流程图,失效模式分析,控制计划.ppt

,ProcessPlanning,AnalysisFMEAscopeistheentireprocess,Case2ModifyanexistingprocessandFMEA;Scopeistheprocessmodifications,interactionswiththeunchangedportionsoftheprocess,andperformancehistory,Case3UseanexistingprocessandFMEAforadifferentapplicationorenvironment(facility);FMEAscopeisthelocationandenvironmentfactors,70,PreventingFailures,Responsibility,ConsumerresponsibilityDealershipresponsibilityAutoMakerresponsibilityDelphiresponsibilitySupplierresponsibility,FailureAvoidance=PreventionThinkingatalllevels,71,OwnershipandSupport,Responsibility,ManufacturingEngineeringisresponsibleforthePFD,PFMEA,andInitialPCP.,Regular(core)membersoftheplanningteamarethemanufacturingengineers,productandqualityengineersandothers(suchasMfg,IE,PCmovepartstoassemblyareausingtransportrack),ElementsofaControlPlan,241,Machine,Device,Jig,ToolsforManufacturingidentifythemachineusedintheprocessstepbespecific:ifonlycertainmachinesoutofmanyareusedforthispart,identifythespecificmachinesinthecontrolplane.g.moldmachines#15,16,17,ElementsofaControlPlan,242,ThissectionContainsadetaileddescriptionofthespecificcharacteristicsthatmustbecontrolledinordertoassurequality.CharacteristicNumberMustidentifyproductandprocesscharacteristicsseparately(notonthesameline)Eachcomponentand/orprocesssteplistedintheprevioussection,“Product/ProcessDescription”,mighthaveseveralcharacteristicsthatneedtobecontrolled.,ElementsofaControlPlan,243,Numbercross-referencenumbertoaproductorprocesscharacteristiconadrawing,sketch,processflowdiagram,FMEA,orotherapplicabledocumenttheuseofthiscolumnisoptionalandthereshouldbenoambiguityfrequentlyusedwhen“process”drawingsarecreatedtodefinefeaturesbeingaddedthroughsubsequentsteps(e.g.machinedfeaturesinvariousop-seqsteps)addsmoredetailtothepart/processnumberapplicabledrawingsandflowdiagramsshouldbeeasilytracedfromthecontrolplan,ElementsofaControlPlan,244,ProductCharacteristicsfeatures,attributes,orpropertiesofapart,component,orassemblyexamples:dimensions,weights,geometricalattributesappearanceitemssuchasglossmaterial-relatedcharacteristicshardness,grainstructure,casedepth,etc.,ElementsofaControlPlan,245,ProcessCharacteristicsprocessvariablesandparametersthathaveacauseandeffectrelationshipwithproductcharacteristicscanonlybemeasuredatthemomentitoccursmoldtemperaturecycletimepressureflowrate,ElementsofaControlPlan,246,SpecialCharacteristics(KPCsandKCCs,QCIsandQCCs)mustbeincludedanddesignatedbytheappropriatesymbolortextinthecontrolplan“SpecialCharacteristicsClassification”column,ElementsofaControlPlan,KCCs,QCCs,Special,Care,AdditionalCare,DefinedCare,StandardCare,(usualandcustomarycare),StandardProduct,Characteristics,Nodesignationor,symbol,SpecialorKey,Product,Characteristics,Important,Product,Characteristics,247,SpecialCharacteristics(Definitions)KPCsKeyProductCharacteristicsthataffectSafety/Compliance(S/C)orFit/Function(F/F)andvariationreductionwillimprovecustomersatisfactionQCIsQuality/CustomerInterfaceCharacteristicsthatmayaffectperformanceorareimportantcustomerinterfacepoints;butreducingvariationwillnotincreasesatisfactionKCCsSpecificKeyProcessControlCharacteristic(s)relatedtoKPCsQCCsSpecificQualityProcessControlCharacteristic(s)relatedtoQCIs,ElementsofaControlPlan,248,TheMethodssectionincludesthe:product/processspecificationandtoleranceevaluation/measurementtechniquesamplesize/frequencycontrolmethod,ElementsofaControlPlan,249,Product/ProcessSpecifications/TolerancesidentifiedforthecharacteristicsthataretobecontrolledinSection2obtainedfromengineeringdrawings,processspecifications,materialstandards,assemblyrequirements,etc.,ElementsofaControlPlan,250,Evaluation/MeasurementTechniqueManydifferenttypesvariableorattributegaugingon-lineoroff-linetestingvisualinspectionerrorproofingShortdescriptionorreferencenumber:measurementgages,fixtures,etc.measurementprocedures,ElementsofaControlPlan,251,Evaluation/MeasurementTechniquesMeasurementSystemAnalysismustbeperformedonanymeasurementsystemusedforcontrollingproductqualityandreferencedintheControlPlanMeasurewhatevercharacteristic(productorprocess)thatwillbeusedforcontrolRepeatability,reproducibility,linearity,stability&biasarerequiredtoqualifymeasuringequipmentforbeingsufficientForattributemeasurementmethods,repeatabilityandreproducibilitymustbeassessed,ElementsofaControlPlan,252,SampleSizeandFrequencyusedwhensamplingispartofcontrolexamples1stpiecepershiftorifonlyaoneortwoshiftoperation,thenfirstandlastpiece5pcseveryhour1stpieceaftersetup/changeover100%ongoingFirstpieceafterpreventivemaintenance,ElementsofaControlPlan,253,Someotherthingstoconsiderwhendeterminingsamplesizeandfrequency:Whatistheprocesscapability?Whatistheproductionrate/hour?Howmanycavitiesordiesarethere?Whatisthestandardpackquantity?Atwhatfrequencyarepartsgoingtobeshipped?Whatisthebuffersize?Howlongdoestheinspectionortesttake?WhataretheprovisionsforLotControl?Whatistheimpactoftoollife?,ElementsofaControlPlan,254,ControlMethodthiscolumncontainsadescriptionofhowtheoperationwillbecontrolled,includingprocedure/instructionnumber(s)wheretheymayapplythecontrolmethodutilizedshouldincludethedocumentation(orprocessmonitoring)formthatisusedtorecordtheresultsofthecharacteristicbeingevaluatedormeasured,ElementsofaControlPlan,255,Examplesofcontrolmethoddocumentationinclude:ProcessMonitoringCheckSheetsStatisticalProcessControlformsOff-linetestrecordsReceivingInspectionrecordsErrorProofingVerificationdocumentationPreventiveMaintenancerecordsCalibrationrecords,ElementsofaControlPlan,256,Correctiveaction(s)tobeperformedtopreventnonconformancesfromreachingthecustomerPreferactionsthatkeeptheprocessincontrolReactionPlansshouldbespecifictothecontrolbesuretomarkandquarantinenonconformingproduct(accordingtoprocedures)documentwhatcorrectiveactionwastakenontheappropriateform,ElementsofaControlPlan,257,TheControlPlanProcess,Updatethecontrolplanastheproductorprocesschanges,orasnewissuesemergethecontrolplanisalivingdocumentthroughouttheproductlifecyclethecontrolplanisALSOarecordthatMUSTbemaintained.,258,ProcessControlPlanExample,QCC4,QCC4,QCC4,QCC4,TB2005,259,ProcessControlPlanExample,Initiateweldsequence/Wirefeed300mm/min.+/-10,Initiateweldsequence/Weldvoltage24+/-2.0volts.,Initiateweldsequence/PerformTIGweldofframeparts.,Initiateweldsequence/InertGasflowrate5cfm+/-0.5,Scrappart&Re-startwelder,Closed-loopmachinecontrol.,Eachweldcycle.,100%,MachineControl,300mm/minute+/-10mm/min.,Weldwirefeedrate,Scrappart&Re-startwelder,Closed-loopmachinecontrol.,Eachweldcycle.,100%,MachineControl,24VoltsAC+/-2.0volts,Weldvoltage,Notifymaintenance.,OperatorcleansgascuptwicepershiftPM-WI-2500.ProcessmonitoringformPMF-2500-010,Pershift.,twice,Visual,5cubicfeet/min.+/-0.5cfm,Inertgasflowrate,Removepartandsendtorepair.,VisualinspectionOWI#2500-010.,Eachpiece.,100%,OperatorevaluationtoVisualStdTB2500-VS1.,Weldappearancemeetsvisualstandard.,Goodwelds,novisibledefects.,Scrapcurrentpart.Shutdown.Notifymaintenance.,Set-upOWI#2500-020&FormPM-2500-020Predictivemaintenancepinchrollerreplace180days.,Shiftstartorchange-overormaint.event,100%,Operatorsetupcheckandverification,300mm/minute+/-10mm/min.,Weldwirefeedrate,Quarantinematerialsincelastgoodpulltest.Notifymaintenance.,Set-upOWI#2500-020&FormPM-2500-020.EquipmentCalibrationProcedure#37568,Shiftstartorchange-overormaint.event,Onceeach,VisualverificationofFlowMeter,5cubicfeet/min.+/-0.5cfm,Inertgasflowrate,Scrapcurrentpart.Shutdown.Notifymaintenance.,Set-upOWI#2500-020&FormPM-2500-020PeriodicmaintenanceperPM-WI#2500.,Shiftstartorchange-overormaint.event,Onceeach,Visual,24VoltsAC+/-2.0volts,Weldvoltage,Quarantinematerialsincelastgoodpulltest.,HydraulicpulltestinstructionTI4321-01ProcessmonitoringformPM-2500-010,Pershift.,1pc.,Pulltestusingtestfixture2500-1.,Tubeweldsmeetpulltestwithfailureinparentmaterial.,Weldbeadsperdesignspecification.,RoboticArmTIGweldersandcontrollers.,212.2,.,RoboticArmTIGwelders,Initiateweldsequence/Closeandlatchcurtain,212.1,Frequency,Size,ReactionPlan,ControlMethod,Sample,EvaluationMeasurementTechnique,Product/ProcessSpecification/Tolerance,Process,Product,No.,Methods,SpecialChar.Class.,Characteristics,Machine,Device,Jig,ToolsforMfg.,ProcessName/OperationDescription,Part/ProcessNumber,QCC4,QCC4,QCC4,QCC4,QCC4,QCC4,Additionaldetailforrequirementsallowstheindividualcontrolstobeidentifiedandevaluated.,260,ThisPCPactivitywillbebasedonthepreviousactivitiesinPFDandPFMEA.ReviewthePFMEAinformationdeveloped&suppliedandusetoidentify:SpecificcontrolsthatmaybeneededduetotheinformationaddedIdentifythecontrolsaretoProductorProcessNoteanySpecialCharacteristicsIdentifyevaluationmethods,frequencyandControlMethodsNoteReactionPlans(particularlyrelatedtoNCparts),ProcessControlPlanActivity#1,261,PFD,PFMEA,PCP,PFDPFMEAPCPLinkage,CustomerEngineeringApproval/Date(IfReqd.),DirectlyTransfers,TranslatesInto,KPC,QCIorothercharacteristicdesignations,ProcessDocuments(StdCell,EOP,Monitoringforms,etc.),Energy&ChassisSystems,2/14/2002PFDTraining,263,ProcessFlowDiagram(PFD),KCCs,QCCs,ProductDefinition:,C,haracteristics:KPCs,QCIs,DFMEA,ProcessDefinition:,FailureModeAnalysis:,PFMEA,LinesideReviewProcess,ControlStrategy:,ControlPlan,Errorproofing,CustomerRequirements:,CharacteristicVerificationMatrix(CVM),Manufacturing:,ProcessMonitoring,StandardCell,LayeredAudit,InformationFlow,SOR,VehicleTechnicalSpecs,SystemTechnicalSpecs,264,ProcessDocumentation,PFD,PFMEA,ControlPlan,MonitoringForm,EntertheOPERATIONnumber(s),correspondingtoProcessFlowDiagram.,StdCellDocs,265,OncetheProcessControlPlaniscompleted,itisusedtocreateProcessOperatorInstructionsTheOperatorInstructionsmustincludeallactionsnecessarytocontroltheprocessasdefinedintheControlPlanControlslistedintheControlPlanareusedtodevelopOperatorInstructionsandtrainingFixtures,gagesPreventivemaintenanceplans,etc.ReactionPlans,OperatorInstructions,266,OperatorinstructionsareusedforavarietyofprocessactivitiesProcessstart-upandshutdownChange-overAssemblysequenceGaugeorTestingToolchangesReactionPlanPreventiveMaintenanceErrorProofVerification,OperatorInstructions,267,WhataretheProcessDocuments,EquipmentFocusAnEquipmentOperatingProcedure(EOP)describesindetailhowtouse,setup,andmaintainamachine.ItissimilartotheUserManualforaRidingLawnMower,PartNumberFocusStandardCelldocumentsrelateinformationthatisspecifictotheproductionofapartnumberorpartfamily,Process“Howto”informationfallsintotwobasicbuckets,268,EquipmentOperatingProcedureContent,EquipmentOperatingProcedurecontainsgeneralequipmentfocusedinformationsuchas:,DescriptionofEquipmentEquipmentInformationMaterialsRequiredforProcessSafetyRequirementsOperatingConditions/SetupInstructionsSpecializedTrainingReqd,StartUpInstructionsRunInstructionsStopInstructionsToolChangeInstructionsPartChangeoverInstructionsMaintenanceInformationDiagnostics,ThisappliestoALLequipment(includinggages)thatcannotbedescribedeasilyintheStdCellDocuments,269,StandardCellDocumentContent,StandardCellDocumentsareusedtodocumentthedetailedinstructionsforallactivitiesrelatedtotheprocess.Thisincludesinstructionstooperators,maintenancepersonnel,set-uppersonnel,materialmovementpersonnel,etc.Theydescribeactivitiessuchas:,BuildingpartsEquipmentSet-upControlPlaninstructionsGaugingparts,ErrorProofingverificationMasteringgaugesToolchangesPMactivities,270,StandardCellForms,StandardCellDocumentsconsistsofmultipleformswhichcontainpartnumberspecific“HowTo”information:IndexSheetTableofcontents,identifiesalldocumentsinpackageSetupSheetListsequipment,tools,fixtures,setupparametersJobElementSheet(JES)InstructionsforactivitiesatastationGeneralformBlanksheetforotherwiseunclassifiedinformationFamilyMembersListIdentifiespartnumberswithinafamilyofsimilarparts,271,StandardCellForms,StandardCellDocumentsalsocontainformswhichdescribeOperatorworkelementsandwalkpath:StandardizedOperationSheet(SOS)Physicalmapofsystemshowing“places”andoperatorpathsWorkCombinationTable(WCT)Listsalltheactivitiesforasingleoperator,272,ThisactivitywillbeareviewofsomeexamplesofStandardCelldocumentsthathavebeencreatedbaseduponthepreviousactivitiesinPFD,PFMEAandPCP.ReviewtheStdCelldocumentstoseeifyoucanobservehowtheyrelatedtothePFDandPCP:Arethereanyitemsthatdonot“track”?Isthereadditionalinformationthatismissingorshouldbeadded?Ina“r