福特FEMA培训材料20

福特福特FEMAFEMA培训材料培训材料2020 1长安福特马自达Changan FordMazda Wele to FMEA欢迎进入FMEA Trainer培训师 Owen Yang Roy JiangProduct Development CFMA2长安福特马自达Changan FordMazda Change Point Approach变化点的处理 New designor processis planned有新的设计或过程的变化 Modification to a ponent process orsystem isplanned including thosedue toGlobal8D有部件 过程或系统的更改 包括由于G8D带来的更改 Com ponent isto beused innew environment location or application部件将要用于新的环境 位置或用途 FMEAs areliving documents and areupdated when FMEA是动态文件 在以下情况下进行更新 3长安福特马自达 Changan FordMazda Whencan FMEAdocuments bediscarded 什么时候可以处理掉FMEA文档 FMEA Documentsmust beretained inaordance withGlobal InformationStandards RecordRetention 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 10years DFMEs 最终使用后 10年 PFMEAs Last use 5years PFMEAs 最终使用后 5年Documentation存档4长安福特马自达Changa n FordMazda如何开展FMEA流程5长安福特马自达Changan FordMazda Targets目标Cross Functional Team跨功能团队History历史FMEA FMEA Process FMEA过程Robustness Toolsare notspecified稳健的工具没有被运用Former FMEAProcess以前的FMEA流程6长安福特马自达Changan FordMazda Boundary Diagram界限图Interface Matrix接口矩阵P Diagram P图FMEA with RobustnessLinkages FMEA 有稳健联系的 Robustness andReliability Checklist稳健和可靠的检查清单Design VerificationPlan DVP 设计验证计划Qualifies andclarifies the relationships betweenSystems鉴定并说明系统之间的关系Identifies andquantifies thestrength ofSystem Interactions识别并量化系统之间的相互作用Identifies Noiseand ControlFactors andError States识别噪音因素 控制因素和误差状态Summarizes ErrorStates Noise Factors and associatedDesign Controls总结误差状态 噪音因素和相关设计控制图FMEAProcess过 程7长安福特马自达Changan FordMazda DFMEA8长安福特马自达Changan FordMazda Design FMEA An Introduction设计FEMA 开始 Identify DFMEATeam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DFMEA的完成9长安福特马自达Changan FordMazda Design FMEA Team设计FMEA 小组Design EngineerManufacturing Process Engineer设计工程师制造 工艺工程师CORE Team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Support Team支持小组Facilitator服务商10长安福特马自达Changan FordMazda Design FMEA Scope设计FMEA 范围 Is theboundary orextent of the analysisdefines whatis includedand excluded分析的界限或范围是否已确定包含什么 不包含什么 Scop e incorrectlydone 不正确的范围会 Lengthens analysis扩大分析 Misses targetanalysis偏离目标分析 Identifies wrongteam membership错误地识别小组成员11长安福特马自达Changan FordMazda Design FMEA Scope设计FMEA 范围 Create a boundary diagram创建界限图 Identify theboundary foranalysis确定分析界限 Confirm positionof supportteam确定支持小组的成员Once coreteam isestablished 一旦成立了核心小组 12长安福特马自达Changan FordMazda ConstructingBoundary Diagrams创建界限图 Denotes Relationshipbetween hardwarethat goeson Interface Matrix Note Only thehardware ponentsappear inboxes onaboundarydiagram Once allofthehardware isidentified byblocks the relationshipsbetween theblocks indicated bya boxwith adotted lineand an are thentransferred tothe InterfaceMatrix Note BoundaryDiagramitems notshown inboxes areP Diagram noisefactors thatcan leadto failures Note GOP is the abbreviationfor GrillOpening PanelAdjustment Screws 2 Headlamp Hdlm Housing GrillOpening Panel GOP Housing GOPAlign Tabs Environmental Road saltHood AttachmentBody Change Over Time Material Fatigue Material Wear Material SetEnvironmental Road MaterialChange OverTime Material Wear Align tabsto Screws Hood adjusterdepth toHousing Headdlamp Housingto Attachment GOP toheadlamp Screws Connector Elect Sys to connector Elect Sys location toHousing Frequentcustomer adjustmentscreate wearover timeChange OverTime Material SetElectrical System Snap fitto Hdlm Snap fitto HdlmPhysical RelationshipOther Relationship Body toHeadlamp13长安福特马自达Changan FordMazda BoundaryDiagram Example界限图 范例Headlamp Assembly前灯装配14长安福特马自达Changan FordMazda InterfaceMatrix接口矩阵 Remended robustnesstool thatacts asan inputtoaDesignFMEA接口矩阵是推荐的作为设计FEMA输入的稳健工 具 Identifies andquantifies thestrength ofsystem interactionsby 接口矩阵可以通过以下方式识别并鉴定系统的相互 作用 Showing whethertherelationshipis necessaryor adverse显示系统间的关系是互利的还是不利的 Identifying thetype ofrelationship确定关系的类型15长安福特马自达Changan FordMazda P Physically touchingI Information exchangeP EI ME Energy transferM Material exchangeInteraction isnecessary forf unctionInteraction isbeneficial but notabsolutely necessary for functionality Interaction does not affectfunctionality Interactioncauses negativeeffects butdoes notprevent functionality Interaction mustbe preventedto achievefunctionality Numbers ineach cornerrepresent theabove interfacetypes with valuesdenoting thefollowing 2 10 1 2Example InterfaceMatrix接口矩阵的范例P Physically touchingI Information exchangeP EI ME Energy transferM Material exchangeInteraction isnecessary forf unctionInteraction isbeneficial but notabsolutely necessaryfor functionalityInteraction does not affectfunctionalityInteractioncauses negativeeffects butdoesnotprevent functionalityInteraction mustbe preventedto achievefunctionality Numbers ineach cornerrepresent theabove interfacetypes with valuesdenoting thefollowing 2 10 1 22222 2 12222212 12222 1 1 2 1 1 1 1 122 12AdjusterHeadlamp HousingUpper Cross MemberHoodAdjuster socket AdjusterHeadlamp HousingUpperCross MemberHoodAdjustersocket16长安福特马自达Changan FordMazda ExampleInterfaceMatrix接口矩阵的范例2222 2 122AdjusterAdjuster socketAdjusterHeadlampHousingUpperCrossMemberHoodP Physical ly touchingI Information exchangeP EI ME Energy transferM Material exchangeInteraction isnecessaryforf unctionInteraction isbeneficial but notabsolutely necessaryfor functionalityInteraction doesnot affectfunctionalityInteractioncauses negativeeffects butdoesnotprevent functionalityInteraction mustbe preventedto achievefunctionality Numbers ineach cornerrepresent theabove interfacetypes with valuesdenoting thefollowing 2 10 1 217长安福特马自达Changan FordMazda P Diagram P图 Remended structuredtool to identify intendedinputs andoutputs fora functionP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 noisefactors control factors ideal function and errorstates描述噪音因素 控制因素 理想的功能和误差状态 Assis ts inthe identificationof 有助于识别 Potential Causesfor failure潜在的失效原因 Failure Modes失效模式 Potential Effectsof failure潜在的失效后果 Current Controls目前的控制方法 Remended Actions建议的措施18长安福特马自达Changan FordMazda ExampleP Diagram P图的范例19长安福特马自达Changan FordMazda HeaderInformation表头信息 Complete eachfield完成每一区域 System Subsystem orComponent Nameand 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 NumberFMEA编号 Prepared By准备人 FMEA DateFMEA日期20长安福特马自达Changan FordMazda DetermineFunction确定功能POTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateAction ResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention Detection21长安福特马自达Changan FordMazda Whatis Function 功能是什么 Design intentor engineeringrequirement设计意图或工程要求 Written inverb noun measurableformat书面的 可以测量的动名词格式 Representation of all wants needs andrequirements both spokenand unspokenfor allcustomers andsystems描述所有顾客和系统的所有需要 需求和要求22长安福特 马自达Changan FordMazda Verb动词Indicates action ourrence being Generate产生Control控制Dispense分配Retain保持Prevent防止Nou n名词Indicates whatthe actionrelates 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23长安福特马自达Changan FordMazda Brainstorming头脑风暴Exercise increative thinkingMethod togenerate ideas通过创造性思维找到解决办法的练习24长安福特马自达Changa n FordMazda Function Trees功能树 Provide anorganized approachtoidentifythe essentialfeatures ofa product or processsometimes 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 ensurethat unspoken and spoken requirements aredefined有助于确保所有的要求已经确定 Provide agraphical representationof functionsto ensure clear total teamunderstanding提供功能的图示描述 以确保全体小组清楚地理 解25长安福特马自达Changan FordMazda FirstLevel第一层Second Level第二层Constructing FunctionTrees建立功能书Third Level第三层HOW 如何做 WHY 为什么 26长安福特马自达Changan FordMazda AdjustHeadlamp调整前灯Vertical TrimmerFunctionTree垂直调整片的功能树HOW 如何做 Permit Main tain HorizontalAdjustment通过 维持水平调整Permit Maintain VerticalAdjustment通过 维持垂直调整Adjust LightBeam Y 调整Y方向的光Locate HeadlampHorizontally前灯水平方向的定位Adjust LightBeam Z 调整Z方向的光Locate HeadlampVertically前灯垂直方向定位WHY 为什么 27长安福特马自 达Changan FordMazda Guidelines指南 Brainstorm allfunctions VERB NOUN 集体讨论所有的功能 Document individualfunctions byasking HOW isfunction achieved 通过提问 如何达到功能 文件化各自的功能 Repeat leftto right until actionablelevel不断从左到右重复 直至到达可执行的层次 Use worksheetto checkthat actionablelevel ismeasurable使用工作表检查可执行的层次是可以测量的 Work rightto leftand checkstructure byasking WHY isfunction 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28长安福特马自达Changan FordMazda POTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionDesign FMEAFunctions设计FMEA的功能Function3Function nFunction2Function1Function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 Sub Function子功能的子功能Sub Sub Function子功能的子功能29长安福特马自达Changan FordMazda DesignFMEA Path Step设计FMEA路径 步骤DFMEA的完成 Failure Modes失效模式 Effects Severity后果 严重度 Potential Special Characteristics潜在特殊特性 Remended Actions建议的措施30长安福特马自达Changan FordMazda DesignFMEA Path Step设计FMEA 步骤 步骤POTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention Detection No Function Partial Over Function Degraded OverTime Intermittent Function Unintended FunctionWhatcan gowrong No Function Partial Over Function Degraded OverTime Intermittent Function Unintended FunctionWhatcan gowrong What arethe Functions Features orRequirements What arethe Functions Features orRequirements What arethe Effect s What arethe Effect s How badis it How badis it Design Changes Process Changes Special Controls Changes toStandards Procedures or GuidesWhatcan bedone Design Changes Process Changes Special Controls Changes toStandards Procedures or GuidesWhatcan bedone 31长安福特马自达Changan FordMazda Potential Failure Modes潜在失效模式POTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionFunction1功能1Potential Failure Modes 潜在失效模式 No function 没有起作用 Partial Over Function Degraded OverTime 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Function2功能2Function3功能3Function4 功能4Function N功能n32长安福特马自达Changan FordMazda Failure Modes Vertical Trimmer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 inone directionDegraded OverTime朝一个方向调整部分 全部的功能降低Intermittent functionAdjustment sometimesand功能的间歇性中断not atothers not incold 有时调整Unintended functionNone known非预期的功能不知道Function Adjust LightBeam Y 功能 调整Y方向的光Failure ModeType PotentialFailure Mode失效模式的类型潜在的失效模式33长安福特马自达Changan FordMazda POTENTIALFAILUREMODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODE AND EFFECTS ANALYSISItemPotentialFailureModePotentialEffect s ofFailure SevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionEffects of Failure Modes失效模式的后果34长安福特马自达Changan FordMazda POTENTIALFAILUREMODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionEffects of Failure Modes失效模式的后果Potential Effectsof Failure Modes 潜在失效模式的后果 Part Sub ponent零件 分部件 Next HigherAssembly更高层的装配 System系统 Vehicle车辆 Governmen t Regulations政府法规 Customer Internal andEnd User 顾客 内部的和最终用户 35长安福特马自达Changan FordMazda POTENTIALFAILUREMODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionDesign FMEA Severity设计FMEA 严重度36长安福特马自达Changan FordMazda Suggested Severity Evaluation Criteria建议的严重度评价准则后果评定准则 后果的严重度严重度 无警告的这是一种非常严重的失效模式 它是在没有任何失效预10严 重危害兆的情况下 影响到行车安全和 或不符合政府的法规有警告 的这是一种非常严重的失效模式 是在具有失效预兆的前提9严重危 害下所发生的 影响到行车安全和 或不符合政府的法规很高车辆 项 目不能运行 丧失基本功能 8高车辆 项目可运行 但性能下降 顾客 非常不满意7中等车辆 项目可运行 但舒适性 方便性项目不能运行 顾客感觉不满意637长安福特马自达Changan FordMazda后果评定准则 后果的严重度严重度低车辆 项目可运行 但舒适性 方便性项目的性能下降 5顾客有些不满意 很低配合和外观 尖响和卡嗒响等项目不舒服 4大多数 75 顾客感 觉有缺陷轻微配合和外观 尖响和卡嗒响等项目不舒服 3有一半顾客 感觉有缺陷很轻微配合和外观 尖响和卡嗒响等项目不舒服 225 顾 客感觉有缺陷无无影响1SuggestedSeverityEvaluation Criteria建议的严重度评价准则38长安福特马自达Changan FordMazda VerticalTrimmer 垂直调整片Retains SettingPotential EffectsofFailure潜在失效后果Part May bestripped duringadjustment 7 零件 可能在调整过程中丢失Next HigherAssembly Headlamp cannotbe adjusted 6 更高层的装配 前灯不能调整System Misaligned lightbeam 8 系统 光束方向偏离Vehicle Impaired night fog performance 7 车辆 夜晚 雾天性能下降Govt Regs Non pliance 10 政府法规 不符合Customer Impaired night fog 7 顾客 减少夜晚 雾天行驶10DFMEA SeverityRating ExampleDFMEA严重度等级的范例S EV Item条款Function功能PotentialFailure Mode潜在失效模式Does notmaintain adjustment不用继续调整39长安福特马自达Changan FordMazda YCS 9S 10DesignFMEA设计FMEA IdentifyPotential SpecialCharacteristics识别潜在的特殊特性40长安福特马自达Cha ngan FordMazda POTENTIALFAILUREMODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionDFMEA Remended ActionsDFMEA 建议的措施41长安福特马自达Changan FordMazda Causes Ourrence原因 发生率 SpecialCharacteristics特殊特性 Actions措施 Design Controls设计控制 Assessing Risk评估风险 Actions措施DesignFMEA Paths Steps设计FMEA路径 步骤DFMEA的完成42长安福特马自达Chan gan FordMazda DesignFMEAPath Step2设计FMEA路径 步骤2POTENTIALFAILUREMODEA ND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention DetectionPOTENTIALFAILURE MODEAND EFFECTSANALYSISItemPotentialFailureModePotentialEffect s of FailureSevClassPotential Cause s Mechanism s of FailureOurCurrentDesignControlsDetecR P N RemendedAction s Responsibility TargetCompletion DateActionResultsActionsTakenSevODetR P N Function Prevention Detection No Function Partial Over Function Degraded OverTime Intermittent Function Unintended FunctionWhatcan gowrong No Function Partial Over Function Degraded OverTime Intermittent Function Unintended FunctionWhatcan gowrong What arethe Cause s What arethe Cause s How oftendoes ithappen How oftendoes ithappen Design Changes Process Changes Special Controls Changes toStandards Procedures or GuidesWhatcan bedone Design Changes Process Changes Special Controls Changes toStandards Procedures or GuidesWhatcan bedone 43长安福特马自达Changan FordMazda PotentialCause ofFailure潜在失效原因An indicationofadesign weakness the consequenceof whichisthefailure 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 44长安福特马自达Changan FordMazda WhatMight CauseFailure 可能导致失效的原因 Item ismanufactured andassembled withinengineering specifications工程规范中已经制造并装配的零件 Design mayinclude adeficiency thatmay causeunaeptable 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 Assumptionsfor Cause 两种假定的原因 45长安福特马自达Changan FordMazda ManufacturingMisbuilds制造的错误构造Due toDesign Deficiencies由设计缺陷引起的 46长安福特马自达Changan FordMazda Manu