《FEMA汽车行业》PPT课件.ppt

2020/5/15,1,潜在的失效模式及后果分析FMEA中国汽车技术研究中心,(PotentialFailureModeandEffectsAnalysis),2020/5/15,2,什么是FMEA,FMEA可以描述为一组系统化的活动，其目的是：（a）发现并评价产品/过程中的潜在失效以及该失效的后果；（b）确定能够消除或减少潜在失效发生机会的措施；（c）将全部过程形成文件。关于确定设计或过程必须做哪些事情才能使顾客满意，FMEA是对这一过程的补充。所有的FMEA都关注设计，无论是产品设计还是过程设计。,2020/5/15,3,FMEA的实施,由于一般的工业倾向是要尽可能持续地改进产品和过程的质量将FMEA作为专门的技术应用以识别并帮助最大程度地减少潜在的隐患一直是非常重要的。对车辆召回的研究结果表明，FMEA项目的全面实施可能会防止很多召回事件的发生。成功实施FMEA项目的最重要因素之一是时间性。其含义是指“事件发生前”的措施，而不是“事实出现后”的练习。为实现最大价值，FMEA必须在产品或过程失效模式被混合到产品或过程之前进行。事先花时间很好地完成FMEA分析，能够最容易、低成本地对产品或过程进行更改，从而最大程度地降低后期更改的危机。FMEA能够减少或消除实施可能会带来更大隐患的预防/纠正性更改的机会。应在所有FMEA小组间提倡交流和协作。,2020/5/15,4,FMEA的实施,2020/5/15,5,设计失效模式及后果分析DesignFailureModeEffectAnalysis(DFMEA),2020/5/15,6,DFMEA设计失效模式及效应分析,DesignPotentialFMEAis:设计潜在失效模式及效应分析是:ananalyticaltechniqueusedprimarilybyDesign-ResponsibleEngineer/Team由负责设计的工程师/小组采用的分析技术toidentifypotentialfailuremodes用作辨别潜在失效模式toidentifyassociatedcause/mechanisms辨别相关原因/机理tosupportthedesignprocessinreducingtheriskoffailures支持设计过程,减少失效风险applytosystem,subsystem,andcomponent应用于系统、子系统及部件,2020/5/15,7,CustomerofDFMEA顾客的定义,CustomerforaDesignFMEA顾客的定义Enduser通常是指“最终使用者”Manufacturing/Process-responsibleengineer也可以是更高一层设计司，制造或装配生产工程司,2020/5/15,8,TeamEffort小组的努力,Design设计Manufacturing制造Quality品质Material材料Reliability可靠性Sub-contractor分供方,2020/5/15,9,DFMEA设计失效模式及效应分析,DesignFMEAisLIVINGdocumentandshould设计FMEA是一份动态的文件beinitiatedbeforeoratdesignconceptfinalization在一个设计概念最终形成之时或之前开始becontinuallyupdated在产品开发的各个阶段,发生更改或获得更多的信息时,持续予以更新befundamentallycompletedbeforeproductiondrawingrelease在产品加工图样完工之前全部完成,2020/5/15,10,DFMEA设计失效模式及效应分析,Assumption:Designwillbemanufactured/assembled假设:该设计将按此意图进行生产Potentialfailuremodesduringproduction“NeedNot”but“MayBe”included制造的失效模式“不需”但“也可能”包括DFMEAnotrelyonprocesscontrolstoovercomedesignweaknessDFMEA不依靠过程控制来克服潜在的设计缺憾DFMEAconsiderstechnicallimitsofmanufacturingDFMEA考虑制造的限制Molddrafts拔模斜度Assemblingspace装配空间Tolerances/capability公差/过程能力,2020/5/15,11,DevelopmentofaDesignFMEA设计FMEA的开始,FirstStepofDFMEA:IDENTIFYDESIGNINTEND第一步:确定设计意图“Listingofwhatdesignisexpectedtodoandwhatisexpectednottodo”“列出设计期望做什么和不期望做什么?,2020/5/15,12,DevelopmentofaDesignFMEA设计FMEA的开始,Sourceofinformation资料来源QFD质量功能展开ProductRequirement产品要求Manufacturingrequirement生产要求,“DesignIntent”“设计意图”,2020/5/15,13,BlockDiagram框图,DFMEARecommendedtool:BlockDiagramDFMEA建议工具:框图,开关C,灯罩A,灯泡总成D,弹簧F-,电池B,极板E+,2,3,4,5,5,4,1,连接方法：1不连接2铆接3螺纹连接4卡扣连接5压紧安装,系统名称：闪光灯,2020/5/15,14,1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,16,17,18,19,20,21,22,_System_Subsystem,POTENTIALFAILUREMODEANDEFFECTSANALYSIS(DesignFMEA),FMEANumber_,CoreTeam_,2020/5/15,15,1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,16,17,18,19,20,21,22,_系统_子系统,POTENTIALFAILUREMODEANDEFFECTSANALYSIS(DesignFMEA)潜在失效模式及后果分析(设计FMEA),FMEA编号_,核心小组_,功能,2020/5/15,16,DetailsofDFMEADFMEA的詳細內容,2020/5/15,17,DesignObjectives:Minimum3000hoursofridingwithoutneedformaintenanceand10,000hoursofridingfordesignlife.Accommodatesmaleadultscomfortablytothe99.5thpercentileectFunction:EaseofusePotentialFailureMode(s):DifficulttosteerDifficulttopedalFunction:ProvidereliabletransportationPotentialFailureMode(s):ChainbreaksfrequentlyTiresrequirefrequentmaintenanceFunction:ProvidecomfortabletransportationPotentialFailureMode(s)Seatingpositionisnotcomfortable,Function:ProvidesstableattachmentforseatsupportPotentialFailureMode(s)StructuralfailureseatsupportExcessivedeflectionofseatsupportFunction:ProvidespleasingappearancePotentialFailureModes(s)Finish(shine)deterioratesPaintchips,HandleBarAssembly,RearWheelAssemble,SprocketAssemble,Function:ProvidesstructuralsupportPotentialFailureMode(s):StructuralfailureExcessivedeflectionFunction:ProvidesdimensionalcontrolforcorrectfinishedframegeometryPotentialFailureMode(s):LengthofframemountingpointstolongLengthframemountingpointstooshortFunction:Supportframeassemblyproductionmethods(welding)PotentialFailureMode(s):,Bicycle,Frame,FrontWheelAssemble,SeatAssemble,ChainAssemble,UpperFrame,LowerfrontTube,LowerRearTube,SprocketTube,SystemLevel,SubsystemLevel,ComponentLevel,2020/5/15,18,设计目标:骑行至少3000小时无需保养,设计寿命为骑行10000小时。适于第99.5百分位成年男子骑用,舒适便利。3.等等.功能:便于使用潜在失效模式:方向把不好用脚踏板不好用功能:提供可靠的交通运输潜在失效模式:链条经常断开需要经常修理车胎功能:提供舒适的交通运输潜在失效模式:车座位置不舒服,功能:为座位支撑提供稳定的附属物潜在失效模式:座位支撑的结构性失效座位支撑的过大变形功能:提供好看的外观潜在失效模式:外观(光亮度)变坏漆皮开裂,把手总成,后轮总成,链轮总成,功能:提供结构性支撑潜在失效模式:结构性失效过大变形功能:对正确的车架几何外形提供尺寸控制潜在失效模式:车架安装点的长度过长车架安装点的长度过短功能:为车架总成的生产方法(焊接)提供支持潜在失效模式:,自行车,车架,前轮总成,车座总成,链条总成,上部车架,下前车管,下后车管,链轮管,系统等级,子系统等级,部件等级,2020/5/15,19,DetailsofDFMEA,2020/5/15,20,DetailsofDFMEADFMEA的详细内容,2020/5/15,21,DetailsofDFMEADFMEA的详细内容,2020/5/15,22,DetailsofDFMEADFMEA的详细内容,2020/5/15,23,DetailsofDFMEADFMEA的详细内容,2020/5/15,24,DetailsofDFMEADFMEA的详细内容,2020/5/15,25,2020/5/15,26,2020/5/15,27,DetailsofDFMEA,2020/5/15,28,DetailsofDFMEADFMEA的详细内容,2020/5/15,29,DetailsofDFMEADFMEA的详细内容,2020/5/15,30,DetailsofDFMEADFMEA的详细内容,2020/5/15,31,DetailsofDFMEA,2020/5/15,32,2020/5/15,33,DetailsofDFMEADFMEA的详细内容,2020/5/15,34,DetailofDFMEADFMEA的詳細內容,Shallconsidertwotypesofdesigncontrols要考虑两种类型的设计控制：Prevention:Preventthecause/mechanismof预防：failureORthefailuremodefromoccurring,orreducetheirrateofoccurrence.防止失效的起因/机理或失效模式出现，或者降低其出现的几率。,2020/5/15,35,DetailofDFMEADFMEA的详细内容,Detection:Detectthecause/mechanismof探测：failureORthefailuremode,eitherbyanalyticalorphysicalmethods,beforetheitemisreleasedtoproduction.在项目投产之前，通过分析方法或物理方法，探测出失效的起因/机理或者失效模式。,2020/5/15,36,DetailofDFMEADFMEA的详细内容,2020/5/15,37,2020/5/15,38,2020/5/15,39,DetailofDFMEADFMEA的详细内容,2020/5/15,40,DetailofDFMEADFMEA的详细内容,OBJECTIBVE主要目的“Reducerisksandincreasecustomersatisfactionbyimprovingthedesign”建议措施的主要目的是通过改进设计,降低风险,提高顾客满意度。,2020/5/15,41,DetailofDFMEADFMEA的详细内容,Typicalrecommendedaction应考虑但不限于以下措施：Reviseddesigngeometry/tolerance修改设计几何尺寸和/或公差RevisedMaterialSpecification修改材料规范DesignofExperiments(particularlywhenmultipleorinteractivecausesarepresent)orotherproblem-solvingtechniques,andDOE试验设计(尤其是存在多重或相互作用的起因时或其它解决问题的技术)，和Revisedtestplan修改试验计划,2020/5/15,42,Impactsofactionson(S),(O)确定过程变量以此聚焦于过程控制；developsarankedlistofpotentialfailuremodes,thusestablishingaprioritysystemforpreventive/correctiveactionconsiderations;and编制一个潜在失效模式的分级表，以便建立一个考虑预防/纠正措施的优选体系；documentstheresultsofthemanufacturingorassemblyprocess记录制造或装配过程的结果,IntroductionofPFMEA过程FMEA,2020/5/15,50,Usually,itmeansEnd-User通常是指“最终使用者”itmayalsobesequentialmanufacturing/assemblyprocess,reworkprocessorgovernmentregulation也可以是随后或下游的制造或装配工序，维修工序或政府法规,IdentificationofCustomer顾客的定义,2020/5/15,51,PFMEAshouldbeinitiated：过程FMEA应：Beforeoratthefeasibilitystage；在可行性阶段或之前进行；Priortotoolingforproduction；在生产用工装到位之前完成；Takeintoaccountallmanufacturingoperations,fromindividualcomponentstoassemblies虑到从单个部件到总成的所有的制造工序Assumption:theproductasdesignedwillmeetthedesignintent过程FMEA假定所设计的产品能够满足设计要求；,过程FMEA,2020/5/15,52,Doesntrelyonproductdesignchangestoovercomeweaknessesintheprocess过程FMEA不依靠改变产品设计来克服过程中的薄弱环节Buttakeintoconsiderationaproductsdesigncharacteristicsrelativetotheplannedmanufacturingorassemblyprocess但要考虑与计划的制造/装配过程有关部门的产品设计特性,过程FMEA,2020/5/15,53,Beginwithaflowchartofthegeneralprocess,thisflowchartshouldidentifytheproduct/processcharacteristicsassociatedwitheachoperation过程FMEA应从一般过程的流程图开始，该流程图应明确与每一工序相关的产品/过程特性。Inordertofacilitatedocumentationoftheanalysisofpotentialfailuresandtheirconsequences,aPFMEAformhasbeendeveloped.为了便于FMEA的文件化，编制了标准的过程FMEA表供参考。,过程FMEA,2020/5/15,54,1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,16,17,18,19,20,21,22,2020/5/15,55,1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,16,17,18,19,20,21,22,2020/5/15,56,编制過程FMEA,1FMEAnumberFMEA编号EntertheFMEAdocumentnumber,whichmaybeusedfortacking填入FMEA文件的编号以便查询2Item项目Enterthenameandnumberofthesystem,subsystem,orcomponentforwhichtheprocessisbeinganalyzed注明正在进行过程分析的系统、子系统或部件的名称和编号,2020/5/15,57,编制過程FMEA,3ProcessResponsibility过程责任者EntertheOEM,department,andgroup.Alsoincludethesuppliername,ifapplicable填入制造/装配产品的车间、部门和小组，若已知，还包括供方4PreparedBy编制人Enterthename,telephonenumber,andcompanyoftheengineerresponsibleforpreparingtheFMEA负责编制FMEA的工程师的姓名、电话和所在公司名称,2020/5/15,58,编制過程FMEA,5ModelYear(s)/Program(s)车型年/项目Entertheintendedmodelyear(s)/program(s)thatwilluseand/orbeaffectedbythedesignbeinganalyzed(ifknow)填入所分析的设计/过程将要应用和/或影响的车型年/项目(若已知)6KeyDate关键日期EntertheinitialFMEAduedate,whichshouldnotexceedthescheduledstartofproductiondate初次FMEA应完成的时间，该日期不应超过计划的投入生产日期Incaseofasupplier,theinitialFMEAduedateshouldnotexceedthecustomerrequiredproductionPPAPsubmissiondate.对于供方，初始的FMEA日期不应超过顾客要求的生产件批准过程的提交日期。,2020/5/15,59,编制過程FMEA,7FMEADateFMEA日期EnterthedatetheoriginalFMEAwascompliedandthelatestrevisiondate填入编制FMEA原始稿的日期及最新修订的日期8CoreTeam核心小组Listthenamesoftheresponsibleindividualsanddepartmentsthathavetheauthoritytoidentifyand/orperformtasks列出有权确定和/或执行任务的责任部门的名称和个人的姓名，建议所有参加人员的姓名、部门、电话、地址等都应记录在一张分发表,2020/5/15,60,9.ProcessFunction/Requirements过程功能/要求,Basedonmanufacturingandassemblyprocessflowchart编制制造与装配过程流程图Basedonteamknowledge以小組的集体知识为基础Whatstheprocessfor?这个生产过程要做什么？Whatsthepurpose?其目的是什么？Whatsthefunction?其功能是什么？,2020/5/15,61,9.ProcessFunction/Requirements過程功能/要求,Enterasimpledescriptionoftheprocessoroperationbeinganalyzed.Wheretheprocessinvolvesnumerousoperationswithdifferentpotentialmodesoffailure,itmaybedesirabletolisttheoperationsasseparateelements.填写过程或操作的简单說明/目的。如果过程包含許多不同的潛在失效模式的操作，則每一操作分別列出。例如，將多工作机床的每一操作或一台加工设备的順序过程都列出。Example:#20:drilling操作#20:钻孔Example:#30:Spotweldingatob操作#30:將零件A焊至零件BExample:#40:Putxintoy操作#40:將零件X裝進部件Y,2020/5/15,62,10.PotentialFailureMode潜在失效模式,Themannerinwhichtheprocesscouldpotentiallyfailtomeettheprocessrequirementsand/ordesignintentasdescribedintheprocessfunction/requirementscolumn,itsadescriptionofthenonconformanceatthatspecificoperation.指过程有可能不能满足过程功能/要求栏中所描述的过程要求和/或设计意图，是对该特定工序上的不符合的描述。,2020/5/15,63,itcanbeacauseassociatedwithapotentialfailuremodeinasubsequentoperationoraneffectassociatedwithatpotentialfailureinapreviousoperation可能是下一工序的某个潜在失效模式的一个相关起因或是上一工序的某个潜在失效模式的一个相关后果Assumption:thattheincomingpartsarecorrect应假定所接收的零件/材料是正确的。,10.PotentialFailureMode潜在失效模式,2020/5/15,64,Poseandanswerthequestions：过程工程师应提出并回答下列问题：Howcantheprocess/partfailtomeetrequirements?零件/过程怎样不满足要求？Whatwouldacustomerconsiderobjectionable?无论工程规范如何，顾客（最终使用者，后续工序或服务）认为的可拒收的条件是什么？,10.PotentialFailureMode潜在失效模式,2020/5/15,65,Typicalfailuremodes：典型的失效模式可能是但不局限于：Bent弯曲Burred毛刺Holeoff-location孔错位Cracked断裂Holetooshallow开孔太浅Holemissing漏开孔Handlingdamage转运损坏Dirty脏污Deformed变形Holetoodeep开孔太深Surfacetoosmooth表面太平滑Surfacetoorough表面太粗糙Opencircuited开路Shortcircuited短路Mislabeled贴错标签Describedinphysicalortechnicalterms,NOTasasymptomnoticeablebythecustomer潜在失效模式应以规范化或技术术语描述，不同于顾客察觉的现象,10.PotentialFailureMode潜在失效模式,2020/5/15,66,11.PotentialEffect(s)ofFailure潜在失效效应,Theeffectsofthefailuremodeonthecustomers下游用户生产过程或最终的客户那里会注意到或体验到的后果。Stateclearlyifthefailuremodecouldimpactsafetyorcausenoncompliancetoregulations若失效模式可能影响安全性或对法规的符合性，要清楚地说明。,2020/5/15,67,11.PotentialEffect(s)ofFailure潛在失效效應,Fortheenduser,theeffectsshouldalwaysbestatedintermsofproductorsystemperformance对于最终使用者来说，失效的后果应一律采用产品或系统的性能来描述，例如：Nose噪音Rough粗糙Unstable不穏定Scrap报废Rework返工Leaks泄露,2020/5/15,68,11.PotentialEffect(s)ofFailure潛在失效效應,Forthenextoperationscustomer,theeffectsshouldalwaysbestatedintermsofprocessoroperationperformance如果顾客是一下工序或后续工序/工位，失效的后果应用过程/工序性能来描述，例如：Cannotfasten无法紧固Doesnotfit不能配合Cannotmount无法安装,2020/5/15,69,12.Severity(S)严重程度(S),S:therankassociatedwiththemostseriouseffectforagivenfailuremode某一给定失效模式最严重的影响后果的等级REDUCTIONonlycanbeeffectedthroughdesignchange/redesignofprocess严重度数值的降低只有通过设计更改或重新设计才能实现Theteamshouldagreeonanevaluationcriteriaandrankingsystem工作组应在使用该表时对每个影响的严重程度的等级取得一致意见,2020/5/15,70,2020/5/15,71,2020/5/15,72,2020/5/15,73,SuggestedPFMEASeverityEvaluationCriteria推荐的严重度评价准则,Notrecommendtomodifycriteriaforrankingvaluesof9and10.不推荐修改9和10的严重度数值。Failuremodeswitharankofseverityshouldnotneanalyzedfurther.严重度定级为1的失效模式不应进行进一步的分析。,2020/5/15,74,13.Classification特性分類,Classification级别classifyanyspecialproductorprocesscharacteristics(eg.critical,key,major,significant)特殊产品或过程特性的分级Highlighthighpriorityfailuremode突出高优先度的失效模式,2020/5/15,75,14.PotentialCause(s)/Mechanism(s)ofFailure失效的潛在起因/机理,Howthefailurecouldoccur?Describedintermsofsomethingthatcanbecorrectedorcontrolled.失效是怎样发生的，并应依据可以纠正或可以控制的原则予以描述Listeveryfailurecauseassignabletoeachpotentialfailuremode,totheextentpossible.尽可能列出可归结到每一失效模式的每一个潜在起因Adesignofexperimentsmaybeconsideredtodeterminewhichrootcausesarethemajorcontributorsandmosteasilycontrolled可以考虑用DOE之类的方法，以明确哪些起因起主要作用，哪些易于控制,2020/5/15,76,14.PotentialCause(s)/Mechanism(s)ofFailure失效的潛在起因/机理,Typicalfailurecauses:典型的失效起因：impropertorque-over,under扭矩不当-过大或过小improperweld-current,time,pressure焊接不当-电流，时间，压力inaccurategauging测量不精确improperheattreat-time,temperature热处理不当-时间，温度inadequategating/venting浇口/通风不足inadequateornolubrication润滑不足,2020/5/15,77,14.PotentialCause(s)/Mechanism(s)ofFailure失效的潛在起因/机理,Typicalfailurecauses:典型的失效起因：partmissingormislocated零件漏装/装错wornlocator磨损的定位器worntool磨损的工装impropermachinesetup不正确的机器设置NOTusingambiguousphrases,eg.,operatorerror,machinemalfunction不应使用含糊不清的词语,如操作者错误,机器工作不正常.,2020/5/15,78,15.Occurance(O)發生頻度(O),Thelikelihoodthataspecificcause/mechanismoffailurewilloccur,withrankingfrom1to10某一特定起因发生的可能性，从1-10等级OnlydesignorprocesschangecouldreduceOsranking唯有通过设计更改或过程更改才能降低频度等级consistentoccurrencerankingsystemagreedonwithintheteam小组对分级方法达成一致，保证连续性Statisticaldata,ifavailable,shouldbeusedtodeterminetheranking统计数据可用来确定频度数,2020/5/15,79,SuggestedPFMEAOccurrenceEvaluationCriteria,2020/5/15,80,過程FMEA的發生頻度評估表-(O),2020/5/15,81,16.CurrentProcessControls现行过程控制,TwotypesofProcessControls：有两类过程控制：Preventive：preferredapproach预防：高优先权Preventthecause/mechanismoffailureORthefailuremodefromoccurring,orreducetheirrateofoccurrence.防止失效的起因或失效模式出现，或者降低其出现的几率Detection：探测：Detectthecause/mechanismoffailureORthefailuremode,andleadtocorrectiveactions探测失效的起因或失效模式，导致采取纠正措施,2020/5/15,82,17.Detection(D)探测度(D),Detectionistherankassociatedwiththebestdetectioncontrollistedintheprocesscontrolcolumn探测度是与过程控制栏中所列的最佳探测控制相关联的定级数dontautomaticallypresumethatthedetectionrankingislowbecausetheoccurrenceislow不得因發生頻度等級低而假定探测度等級低theteamshouldagreeonanevaluationcriteriaandrankingsystemthatisconsistent小组应对评定准则和定级方法达成一致意见,2020/5/15,83,A:error-proofedB:gaugingC:manualinspection,2020/5/15,84,推荐的PFMEA探测度评价准则-(D),2020/5/15,85,18.DetailsofPFMEA风险顺序數(RPN),RiskPriorityNum