福特FEMA培訓(xùn)材料210FMEATrainingDFMEAV10課件

1、福特FEMA培訓(xùn)材料210FMEATrainingDFMEAV10課件福特FEMA培訓(xùn)材料210FMEATrainingDFMEAWhen can FMEA documents be discarded? 什么時候可以處理掉FMEA文檔FMEA Documents must be retained in accordance with Global Information Standards Record Retention Schedule: FMEA必須按照全球信息記錄保持時間標(biāo)準(zhǔn)對這些文檔進行保存DFMEAs: Last use +10 years DFMEs：最終使用后+10年P(guān)FME

2、As: Last use +5 years PFMEAs：最終使用后+5年Documentation存檔When can FMEA documents be dis如何開展FMEA流程如何開展FMEA流程Targets目標(biāo)Cross- Functional Team跨功能團隊History歷史FMEAFMEAProcessFMEA過程Robustness Tools are not specified穩(wěn)健的工具沒有被運用Former FMEA Process以前的FMEA流程TargetsCross- Functional TeamHBoundaryDiagram界限圖InterfaceMat

3、rix接口矩陣P-DiagramP圖FMEA (withRobustnessLinkages)FMEA(有穩(wěn)健聯(lián)系的)Robustness and Reliability Checklist穩(wěn)健和可靠的檢查清單Design Verification Plan (DVP)設(shè)計驗證計劃Qualifies and clarifies the relationships between Systems鑒定并說明系統(tǒng)之間的關(guān)系Identifies and quantifies the strength of System Interactions識別并量化系統(tǒng)之間的相互作用Identifies Nois

4、e and Control Factors and Error States識別噪音因素，控制因素和誤差狀態(tài)Summarizes Error States, Noise Factors, and associated Design Controls總結(jié)誤差狀態(tài)，噪音因素和相關(guān)設(shè)計控制圖FMEA Process過程BoundaryDiagramInterfaceMatrDFMEADFMEADesign FMEA - An Introduction設(shè)計FEMA-開始Identify DFMEA Team 成立DFEMA小組Establish Scope 確定范圍Describe Function

5、功能描述Brainstorming頭腦風(fēng)暴Function Trees功能樹Step1DFMEA的完成Design FMEA - An IntroductionDesign FMEA Team設(shè)計FMEA-小組Design EngineerManufacturing / Process Engineer設(shè)計工程師制造/工藝工程師CORETeam核心小組Representatives from:需要的代表：Customer Service 顧客服務(wù)Suppliers 供方Test Operations 測試部門Corporate Quality 質(zhì)量部門SupportTeam支持小組Facili

6、tator服務(wù)商Design FMEA Team設(shè)計FMEA-小組DeDesign FMEA Scope設(shè)計FMEA-范圍Is the boundary or extent of the analysis defines what is included and excluded 分析的界限或范圍是否已確定包含什么，不包含什么？Scope incorrectly done: 不正確的范圍會：Lengthens analysis 擴大分析Misses target analysis 偏離目標(biāo)分析Identifies wrong team membership 錯誤地識別小組成員Design FM

7、EA Scope設(shè)計FMEA-范圍IDesign FMEA Scope設(shè)計FMEA-范圍Create a boundary diagram 創(chuàng)建界限圖Identify the boundary for analysis 確定分析界限Confirm composition of support team 確定支持小組的成員 Once core team is established.一旦成立了核心小組Design FMEA Scope設(shè)計FMEA-范圍CConstructing Boundary Diagrams創(chuàng)建界限圖Constructing Boundary DiagramsBoundar

8、y Diagram Example界限圖-范例Headlamp Assembly前燈裝配Boundary Diagram Example界限圖Interface Matrix接口矩陣Recommended robustness tool that acts as an input to a Design FMEA 接口矩陣是推薦的作為設(shè)計FEMA輸入的穩(wěn)健工具Identifies and quantifies the strength of system interactions by: 接口矩陣可以通過以下方式識別并鑒定系統(tǒng)的相互作用：Showing whether the relation

9、ship is necessary or adverse 顯示系統(tǒng)間的關(guān)系是互利的還是不利的Identifying the type of relationship 確定關(guān)系的類型Interface Matrix接口矩陣Recommend P: Physically touching I: Information exchange P E I M E: Energy transfer M: Material exchange Interaction is necessary for function Interaction is beneficial, but not absolutely n

10、ecessary for functionality Interaction does not affect functionality Interaction causes negative effects but does not prevent functionality Interaction must be prevented to achieve functionality Numbers in each corner represent the above interface types, with values denoting the following: +2 +1 0 -

11、 1 - 2 Example Interface Matrix接口矩陣的范例 P: Physically touching I: Information exchange P E I M E: Energy transfer M: Material exchange Interaction is necessary for function Interaction is beneficial, but not absolutely necessary for functionality Interaction does not affect functionality Interaction

12、causes negative effects but does not prevent functionality Interaction must be prevented to achieve functionality Numbers in each corner represent the above interface types, with values denoting the following: +2 +1 0 - 1 - 2 P: Physically touching I: InfExample Interface Matrix 接口矩陣的范例 P: Physicall

13、y touching I: Information exchange P E I M E: Energy transfer M: Material exchange Interaction is necessary for function Interaction is beneficial, but not absolutely necessary for functionality Interaction does not affect functionality Interaction causes negative effects but does not prevent functi

14、onality Interaction must be prevented to achieve functionality Numbers in each corner represent the above interface types, with values denoting the following: +2 +1 0 - 1 - 2 Example Interface Matrix 接口矩陣P-DiagramP圖Recommended structured tool to identify intended inputs and outputs for a function P圖

15、是推薦的，用于識別某一功能的預(yù)期輸入和輸出的結(jié)構(gòu)化的工具Describes noise factors, control factors, ideal function, and error states 描述噪音因素，控制因素，理想的功能和誤差狀態(tài)Assists in the identification of: 有助于識別：Potential Causes for failure 潛在的失效原因Failure Modes 失效模式Potential Effects of failure 潛在的失效后果Current Controls 目前的控制方法Recommended Actions 建

16、議的措施P-DiagramP圖Recommended structExample P-DiagramP圖的范例Example P-DiagramP圖的范例Header Information表頭信息Complete each field 完成每一區(qū)域：System, Subsystem or Component Name and Number 系統(tǒng)、子系統(tǒng)或零件名稱和編號Model Years/Program(s) 車型 年份/項目Team 小組成員Design Responsibility 設(shè)計責(zé)任人Key Date. 關(guān)鍵時間FMEA Number FMEA編號Prepared By 準(zhǔn)備

17、人FMEA Date FMEA日期Header Information表頭信息CompletDetermine Function確定功能Determine Function確定功能What is Function?功能是什么？Design intent or engineering requirement 設(shè)計意圖或工程要求Written in verb-noun measurable format 書面的，可以測量的動名詞格式Representation of all wants, needs and requirements, both spoken and unspoken for al

18、l customers and systems 描述所有顧客和系統(tǒng)的所有需要，需求和要求What is Function?功能是什么？DesignVerb 動詞Indicates action, occurrence, beingGenerate產(chǎn)生Control控制Dispense分配Retain保持Prevent防止Noun 名詞Indicates what the action relates toDescribe Function功能描述Light照明Speed速度Fuel燃料Seat Track座椅調(diào)節(jié)輪Rust生銹Verb 動詞Indicates action, occurBrai

19、nstorming頭腦風(fēng)暴Exercise in creative thinking Method to generate ideas通過創(chuàng)造性思維找到解決辦法的練習(xí)Brainstorming頭腦風(fēng)暴Exercise in Function Trees 功能樹Provide an organized approach to identify the essential features of a product (or process sometimes) 提供一種結(jié)構(gòu)化的方法，用于識別產(chǎn)品（或過程）必要的特征Help ensure that unspoken and spoken requi

20、rements are defined 有助于確保所有的要求已經(jīng)確定Provide a graphical representation of functions to ensure clear, total team understanding 提供功能的圖示描述，以確保全體小組清楚地理解Function Trees 功能樹Provide an First Level第一層Second Level第二層Constructing Function Trees建立功能書Third Level第三層HOW ?如何做？WHY ?為什么？First LevelSecond LevelConstruAd

21、justHeadlamp調(diào)整前燈Vertical Trimmer Function Tree 垂直調(diào)整片的功能樹HOW ?如何做？Permit / Maintain HorizontalAdjustment通過/維持水平調(diào)整Permit / Maintain Vertical Adjustment通過/維持垂直調(diào)整Adjust Light Beam Y調(diào)整Y方向的光Locate Headlamp Horizontally 前燈水平方向的定位Adjust Light Beam Z調(diào)整Z方向的光Locate Headlamp Vertically 前燈垂直方向定位WHY ?為什么？AdjustVe

22、rtical Trimmer FunctioGuidelines 指南Brainstorm all functions (VERB - NOUN) 集體討論所有的功能Document individual functions by asking “HOW is function achieved?” 通過提問“如何達到功能？”文件化各自的功能Repeat left to right, until actionable level 不斷從左到右重復(fù)，直至到達可執(zhí)行的層次Use worksheet to check that actionable level is measurable 使用工作表

23、檢查可執(zhí)行的層次是可以測量的Work right to left and check structure by asking “WHY is function included?” 從右到左進行，通過提問“為什么包含此功能”檢查功能樹的結(jié)構(gòu)Guidelines 指南Brainstorm all Design FMEA Functions設(shè)計FMEA的功能Function 3Function nFunction 2Function 1Function功能Sub-Function子功能Sub-Function子功能Sub-Function子功能Sub-Sub-Function子功能的子功能Sub-

24、Sub-Function子功能的子功能Sub-Sub-Function子功能的子功能Design FMEA Functions設(shè)計FMEA的功Design FMEA Path/Step 設(shè)計FMEA 路徑/步驟Step2DFMEA的完成Failure Modes 失效模式Effects - Severity 后果-嚴(yán)重度Potential Special Characteristics 潛在特殊特性Recommended Actions 建議的措施Design FMEA Path/Step 設(shè)計FMEA Design FMEA Path/Step 設(shè)計FMEA-步驟/步驟Design FMEA

25、 Path/Step 設(shè)計FMEPotential Failure Modes潛在失效模式Function 1功能1Potential Failure Modes:潛在失效模式：No function沒有起作用Partial/Over Function/Degraded Over Time部分/全部功能降低Intermittent function功能間歇性中斷Unintended function非預(yù)期的功能Function 2功能2Function 3功能3Function 4功能4Function N功能nPotential Failure Modes潛在失效模式Failure Mode

26、s - Vertical Trimmer失效模式-垂直調(diào)整片 No function 沒有起作用No adjustment 不能調(diào)整Partial/Over Function/Adjustment in one direction Degraded Over Time朝一個方向調(diào)整部分/全部的功能降低Intermittent functionAdjustment sometimes and 功能的間歇性中斷not at others (not in cold) 有時調(diào)整Unintended functionNone known非預(yù)期的功能不知道Function: Adjust Light Be

27、am Y功能：調(diào)整Y方向的光Failure Mode Type Potential Failure Mode失效模式的類型 潛在的失效模式Failure Modes - Vertical TrimEffects of Failure Modes失效模式的后果Effects of Failure Modes失效模式的Effects of Failure Modes失效模式的后果Potential Effects of Failure Modes:潛在失效模式的后果：Part / Sub-component 零件/分部件Next Higher Assembly 更高層的裝配System 系統(tǒng)Veh

28、icle 車輛Government Regulations 政府法規(guī)Customer (Internal and End User)顧客（內(nèi)部的和最終用戶）Effects of Failure Modes失效模式的Design FMEA Severity設(shè)計FMEA-嚴(yán)重度Design FMEA Severity設(shè)計FMEA-Suggested Severity Evaluation Criteria建議的嚴(yán)重度評價準(zhǔn)則后果 評定準(zhǔn)則：后果的嚴(yán)重度 嚴(yán)重度無警告的 這是一種非常嚴(yán)重的失效模式，它是在沒有任何失效預(yù) 10嚴(yán)重危害 兆的情況下，影響到行車安全和/或不符合政府的法規(guī) 有警告的 這是一

29、種非常嚴(yán)重的失效模式，是在具有失效預(yù)兆的前提 9 嚴(yán)重危害 下所發(fā)生的，影響到行車安全和/或不符合政府的法規(guī) 很高 車輛/項目不能運行（喪失基本功能） 8高 車輛/項目可運行，但性能下降，顧客非常不滿意 7中等 車輛/項目可運行，但舒適性/方便性項目不能運行， 顧客感覺不滿意 6Suggested Severity Evaluation 后果 評定準(zhǔn)則：后果的嚴(yán)重度 嚴(yán)重度低 車輛/項目可運行，但舒適性/方便性項目的性能下降， 5 顧客有些不滿意。 很低 配合和外觀/尖響和卡嗒響等項目不舒服， 4 大多數(shù)(75%)顧客感覺有缺陷 輕微 配合和外觀/尖響和卡嗒響等項目不舒服， 3 有一半顧客感覺

30、有缺陷 很輕微 配合和外觀/尖響和卡嗒響等項目不舒服， 2 25%顧客感覺有缺陷 無 無影響 1Suggested Severity Evaluation Criteria建議的嚴(yán)重度評價準(zhǔn)則后果 評定準(zhǔn)則：后果的嚴(yán)重度 Vertical Trimmer/垂直調(diào)整片Retains SettingPotential Effects of Failure 潛在失效后果Part: May be stripped during adjustment(7) 零件：可能在調(diào)整過程中丟失 Next Higher Assembly: Headlamp cannot be adjusted (6) 更高層的裝配

31、：前燈不能調(diào)整 System: Misaligned lightbeam(8) 系統(tǒng)：光束方向偏離 Vehicle: Impaired night/fog performance (7) 車輛： 夜晚/霧天性能下降 Govt Regs: Non-compliance (10) 政府法規(guī)： 不符合 Customer: Impaired night/ fog (7) 顧客：減少夜晚/霧天行駛10DFMEA Severity Rating ExampleDFMEA嚴(yán)重度等級的范例SEVItem 條款Function 功能Potential Failure Mode潛在失效模式Does not mai

32、ntain adjustment不用繼續(xù)調(diào)整Potential Effects of Failure 1YCS=9 S=10Design FMEA 設(shè)計FMEAIdentify Potential Special Characteristics識別潛在的特殊特性YCS=9Design FMEA Identify PoteDFMEA - Recommended ActionsDFMEA - 建議的措施DFMEA - Recommended ActionsDFCauses Occurrence 原因-發(fā)生率Special Characteristics 特殊特性Actions 措施 Design

33、Controls 設(shè)計控制Assessing Risk 評估風(fēng)險Actions 措施Design FMEA Paths/Steps 設(shè)計FMEA 路徑/步驟Step3DFMEA的完成Causes OccurrenceDesign FMEADesign FMEA Path/Step 2設(shè)計FMEA 路徑/步驟2Design FMEA Path/Step 2設(shè)計FMEAPotential Cause of Failure潛在失效原因 An indication of a design weakness, the consequence of which is the failure mode 潛在

34、失效原因是由設(shè)計缺陷引起的，其結(jié)果就是失效模式。 Potential Cause of Failure潛在失What Might Cause Failure?可能導(dǎo)致失效的原因？Item is manufactured and assembled within engineering specifications 工程規(guī)范中已經(jīng)制造并裝配的零件Design may include a deficiency that may cause unacceptable variation (misbuilds, errors, etc.) 設(shè)計中可能包含某種缺陷，這種缺陷可能引起不可接受的變差（錯誤構(gòu)

35、造，誤差等）Two Assumptions for Cause .兩種假定的原因What Might Cause Failure?可能導(dǎo)致Manufacturing Misbuilds 制造的錯誤構(gòu)造Due to Design Deficiencies由設(shè)計缺陷引起的+-+-Manufacturing Misbuilds 制造的錯誤Manufacturing Misbuilds 制造的錯誤構(gòu)造Due to Design Deficiencies由設(shè)計缺陷引起的+-+-Manufacturing Misbuilds 制造的錯誤Use a Fishbone Diagram使用魚刺圖Causes o

36、f Failure失效的原因No Adjustment沒有調(diào)整Thread SeizureBroken Bracket有故障的支架Interface not Understood by User用戶沒有理解接口Thermostat GeometryThread FusionMaterial PropagationScrew Thread Specification Oversize螺旋的螺紋太大Support Area too Small支持范圍太窄Use a Fishbone DiagramCauses oCauses of Failure - Why Ladder失效原因-梯形為什么Mat

37、erial crackedPartBends零件彎曲Support area too small支持范圍太窄WHY?為什么？WHY?為什么？WHY?為什么？Level 3第3層Level 2第2層Level 1第1層Broken Bracket有故障的支架Causes of Failure - Why LaddeSentencing Technique判斷的技巧FailureMode失效模式Could result in可能導(dǎo)致Effect后果Cause原因Leads to引起TIME 時間Due to由于Sentencing Technique判斷的技巧FailSentencing Tech

38、nique Example判斷技巧的范例No Adjustment沒有調(diào)整Could result in可能導(dǎo)致Misaligned Beams方向偏離的光線Due to由于Thread Seizure螺紋咬死Leads to導(dǎo)致 TIME 時間Sentencing Technique Example判Causes of Failures失效的原因Function1功能1Failure Mode 1失效模式1Failure Mode 2失效模式2Failure Mode n失效模式nWHY?為什么？M E P E MCauses of Failures失效的原因FunctiDesign FME

39、A Occurrence設(shè)計FMEA-發(fā)生率Design FMEA Occurrence設(shè)計FME失效發(fā)生的可能性 可能的失效率 頻度數(shù)很高：持續(xù)性失效 100個 每1000輛車/項目 10 50個 每1000輛車/項目 9高：經(jīng)常性失效 20個 每1000輛車/項目 8 10個 每1000輛車/項目 7中等：偶然性失效 5個 每1000輛車/項目 6 Suggested Occurrence Evaluation Criteria建議的發(fā)生率評價準(zhǔn)則失效發(fā)生的可能性 可能的失效率 頻度數(shù)Suggested Occurrence Evaluation Criteria建議的發(fā)生率評價準(zhǔn)則失效發(fā)

40、生的可能性 可能的失效率 頻度數(shù)中等：偶然性失效 2個 每1000輛車/項目 5 1個 每1000輛車/項目 4低：相對很少 0.5個 每1000輛車/項目 3 發(fā)生的失效 0.1個 每1000輛車/項目 2極低：失效不太 0.010個 每1000輛車/項目 1 可能發(fā)生Suggested Occurrence EvaluatioYCYSS=9 S=10S=5-8O=4-10Design FMEA設(shè)計FMEAIdentify Potential Special Characteristics識別潛在特殊特性YCYSS=9S=5-8Design FMEAIdentifRecommended Ac

41、tions建議的措施Recommended Actions建議的措施DFMEA - Design ControlsDFMEA-設(shè)計控制Type 1Prevention: Prevent the cause/mechanism or failure mode/effect from occurring, or reduce the rate of occurrence類型1 預(yù)防：預(yù)防失效原因/機理或者失效模式/后果，或減少發(fā)生度Type 2Detection: Detect the cause/mechanism or failure mode, either by analytical or physical methods, before the item is released to production類型2 探測：在零件生產(chǎn)之前，用分析或物理方法探測失效原因/機理或失效模式DFMEA - Design ControlsDFMEA-Design FMEA Detection設(shè)計FMEA-探測度Design FMEA Detection設(shè)計FMEASuggested De