p

17、roblems.資料收集Data Collection三、DFMEA 制作流程DFMEA Make process 使用維修； Use Maintain. 環(huán)境. Environment. 表格格式 Table Format. 分層層次 Delamination Administrative levels. 失效定義 Failure Definition. 成果整合 Achievement Integration. 時機(jī) Opportunity.資料收集Data Collection制訂執(zhí)行方案Formulate implement Plan三、DFMEA 制作流程DFMEA Make pro

18、cess分析制程特性Analysis Process Character定義制造流程Definition production Process分析產(chǎn)品特性Analysis Product Character分析失效原因Analysis Failure Cause分析現(xiàn)行控制方法Analysis Control Method分析失效效應(yīng)Analysis Failure Effect分析發(fā)生率Analysis Occurrence Rate分析難檢度Analysis Detection分析嚴(yán)重度Analysis Severity計算風(fēng)險優(yōu)先數(shù)Calculated Risk Priority Num

19、ber分析制程特性Analysis Process Character三、DFMEA 制作流程DFMEA Make process決定優(yōu)先改善的失效模式Decide Ameliorative Failure Mode建議改善措施Recommendation Improvement Measures改善實施Improvement Implement結(jié)果確認(rèn)有效Result Notarize Effective四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度、發(fā)生率、難檢度、風(fēng)險優(yōu)生數(shù)Severity, Occurrence, Detection, RPN嚴(yán)重度 Severit

20、y-S發(fā)生率 Occurrence-O難檢度 Detection-D風(fēng)險優(yōu)生數(shù) Risk Priority Number-RPNRPN=S*O*D四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度Severity衡量失效的影響程度.Assessment failure incidence失效影響產(chǎn)品或制程，某一失效會對產(chǎn)品外觀、結(jié)構(gòu)、功能、性能穩(wěn)定性、可靠性的影響；或?qū)ο乱粋€制程，使用者和設(shè)備的影響；或?qū)ψ罱K客戶，政府法規(guī)、安全、環(huán)保等的違及.Failure affect product or process, a failure to product appearance,

21、 structure, function, performance stability and reliability of the influence; Or to the next process, the user and the influence of the equipment; Or to end customers, government regulations, safety, and environmental protection, and a default.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度Severity嚴(yán)重度的劃分標(biāo)準(zhǔn)-主觀判定S

22、everity Classification Standard-Subjectivity Decide其大小由失效模式的影響程度而定，以1至10表示等級.Its size of the failure mode of the influence degree to decide, be 1 to 10 show level.1級最輕微，10級最嚴(yán)重. 1Level best slight , 10 Level best grave.1級-幾乎不會有什么影響.1Level-Almost has no influence.10級-違反安全和法規(guī).10Level-Violation of safet

23、y and regulations.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度分類Severity Classify 耐火性、自然性、UL 、RHoS&HF Fire Resistance, Naturalness,UL,RHoS&HF一、 危險特性 Catastrophic 工業(yè)標(biāo)準(zhǔn)(無法滿足而不能銷售） Industry StandardIncapable Con not Market. 客戶要求 Customer Request 內(nèi)部工程需要由Critical測量項目 Internal ENG need for critical measure

24、project四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度分類Severity Classify 客戶及供應(yīng)商共同制定特性； Customer and Supplier together formulate features.二、 重大特性 Significant 或客戶指定特性，如導(dǎo)電或絕緣；(滿足而不能銷售給指定客戶) Or customer appoint features, For instance EC & Insulation.Content Con not Market 設(shè)計工程指定的特性； Designation Customer DE appo

25、int features. 行業(yè)標(biāo)準(zhǔn). Industrial standard.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度分類Severity Classify 可靠性測試，如拉拔力測試； . Reliability Testing, For example drawing force test .三、 主要特性 Major 產(chǎn)品制程不良率及分析 Product process reject ratio and analysis.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度等級標(biāo)準(zhǔn)Severity Rank Standard等級/評分Rank劃

26、分標(biāo)準(zhǔn)Divide Standard1幾乎無影響Almost no influence2產(chǎn)品在客戶使用組裝過程中，組裝性差，客戶一般難已發(fā)現(xiàn)，關(guān)注的問題.Products in the customers to use assembly process, assembly sex difference, the customer general difficult has found, pay attention to the problem.3產(chǎn)品之中主要應(yīng)用的功能稍有瑕疵，如絕緣等，非專業(yè)人員無法識別，EMC II級要求.The product is mainly used in the

27、function of the slightly defects, such as insulation, laypeople cant identify, EMC level II requirements.4在高于產(chǎn)品承諾的環(huán)境中使用失效，但此環(huán)境低于公司內(nèi)部控制標(biāo)準(zhǔn)或者已達(dá)到行業(yè)協(xié)會標(biāo)準(zhǔn)要求，EMC I級要求.不符合標(biāo)準(zhǔn)化的定義.In the above product promised environment with failure, but the environment is lower than the internal control standards or has rea

28、ched industry association standard requirements, EMC I level requirement. Do not conform to the standard definition.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度等級標(biāo)準(zhǔn)Severity Rank Standard等級/評分Rank劃分標(biāo)準(zhǔn)Divide Standard5存在的問題使產(chǎn)品長期運(yùn)行的可靠性能降低，如產(chǎn)品粘力、導(dǎo)電產(chǎn)品的導(dǎo)電性能等，產(chǎn)品結(jié)構(gòu)復(fù)雜，甚至需要培訓(xùn)才能完成或當(dāng)前的技術(shù)無法解決的功能性問題 .Problems make the produ

29、ct long-term operation of the lower reliability, such as product viscous force, conductive products of conductive performance and so on, the product structure is complex, even need training to complete or current technology cannot solve the problem of functional.6產(chǎn)品維護(hù)復(fù)雜，裝配、生產(chǎn)非常困難；設(shè)計的產(chǎn)品公司工藝無法完成；客戶獨特配

30、件的兼容性問題 ；不能95以%以上機(jī)率復(fù)現(xiàn)的問題；計算機(jī)監(jiān)測功能失效或誤差大.Product maintenance, assembly, production is very difficult; Design products company process was unable to complete; Customer unique accessories compatibility problem; Cant 95 to % above probability reproduction; Computer monitoring function failure or big erro

31、r.7客戶關(guān)注的重點功能性問題或者是產(chǎn)品主推場所應(yīng)用的兼容性問題；產(chǎn)品量化參數(shù)不達(dá)標(biāo).Customer focus of concern functional problems or is the product of the main place the application compatibility problem; Product quantitative parameters not standard.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter嚴(yán)重度等級標(biāo)準(zhǔn)Severity Rank Standard等級/評分Rank劃分標(biāo)準(zhǔn)Divide Standard8基本

32、功能失效，失效影響計算機(jī)數(shù)據(jù)處理功能.The basic function failure and influence the computer data processing function.9影響產(chǎn)品安全運(yùn)行或者包含不符合法律、法規(guī)；產(chǎn)品執(zhí)行標(biāo)準(zhǔn)影響人身安全；產(chǎn)品失效時有警告.Influence the safe operation of the product or contain does not comply with the laws, rules and regulations. Product standards affect personal safety; Product

33、 failure is warning.10影響產(chǎn)品安全運(yùn)行或者包含不符合法律、法規(guī)；產(chǎn)品執(zhí)行標(biāo)準(zhǔn)影響人身安全；產(chǎn)品失效時無警告.Influence the safe operation of the product or contain does not comply with the laws, rules and regulations. Product standards affect personal safety; Product failure isnt warning.四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter發(fā)生率Occurrence某一原因而導(dǎo)致失效發(fā)生

34、的幾率.A reason to the odds of failure.劃分標(biāo)準(zhǔn)：依據(jù)不良品出現(xiàn)的機(jī)率來定，以1至10表示等級.The division standard: according to the probability of bad product appeared to decide, be 1 to 10 show level.1級最輕微，10級最嚴(yán)重. 1Level best slight , 10 Level best grave.1級-幾乎不會發(fā)生.1Level- Almost wont happen.10級-肯定會發(fā)生.10Level- Will happen四、DFM

35、EA 關(guān)鍵參數(shù)DFMEA Key Parameter發(fā)生率Occurrence劃分標(biāo)準(zhǔn)-CPK、主觀判定、統(tǒng)計資料Divide Standard-CPK, Subjective judge, statistical information劃分標(biāo)準(zhǔn) Divide Standard等級/評分Rank描述Describe發(fā)生率OccurrenceCPK1(Remote)幾乎不可能發(fā)生Almost wont happen.1/1500K1.672(Very Low)有輕度發(fā)生的可能With mild possible1/150K1.503(Low)有可能發(fā)生possible1/15K1.334(Mod

36、erate)偶爾發(fā)生，但不占有大的比例Occasionally occur, but dont have great proportion1/2K1.175(Moderate)1/400PCS1.006(Moderate)1/80PCS0.83四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter發(fā)生率Occurrence劃分標(biāo)準(zhǔn)-CPK、主觀判定、統(tǒng)計資料Divide Standard-CPK, Subjective judge, statistical information劃分標(biāo)準(zhǔn) Divide Standard等級/評分Rank描述Describe發(fā)生率OccurrenceCP

37、K7(High)經(jīng)常發(fā)生Often occur1/20PCS0.678(High)1/8PCS0.519(Very high)幾乎不可避勉Almost do not avoid layer1/3PCS0.3310(Very high)1/2PCS0.33四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter難檢度Detection在現(xiàn)行的控制措施下，偵測失效發(fā)生的能力.In the current control measures, the ability to detect failure happened.劃分標(biāo)準(zhǔn)：依據(jù)失效模式檢驗的難易程度來定，以1至10表示等級.The div

38、ision standard: According to the failure mode of the test difficulty to set, be 1 to 10 show level.1級最容易，10級為幾乎不可能發(fā)現(xiàn). 1Level best easy , 10 Level for Almost impossibility find.1級-用有效的手段完全可以檢測出來1Level-With effective means completely can be detected.10級-無任何手段可以檢測出來.10Level-No means can be detected.四、D

39、FMEA 關(guān)鍵參數(shù)DFMEA Key Parameter難檢度Detection劃分標(biāo)準(zhǔn)-主觀判定、統(tǒng)計資料Divide Standard-Subjective judge, statistical information劃分標(biāo)準(zhǔn) Divide Standard等級/評分Rank描述Describe可偵度Detection12幾乎可以肯定地檢測出來Almost certainly detected99.99%35有良好的手段可以檢測出來Have good means can be detected99.80%68可能能檢測出來Might be able to test out98.00%9有可

40、能檢測不出May cannot be detected90.00%10很有可能檢測不出來Very likely test does not come out90.00%四、DFMEA 關(guān)鍵參數(shù)DFMEA Key Parameter風(fēng)險系數(shù)Risk Priority NumberRPN=S*O*D風(fēng)險系數(shù)RPN排出次序后，RPN越大越優(yōu)先解決.RPN在100以上必須解決；50RPN100應(yīng)盡可能解決，不能解決必須加嚴(yán)控制；RPN50可不加控制.當(dāng)嚴(yán)重度(S)很高或發(fā)生率(O)很高時，不管RPN大小如何，都必制定相應(yīng)改善或控制措施，并指定責(zé)任人和改善完成日期.Risk coefficient RP

41、N discharge order, the bigger the RPN priority. RPN in more than 100 must be solved; 50 RPN 100 should as far as possible to solve, cant solve must be tightened control; RPN 50 dont add control. When the severity (S) or high incidence (O) is very high, no matter how RPN size will be formulate the co

42、rresponding improvement or control measures, and appoint responsible persons and improve the completion date.如何制定改善措施How to make the improvement measures針對預(yù)防/糾正措施，以降低評價等級的內(nèi)容順序為：嚴(yán)重度、發(fā)生率及偵測度；Aiming at preventing/corrective measures, in order to reduce the content of the evaluation grade order: (S), (O

43、) ,(D).通過設(shè)計變更來消除或控制一個或多個失效模式的起因機(jī)理，能降低嚴(yán)重度等級；Through the design change to eliminate or control one or more of the cause of the failure mode mechanism, can reduce the severity level;透過設(shè)計變更，去除或管制某一或多個影響失效模式的原因或設(shè)備，只能降低發(fā)生率的等級.Through the change of the design, remove or control one or more of the cause of

44、the failure mode effect or equipment, can reduce the incidence of grade.增加設(shè)計驗證，修改測試計劃，修改原物料規(guī)格，只可降低難檢度.To increase the design verification, modifying the test plan, modify the original material specifications, can only reduce the difficult degree of test.五、DFMEA 表單填寫說明1DFMEA Notes on completing the f

45、orm(1) DFMEA 編號：填入DFMEA文件的編號，以便要詢； DFMEA Numbers: fill in the DFMEA file Numbers, so that to information; 項目：填入所分析的系統(tǒng)、子系統(tǒng)或零件的過程名稱，編號； Project: fill in the analysis of the system, subsystem or parts of the process name, Numbers; 設(shè)計責(zé)任：部門、小組還應(yīng)包括供方的名稱； Design responsibility: department, the team also sh

46、ould include the name of the supplier; 填入負(fù)責(zé)DFMEA 工作的工程師姓名、電話及所在公司名稱； Fill in the responsible of the engineers DFMEA name, phone number and the name of the company; 填入將使用或正被分析的設(shè)計過程影響的預(yù)期的機(jī)型和料號； Fill in will use or are being analyzed the influence of the design process of the expected type and material

47、 number; 關(guān)鍵日期：填入DFMEA初次預(yù)定完成日期，該日期不應(yīng)超過計劃開始設(shè)計生產(chǎn)發(fā)布日期. The key date: fill in the DFMEA first target completion date, this date shall not exceed the design plan to begin production release date.五、DFMEA 表單填寫說明2DFMEA Notes on completing the form(2) DFMEA 日期：填入編制DFMEA原始稿的日期及最新修訂日期； DFMEA date: fill in the d

48、raw up DFMEA date and latest revision date. 核心小組：列出有權(quán)確定和執(zhí)行任務(wù)的責(zé)任部門和個人姓名，如果對某一特定原因無建議措施，那么 就在該欄中寫“N/A”. The core team: list shall have the right to determine and implement the responsibility of the department and individual task name, if for A particular reason no suggested measures, then write in the

49、 column of N/A. 項目/功能：填入被分析項目的名稱和編號，若該項目有多種功能，且有不同的失效模式，應(yīng)把所有功 都單獨列出. Project/function: fill in the name of the project are analyzed and Numbers, if the project has a variety of functions, and have different failure mode, we should put all functions are listed separately. 潛在失效模式：對一個特定項目及其功能，應(yīng)用規(guī)范化，專業(yè)性

50、的術(shù)語來列出每一個潛在的失效模式 前提是這種失效可能發(fā)生，但不一定發(fā)生. Potential failure mode: for a specific project and its function, the application of standardized, professional terms to list each potential failure mode provided that failure may occur, but does not necessarily occur.五、DFMEA 表單填寫說明3DFMEA Notes on completing the form(3) 潛在失效后果，就是失效模式對系統(tǒng)功能的影響，一般是客戶在使用時看到的狀況； Potential failure consequences, is the failure mode of the influence of the system function, it is to see the customers in the use of the situation. 嚴(yán)重度(S) Severity 分級（重要程序）用于對零件、系統(tǒng)、子系統(tǒng)的產(chǎn)品特性分級：關(guān)鍵、主要、重要、輕微等. Classification (important progra