aae.FMEA培训-Failure Mode and Effect Analysis.ppt

PhilipsFMEA,FailureModeandEffectAnalysis,Contentofthecourse,IntroductionProduct-FMEABlockdiagram,functiontreeProcess-FMEAProcess-flowdiagram(macro-level),micro-levelFacilitatorskills,FMEAIntroduction,WhyFMEAs?Definition,Purpose,Types,BenefitsTeamApproach,WhyFMEAs?,Appropriaterecommendedactionsmaynothavebeentaken.Savingsinengineeringtime.Reductionofchangesimmediatelybeforeproductionstart(CommercialRelease).,FMEADefinition,IdentifypotentialfailuremodesPrioritizeactionsDocumenttheprocess.,Structuredgroupofactivitieswhich.,FMEAPurpose,Failures,Time,RateseverityoffailuremodesIdentifyactionstoreduceoccurenceTestadequacyofcontrols,FMEAPurpose,FMEAsareintendedto.,FMEATypes,Optical,Product-FMEA,Mechanical,Process-FMEA,Electrical,Mechanical,Electrical,Optical,FMEASessions,BenefitsProduct-FMEAs,Assessfailuremodeeffectsonallcustomers.AidsinevaluatingtestspecificationsEvaluationofdesignrelatingtoDFMDFADFTIncreasesthepossibilitytodetectpossiblefailuremodes.,Proces,Product,VoordelenProces-FMEAs,AssesseffectsonallcustomersIdentifiespotentialmanufacturingandassemblycausestofocuscontrolsonreducingoccurrenceorincreasingdetection.,Design,Proces,GeneratingFMEAs,FMEAs,Whoinitiates?,FailureModeandEffectAnalysis,Whoupdates?,WhoisFMEA-customer?,Startingdate/revisiondate?,Whencompleted?,Howdocu-mented?,Whentodiscard?,Whoprepares?,ManagingFMEAs,ModificationtoaproductorprocessisplannedComponentistobeusedinnewenvironmentCustomerrejections,FMEAsarelivingdocumentsandareupdated.,FMEATeamApproach,Support-team,Product-FMEAContent,DefineFMEA-teamDefinescopeDescribefunctionsBrainstormingFunctionTrees,Product-FMEATeam,Product-FMEAScope,CreateBlockdiagramIdentifythebounderyforAnalysisConfirmcompositionofsupportteam.,Oncecoreteamisestablished.,Blockdiagram,Component/Assembly,Screw,Weld,Adhesive,Exampleblockdiagram(SettopWildfire),Front,Klicked,DisplayPCB,PSU,SmartcardPCB,Frame,Cover,Klicked,Klicked,Screwed,Screwed,DetermineFunctions,DescribestheintentofthedesignMustbemeasurebleorsetatanactionablelevelRepresentsallwants,bothspokenandunspoken.,Whatarethefunctionsofthedesign?,GenerateControlDisplay,DescribeFunction,lightspeedinformation,DescribeFunctions,Thoughtstarters.SatisfyuserAttractuserGuaranteedurabilityEasytorepareSafetyrequirements,Brainstorming,Functiontree,ProvidesanorganizedapproachtoidentifytheessentialfeaturesofaproductDefinesallspokenandunspokenrequirementsProvidestheteamwithaclearoverviewofallthefunctionsoftheproduct.,ConstructingFunctiontrees,DisplayInformation,FunctiontreeFrontbutton(Settop),Guidelines,Brainstormallfunctions(VERB-NOUN)Documentindividualfunctionsbyasking“Howisthisfunctionachieved?”Repeatlefttoright,untilactionablelevelWorkrighttoleftandcheckstructurebyasking“Whyisthisfunctionincluded?”,Product-FMEAFunctions,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,MC,ML,P,PotentialfailureModes,NofunctionPartialfunction,FailureModeTypeExample,NotoperationalNotalloffunctionoperating,FailureModes:Frontbutton,NofunctionNotekstavailablePartialfunctionTekstpartialavailable,Function:Tekstclearvisibleafter100 xcleaning.,FailureModeTypeExample,Product-FMEAModesoffailure,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,Effectsfailure,Whataretheeffectsofthefailurerelatingto:,-anotherpart-thecompleteassembly-thecustomer-theenduser-thegovernmentalregulations,Product-FMEATabelofeffects,FailureModeTekstunread-able,Frontbutton,CompleteAssemblyDifficulttosale,CustomerDissatisfied,EnduserDissatisfied,GovernmentalregulationNone,AnotherpartNone,Product-FMEAEffectsoffailure,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,AssemblynotpossibletosaleCustomerdissatisfied,Severity(Weightfactor),Whatistheseverityoftheeffects?,Criteria:Severityofeffect,Class,Effect,Acceptedfailure,D,None,Safetyfailure,S,Unacceptablerisk,Non-conformingwithsafety,Correctionisnescessary,A,Relativebigrisk,Correctieisrecommended,B,risico,Correctieisnuttig,C,RatingcriteriavoorSeverity(Weightfactor),Minimumrisk,Correctieisusefull,C,Frontbutton/TekstreadableafterPQR-test,FailureModeTekstunreadable,EffectsAssembly:unsaleable(A)Customer:Dissatisfied(A)Gov.Reg.:None(D),A,RatingofWeightfactorexample,Sev.,Part,Function,Product-FMEAWeightfactor,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,AssemblynotpossibletosaleCustomerdissatisfied,A,PotentialCauseofFailure,Aweaknessinthedesignwithafailuremodeaseffect.,Manufacturingmisbuilds,DuetodesignDeficiencies,+-,+-,Manufacturingmisbuilds,RobustDesign,+-,+-,UseFishboneDiagram,Causeoffailure,Tekstunreadable,Inktofpoorquality,Tekstonwronglocation,Causeoffailure“Why”-ladder,Designrequirement,WHY?,level1,Tekstunreadable,WHY?,level2,WHY?,level3,Inktdoesntstick,Surfaceroughnessnotok.,SentencingTechnique,FailureMode,SentencingTechnique-Example,Tekstunreadable,Product-FMEACause,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,AssemblynotpossibletosaleCustomerdissatisfied,A,Tekstonwronglocation,Product-FMEAOccurrence,Whatisthepossibilitythatthefailureoccurrs?,PossibleFailureRates,Ranking,Probabilityoffailure,1of20,Veryhigh,Moderate,1of400,1of15000,Low,1of15000,4,5,3,2,1,Ratingcriteriaoccurrence,1of3,Product-FMEAOccurrence,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,AssemblynotpossibletosaleCustomerdissatisfied,A,Tekstonwronglocation,5,Produkt-FMEAAction/Solution,Whatarepossibleactionsto:-eliminatethefailure-reduceeffect-reduceoccurrence.,Product-FMEAAction/Solution,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,AssemblynotpossibletosaleCustomerdissatisfied,A,Tekstonwronglocation,5,Notekstonbuttons,JD,DefineEvolutionfactor,Causenotknown4Solutionnotknown3Solutionnotevaluated2Solutionnotimplemented1Solutionimplemented0,Product-FMEAEvolutionfactor,DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,Front,Button,TekstclearvisibleafterPQR-test,Tekstunread-able,MC,ML,P,AssemblynotpossibletosaleCustomerdissatisfied,A,Tekstonwronglocation,5,Notekstonbuttons,JD,1,Riskevaluation,Severity(Weightfactor)OccurrenceEvolutionfactorRiskmaturity-grid,MaturityGrid,WeightFactor,EvolutionFactor,EvolutionFactor,S,A,B,C,D,0,1,2,3,4,0,1,2,3,4,3,7,5,4,5,1,2,3,Product-FMEAElectrical(Example),DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,P,Frontend,Tuner,Put-throughselectedsignal(SD12XX),Tunergetsdisturbedbynoisegeneratedby14-18Vgeneration,Tunergivesbadsignalthrough,A,Lowfrequentnoiseisnotfiltered,5,ML,MC,AddbeadinLNBAline,rightnexttotuner,GD,2,Proces-FMEAContent,FMEA-teamDefinescopeDescribefunctions,Proces-FMEATeam,Process-FMEAScope,Createflow-diagramDefinescopeDefinesupport-team.,Process-FMEA(Example),DescriptionLevel1,DescriptionLevel2,Function,ModeofFailure,Effect,Cause,Action/Solution,Resp.,P,Glue,Gluewithcyano-acrylate,Joinparts,Cyanoacrylatenotwellcured,Lifetimeproblems,A,Gluevolumetohigh,5,ML,MC,Useactivator,JD,2,FMEA,Tasks&Responsibilities.,FMEATeamleader,PreparationoftheFMEA-sessiondistributionoftheproducttotheparticipants1or2weeksbeforethemeetingtogatheralltherelevantinformation.Prepare(fill-in)FMEA-worksheetasgoodaspossible(functions,failuremodes,.),Tasksoftheteamleader:,FMEATeamleader,PreparationoftheFMEA-session:Distribute/displayimportantinformation:agenda,FMEA-methodDefinetasksoftheteam-members:Whoistheteamleader,facilitator,timekeeper,secretary?,Tasksoftheteamleader:,FMEAFacilitator,HelpspreparingtheFMEA-sessionSupportstheteamleaderTakescarethatFMEA-metholodgyiscorrectlyusedTakescareoftheteam-process.,Tasksofthefacilitator:,FMEAFacilitator,PreparationoftheFMEA-sessionpreparationtogetherwiththeteam-leaderdefineagendaforthemeetingproduct-FMEA:createblockdiagramprocess-FMEA:createflowdiagramdefineparticipants(6-8persons).,Tasksofthefacilitator:,FMEAFacilitator,Supportingtheteamleader:theteamleaderisfocussedontheproject(timing,technicalsollutions,).ThefacilitatortakescareforcorrectapplyingoftheFMEA-proces.SupportstheteamleaderwiththepreparationofthemeetingandduringtheFMEA-session.,Tasksofthefacilitator:,FMEAFacilitator,TakingcareforcorrectapplyingFMEA-metholodgy:arefunktionscorrectwrittendown(verb/noun)?areallfailuremodesmentioned,listed?areeffectsofthefailuremodescorrect?(noconfusionbetweencausesandeffects).,Tasksofthefacilitator:,FMEAFacilitator,TakingcareforcorrectapplyingFMEA-metholodgy:Isforeacheffectaweigthfactormentioned,foreachcausetheprobabilityandforeachsollutiontheevolutionfactordefinedIstheFMEA-worksheetcompletelyfilled-in(actions,responsibleperson,date)?,Tasksofthefacilitator