13. Change Point Approach变化点的处理New design or process is planned
有新的设计或过程的变化
Modification to a component, process or system is planned, including those due to Global 8D
有部件,过程或系统的更改,包括由于G8D带来的更改
Component is to be used in new environment, location, or application
部件将要用于新的环境,位置或用途。FMEAs are living documents, and are updated when ...
FMEA是动态文件,在以下情况下进行更新…
14. When can FMEA documents be discarded? 什么时候可以处理掉FMEA文档FMEA Documents must be retained in accordance with Global Information Standards Record Retention Schedule:
FMEA必须按照全球信息记录保持时间标准对这些文档进行保存
DFMEAs: Last use +10 years
DFMEs:最终使用后+10年
PFMEAs: Last use +5 years
PFMEAs:最终使用后+5年Documentation存档
15. Targets
目标Cross- Functional Team
跨功能团队History
历史FMEAFMEAProcess
FMEA过程Robustness Tools are not specified
稳健的工具没有被运用Former FMEA Process以前的FMEA流程
16. BoundaryDiagram
边界框图InterfaceMatrix
界面矩阵P-Diagram
P图FMEA (withRobustnessLinkages)
FMEA(有稳健联系的)Robustness and Reliability Checklist
稳健和可靠的检查清单Design Verification Plan (DVP)
设计验证计划Qualifies and clarifies the relationships between Systems
鉴定并说明系统之间的关系Identifies and quantifies the strength of System Interactions
识别并量化系统之间的相互作用Identifies Noise and Control Factors and Error States
识别噪音因素,控制因素和误差状态Summarizes Error States, Noise Factors, and associated Design Controls
总结误差状态,噪音因素和相关设计控制图FMEA Process现在的FMEA过程
17. DFMEA设计失效模式与后果分析
18. Design FMEA - An Introduction设计FEMA - 简介Identify DFMEA Team
成立DFEMA小组
Establish Scope
确定范围
Describe Function
功能描述
Brainstorming
头脑风暴
Function Trees
功能树
Step1
DFMEA的完成
19. Design FMEA - Team设计FMEA - 小组Design Engineer
Manufacturing / Process Engineer
设计工程师
制造/工艺工程师CORETeam
核心小组Representatives from:
需要的代表:
Customer Service
顾客服务
Suppliers
供方
Test Operations
测试部门
Corporate Quality
质量部门SupportTeam
支持小组Facilitator
协调员
20. Design FMEA - Scope设计FMEA - 范围Is the boundary or extent of the analysis defines what is included and excluded
分析的界限或范围是否已确定包含什么,不包含什么?
Scope incorrectly done:
不正确的范围会:
Lengthens analysis
扩大分析
Misses target analysis
偏离目标分析
Identifies wrong team membership
错误地识别小组成员
21. Design FMEA - Scope设计FMEA - 范围Create a boundary diagram 创建边界框图
Identify the boundary for analysis 确定分析界限
Confirm composition of support team 确定支持小组的成员
Once core team is established...
一旦成立了核心小组…
24. Interface Matrix界面矩阵Recommended robustness tool that acts as an input to a Design FMEA
界面矩阵是推荐的作为设计FEMA输入的稳健工具
Identifies and quantifies the strength of system interactions by:
界面矩阵可以通过以下方式识别并鉴定系统的相互作用:
Showing whether the relationship is necessary or adverse
显示系统间的关系是互利的还是不利的
Identifying the type of relationship
确定关系的类型
25. P: Physically touchingI: Information exchangePEIME: Energy transferM: Material exchangeInteraction is necessary for functionInteraction is beneficial, but not absolutely necessary for functionalityInteraction does not affect functionalityInteraction causes negative effects but does not prevent functionalityInteraction must be prevented to achieve functionalityNumbers in each corner represent the above interface types, with values denoting the following:+2+10-1-2Example Interface Matrix界面矩阵的范例P: Physically touchingI: Information exchangePEIME: Energy transferM: Material exchangeInteraction is necessary for functionInteraction is beneficial, but not absolutely necessary for functionalityInteraction does not affect functionalityInteraction causes negative effects but does not prevent functionalityInteraction must be prevented to achieve functionalityNumbers in each corner represent the above interface types, with values denoting the following:+2+10-1-2
26. Example Interface Matrix 界面矩阵的范例P: Physically touchingI: Information exchangePEIME: Energy transferM: Material exchangeInteraction is necessary for functionInteraction is beneficial, but not absolutely necessary for functionalityInteraction does not affect functionalityInteraction causes negative effects but does not prevent functionalityInteraction must be prevented to achieve functionalityNumbers in each corner represent the above interface types, with values denoting the following:+2+10-1-2
27. P-DiagramP图Recommended structured tool to identify intended inputs and outputs for a function
P图是推荐的,用于识别某一功能的预期输入和输出的结构化的工具
Describes noise factors, control factors, ideal function, and error states
描述噪音因素,控制因素,理想的功能和误差状态
Assists in the identification of:
有助于识别:
Potential Causes for failure 潜在的失效原因
Failure Modes 失效模式
Potential Effects of failure 潜在的失效后果
Current Controls 目前的控制方法
Recommended Actions 建议的措施
28. Example P-DiagramP图的范例
29. FMEA Header InformationFMEA表头信息Complete each field
完成每一区域:
System, Subsystem or Component Name and Number
系统、子系统或零件名称和编号
Model Years/Program(s)
车型 年份/项目
Team 小组成员
Design Responsibility 设计责任人
Key Date. 关键时间
FMEA Number FMEA编号
Prepared By 准备人
FMEA Date FMEA日期
30. Determine Function确定功能
31. What is Function?功能是什么?Design intent or engineering requirement
设计意图或工程要求
Written in verb-noun measurable format
书面的,可以测量的动名词格式
Representation of all wants, needs and requirements, both spoken and unspoken for all customers and systems
描述所有顾客和系统的所有需要,需求和要求
32. Verb 动词Indicates action, occurrence, being Generate
产生
Control
控制
Dispense
分配
Retain
保持
Prevent
防止Noun 名词Indicates what the action relates toDescribe Function功能描述Light
照明
Speed
速度
Fuel
燃料
Seat Track
座椅调节轮
Rust
生锈
33. Function Trees 功能树Provide an organized approach to identify the essential features of a product (or process sometimes)
提供一种结构化的方法,用于识别产品(或过程)必要的特征
Help ensure that ‘unspoken’ and ‘spoken’ requirements are defined
有助于确保所有的要求已经确定
Provide a graphical representation of functions to ensure clear, total team understanding
提供功能的图示描述,以确保全体小组清楚地理解
34. First Level
第一层Second Level
第二层Constructing Function Trees建立功能树Third Level
第三层HOW ?
如何做?WHY ?
为什么?
36. Guidelines 指南Brainstorm all functions (VERB - NOUN)
集体讨论所有的功能(动-名词)
Document individual functions by asking “HOW is function achieved?”
通过提问“如何达到功能?”文件化各自的功能
Repeat left to right, until actionable level
不断从左到右重复,直至到达可执行的层次
Use worksheet to check that actionable level is measurable
使用工作表检查可执行的层次是可以测量的
Work right to left and check structure by asking “WHY is function included?”
从右到左进行,通过提问“为什么包含此功能”检查功能树的结构
40. Potential Failure Modes潜在失效模式Function
1
功能1Potential Failure Modes:
潜在失效模式:
No function
没有起作用
Partial/Over Function/Degraded Over Time
部分/全部功能降低
Intermittent function
功能间歇性中断
Unintended function
非预期的功能Function
2
功能2Function
3
功能3Function
4
功能4Function
N
功能n
41. Failure Modes -- Vertical Trimmer如:失效模式 - 垂直调整片 No function 没有起作用 No adjustment 不能调整
Partial/Over Function/ Adjustment in one direction Degraded Over Time 朝一个方向调整
部分/全部的功能降低
Intermittent function Adjustment sometimes and 功能的间歇性中断 not at others (not in cold)
有时调整
Unintended function None known
非预期的功能 不知道Function: Adjust Light Beam Y°
功能:调整Y方向的光Failure Mode Type Potential Failure Mode
失效模式的类型 潜在的失效模式
42. Effects of Failure Modes失效模式的后果
43. Effects of Failure Modes失效模式的后果Potential Effects of Failure Modes:
潜在失效模式的后果:
Part / Sub-component 零件/分部件
Next Higher Assembly 更高层的装配
System 系统
Vehicle 车辆
Government Regulations 政府法规
Customer (Internal and End User)
顾客(内部的和最终用户)
52. Potential Cause of Failure潜在失效原因 An indication of a design weakness, the consequence of which is the failure mode
潜在失效原因是由设计缺陷引起的,其结果就是失效模式。
53. What Might Cause Failure?可能导致失效的原因?Item is manufactured and assembled within engineering specifications
工程规范中已经制造并装配的零件
Design may include a deficiency that may cause unacceptable variation (misbuilds, errors, etc.)
设计中可能包含某种缺陷,这种缺陷可能引起不可接受的变差(错误构造,误差等)Two Assumptions for Cause ...
两种假定的原因…
54. Manufacturing Misbuilds 制造的错误构造Due to Design Deficiencies
由设计缺陷引起的+
-+
-
55. Manufacturing Misbuilds 制造的错误构造Due to Design Deficiencies
由设计缺陷引起的+
-+
-
56. Use a Fishbone Diagram
使用鱼刺图Causes of Failure失效的原因No Adjustment
没有调整Thread SeizureBroken Bracket
有故障的支架Interface not Understood by User
用户没有理解接口Thermostat GeometryThread FusionMaterial PropagationScrew Thread Specification Oversize
螺旋的螺纹太大Support Area too Small
支撑范围太窄
57. Causes of Failure - Why Ladder失效原因 - 梯形为什么Material cracked
材料爆裂Part Bends
零件弯曲Support area too small
支撑范围太窄WHY?
为什么?WHY?
为什么?WHY?
为什么?Level 3
第3层Level 2
第2层Level 1
第1层Broken Bracket
有故障的支架
58. Sentencing Technique判断的技巧Failure
Mode
失效模式Could result in
可能导致Effect
后果Cause
原因Leads to
引起TIME 时间Due to
由于
59. Sentencing Technique Example判断技巧的范例No Adjustment
没有调整Could result in
可能导致Misaligned Beams
方向偏离的光线Due to
由于Thread Seizure
螺纹咬死Leads to
导致 TIME 时间
60. 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?
为什么?M E P E M
64. YCYSS=9
S=10S=5-8
O=4-10Design FMEA
设计FMEAIdentify Potential Special Characteristics识别潜在特殊特性
65. Recommended Actions建议的措施
66. DFMEA - Design ControlsDFMEA - 设计控制Type 1 Prevention: Prevent the cause/mechanism or failure mode/effect from occurring, or reduce the rate of occurrence
类型1 预防:预防失效原因/机理或者失效模式/后果,或减少发生度
Type 2 Detection: Detect the cause/mechanism or failure mode, either by analytical or physical methods, before the item is released to production
类型2 探测:在零件生产之前,用分析或物理方法探测失效原因/机理或失效模式
71. S X O X D =
2 10 10
10 10 2
10 2 10
RPN
200
200
200
RPN - ExamplesRPN - 范例
72. Assessing Risk 风险评估Severity (S) 严重度
Severity X Occurrence (SO = Criticality) 严重度 X 发生频度(SO = 危机度)
Severity X Occurrence X Detection(SOD = RPN) 严重度 X 发生频度 X 探测度(SOD = 风险顺序数)Risk Priority Number风险顺序数(RPN)
73. Recommended Actions建议的措施Enter an action as required and appropriate 填写要求的适当措施
Assign each action to a team member with a specific due date 把每一项措施分配给每一个小组成员,并指定相应的时间
If no action is planned, enter “None” or “None at this time”
如果没有计划的措施,请填写“无”或“此时无”
74. Future Actions未来的措施Action ResultsecAction(s)Responsibility &TaFMEA HandbooketCompletion DateActionsSeOcDetRPNAction Results 措施结果
ActionsTaken S O D R
采取的措施 e c e P
v c t N
75. PFMEA过程失效模式及后果分析
76. Process FMEA - Team过程FMEA - 小组Manufacturing / Process Engineer
制造/过程工程师
Design Engineer
设计工程师CORETeam
核心小组Representatives from:
代表来自:
Specialists 专家
Suppliers 供方
Maintenance
维修技师
Production 生产
Next Process Engineer
下一个过程的工程师SupportTeam
支持小组Facilitator or Application Engineer
协调员或应用工程师
77. Process FMEA - Scope过程FMEA - 范围Create macro flow diagram 建立宏观的流程图
Identify boundary for analysis 确认分析的界限
Create micro flow diagram 建立微观的流程图
Define support team composition 确定支持小组成员
78. Assemble Bulb Holder
安装灯座
Assemble Lens to Reflector Assemble 安装灯壳到反射器Vertical Trimmer to Reflector
给反光镜装配垂直调整片
Assemble Horizontal Trimmer
to Reflector
给反光镜装配水平调整片Assemble Bulb to Reflector
灯泡装配到反光镜
Bulb Test
灯泡试验
Assemble Rear Cover
装配后盖
Photometric Test
光度试验
Load onto Pallet
防入货架Inspection Operation Storage Transportation
检查 操作 存储 传递 104070Headlamp Assembly - Macro前灯装配 - 宏观3020506080
79. Op 30 - Assemble Vertical Trimmer to Reflector
Op 30-在反光镜上装配垂直调整片Locate and fix (2 screws) base plate to reflector
将基座定位和安装(两颗螺钉)于反射镜。
Insert nose and positively locate pre-assembled screw and spring
前端装配、定位预先装配的螺栓和弹簧
Visually inspect trimmer assembly
从视觉上检查调整片的装配30.130.330.2Headlamp Assembly - Micro前灯装配 - 微观
80. PFMEA FormPFMEA表格ITEM:要分析的系统、子系统或零部件的名称和号码;
Model Year(s)/Program(s): 车型年份;
Core Team: 核心成员;
Process Responsibility:公司、部门名称;表头信息:Key Date:初始日期;
FMEA Number:编号;
Prepared By:责任工程师的名字及联系方式;
FMEA Date:最后被编制或修订日期。
81. Determine Function功能定义
82. Define Process Purpose定义过程目标What does the process do at this operation?
在此操作中,过程起什么作用?
Written in verb/noun/measurable format
使用动词/名词/可测量的格式填写
All process functions/purposes are considered
所有的过程功能和目的都要考虑到
83. Micro Flow - Process Purpose微观流程 - 过程目标Purpose 目的
Locate base plate -- correct orientation
固定基座—方向正确
Secure 2 screws to specified torque
确保两个螺钉达到指定的扭力
Insert nose to correct position per visual aid
将前端插入校正位置
Positively locate screw/spring sub-assembly
确保在子装配时螺栓/弹簧的正确定位
Visually inspect (to comply with part drawing): screw, spring, location, fixing
目视检查(符合图纸):螺栓,弹簧,位置,安装Locate and fix (2 screws) base plate to reflector
将基座定位和安装(两颗螺钉)于反射镜。
Insert nose and positively locate pre-assembled screw and spring
前端装配、定位预先装配的螺栓和弹簧
Visually inspect trimmer assembly
从视觉上检查调整片的装配30.130.330.2
84. Determine Failure Modes 定义失效模式
85. Failure Mode Types失效模式类型No function 没有起作用
Partial/Over Function/Degraded Over Time 部分/全部功能降低
Intermittent function 功能间歇性中断
Unintended function 非预期的功能
86. Example示例用电动工具将A零件正确的装配到B零件。
87. Effects of Failure Modes失效模式的后果
88. Effects of Failure失效的后果Operator safety
操作员安全
Next user
下一位用户
Downstream users
下游用户
Machines/equipment
机器/设备Vehicle operation
车辆行驶
Ultimate customer
最终顾客
Compliance with government Regulations
符合政府法规规则
Identify the consequences of each Failure Mode for:
识别每个实效模式对下述的影响:
98. Process FMEA Path/Step 2过程FMEA 路径/步骤2Step 1不能消除失效模式或减轻失效后果时,需要进入Step 2.
99. Assumptions for Cause可能的原因Incoming parts/materials to the operation are correct
零件/材料到达操作前是正确的
Examples:Two assumptions are made in identifying Causes in the Process
分析过程原因时,可以做两方面的设想• Tool set to wrong depth
工装深度不对
• Tool worn
工具用旧
• Torque too low
扭力低
• Oven temperature too high
烤箱温度过高
• Cure time too short
处理时间过短• Air pressure too low
空气压力过低
• Conveyor speed not constant
传输速度不稳定
• Material feed too fast
材料供给太快
• Limit switch installed off center 限值偏移中值
• Washer jets plugged
喷嘴堵塞
100. Assumptions for Cause可能的原因Consider incoming sources of variation. (For example, outside purchased parts/material, or parts/material from a prior operation)
考虑源头的变差(例如,外购的零件或材料、上道工序的零件或材料)
Examples 如:
• Material too hard/too soft/too brittle
材料太硬/太软/易碎
• Dimension does not meet specification
尺寸不满足规范
• Surface finish does not meet specification
表面质量不满足规范
• Locator hole off-location
定位孔偏移