failure mode effects analysis（fmea）.ppt

FailureModeEffectsAnalysis(FMEA),Abbr.VersionDTQS-NPQJuly2000,天马行空官方博客：,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,2,FAILURE,WhatsthefailureFailureclassFailureoccurrenceWhatsthereasonforfailure,天马行空官方博客：,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,3,Questions?,FAILURE,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,4,FailureModeEffectsAnalysis,FMEAAsystematicgroupofactivitiesintendedto:Recognizethepotentialfailure(s)ofaproductorprocessandtheseverityofeffectofthatfailure(s).Identifycriticalcharacteristics.Rankorderpotentialdesignandprocessdeficiencies.Identifyactionsthatcaneliminateorreducethechanceofthepotentialfailurefromoccurringandreachingthecustomer.Documenttheprocess.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,5,FMEAPurpose,Toeliminatethecauseoffailure,ifthisisnotpossible,reducehowoftenthefailureoccursimprovetheabilitytodetectthefailurebeforeitreachesthecustomer,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,6,FMEAHistoryandTypes,History50FighterPlaneDesign60ApolloPlan70Automobile/MedicalInstrument80Micro-electronic90QS9000,ISO9000TypesDFMEAPFMEA,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,7,ProcessFMEAForm,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,8,ProcessFMEAFlow,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,9,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,10,ProcessFMEA,TeamSelection,CrossFunctionalandMultilevelOperators,Mechanics,Engineers,LeadersTeamLeaderDesignatedRecommendedtobeProcessOwnerMustbeEmpoweredtoimplementactionsFunctionalexpertscanbepulledinasneededSmaller“Core”groupmaybeusefulinitiallytoprovideframework.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,11,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,12,ProcessFMEA,DefineProcess,DevelopaProcessFlowdiagramthatisrepresentativeoftheprocessasittrulyis.DecidetheRatingScalesOutlineOperator,Machine,ProductInteractions,Operatorinvolvementisimperativeatthisstep!,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,13,SeverityRating,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,14,OccurrenceRating,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,15,DetectionRating,*Couldbetimebasede.g.Takesxminutesordaystodetectafailure.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,16,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,17,ProcessFMEA,DetailFailureModeCausesEffects,Brainstormfailuremodes.Selectanddefinefailuremodesthatimpactcriticalcharacteristics.Identifyrootcauses.Defineeffectsoffailuremode.Determinehowoftenfailuremodesoccur.Determinecurrentcontrolsabilitytodetect.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,18,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,19,ProcessFMEA,CalculateRiskNumbers,CalculateRiskPriorityNumber(RPN)foreachfailuremode.RPN=severityxoccurrencexdetection.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,20,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,21,ProcessFMEA,BuildParetoChart,BuildParetosOneforSeverityOneforSeverityxOccurrenceOneforRPN(SeverityxOccurrencexDetection)Identify“VitalFew”FailureModesCanalsouse$,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,22,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,23,ProcessFMEA,DevelopRecommendedActions,Developandimplementactionson“VitalFew”FailureModes,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,24,ProcessFMEAFlow,TeamSelection,CalculateRiskNumbers,DefineProcess,DetailFailureModeCausesEffects,BuildParetoChart,DevelopRecommendedActions,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,25,ProcessFMEA,Evaluateeffectofactionstakenonprocessintermsofseverity,occurrenceanddetection.RecalculateRPNandreassessrisknumber.Reprioritizeandrepeat.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,26,ProcessFMEAFormat,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,27,ProcessFMEARelationships,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,28,ProcessFMEARelationships,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,29,FMEASummary,IdentifyPotentialFailureMode,IdentifyCurrentControls,Effect,Cause,DetermineSeverity,DetermineOccurrence,DetermineDetectability,ActionsleadingtoContinuousImprovement,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,30,PotentialFailureMode,Theproblem,theconcern,theopportunitytoimprove,thefailure,thereject.Thinkofthespecificlossoftheprocessfunction.ExampleQuestions:Howcouldthisprocessfailtocompleteitsintendedfunction?Whycouldthispartberejectedatthisoperation?Whatdoesthecustomer(internalorexternal)findunacceptable?Howwouldthepartnotconformtospecificationsatthisoperation?,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,31,PotentialEffect(s)ofFailure,Theconsequenceofthefailuremodeonthenextprocess,operation,product,customer(internalorexternal)and/orgovernmentregulations.ExampleQuestions:Whatdoesthecustomer(internalorexternal)experienceasaresultofthefailuremodedescribed?Whathappensorwhataretheramificationsofthisfailure?Consequencesmaybetothedesignitself,theproduct,thecustomer,and/orgovernmentregulations.Severityrankingappliestotheeffectonly.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,32,PotentialCauseofFailure(s),Theprocessdeficiencythatresultsinthefailuremode.Therootcause.ExampleQuestions:Inwhatwaycanthissystemfailtoperformitsintendedfunction?Why?Why?Why?Why?Why?Whatcircumstancescouldcausethefailure?Howorwhycanthepartfailtomeetitsengineeringspecifications?Occurrencerankingishowoftenthespecificcauseoccurs.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,33,CurrentControls,Amethod,procedure,testorengineeringanalysisdesignedtocatchtheproblembeforeitreachesthenextoperationorcustomer.Canbesimple,ex.Audits,sampling,sensors,SPC,operatorchecks,inprocesstests,fixturing.Canbecomplex,ex.FEI,MilStandards,ComputerSimulation,LaboratoryTests.Focusforthedetectionratingisintheeffectivenessofthecontroltocatchtheproblembeforeitreachesthecustomer.,ProprietaryMaterialofDuracellGlobalBusinessManagementGroup,34,RecommendedActions,Maybeaspecificactiontocorrectadeficiencyormitigatearisk.Maybearecommendationforfurtherstudy