福特FEMA培训材料210FMEATrainingDFMEAV10课件

1、福特FEMA培训材料210FMEATrainingDFMEAV10课件福特FEMA培训材料210FMEATrainingDFMEAWhen can FMEA documents be discarded? 什么时候可以处理掉FMEA文档FMEA Documents must be retained in accordance with Global Information Standards Record Retention 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 +10 years DFMEs：最终使用后+10年PFME

2、As: Last use +5 years PFMEAs：最终使用后+5年Documentation存档When can FMEA documents be dis如何开展FMEA流程如何开展FMEA流程Targets目标Cross- Functional Team跨功能团队History历史FMEAFMEAProcessFMEA过程Robustness Tools are not specified稳健的工具没有被运用Former FMEA Process以前的FMEA流程TargetsCross- Functional TeamHBoundaryDiagram界限图InterfaceMat

3、rix接口矩阵P-DiagramP图FMEA (withRobustnessLinkages)FMEA(有稳健联系的)Robustness and Reliability Checklist稳健和可靠的检查清单Design Verification Plan (DVP)设计验证计划Qualifies and clarifies the relationships between Systems鉴定并说明系统之间的关系Identifies and quantifies the strength of System Interactions识别并量化系统之间的相互作用Identifies Nois

4、e and Control Factors and Error States识别噪音因素，控制因素和误差状态Summarizes Error States, Noise Factors, and associated Design Controls总结误差状态，噪音因素和相关设计控制图FMEA Process过程BoundaryDiagramInterfaceMatrDFMEADFMEADesign FMEA - An Introduction设计FEMA-开始Identify DFMEA Team 成立DFEMA小组Establish Scope 确定范围Describe Function

5、功能描述Brainstorming头脑风暴Function Trees功能树Step1DFMEA的完成Design FMEA - An IntroductionDesign FMEA Team设计FMEA-小组Design EngineerManufacturing / Process Engineer设计工程师制造/工艺工程师CORETeam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SupportTeam支持小组Facili

6、tator服务商Design FMEA Team设计FMEA-小组DeDesign FMEA Scope设计FMEA-范围Is the boundary or extent of the analysis defines what is included and excluded 分析的界限或范围是否已确定包含什么，不包含什么？Scope incorrectly done: 不正确的范围会：Lengthens analysis 扩大分析Misses target analysis 偏离目标分析Identifies wrong team membership 错误地识别小组成员Design FM

7、EA Scope设计FMEA-范围IDesign FMEA Scope设计FMEA-范围Create a boundary diagram 创建界限图Identify the boundary for analysis 确定分析界限Confirm composition of support team 确定支持小组的成员 Once core team is established.一旦成立了核心小组Design FMEA Scope设计FMEA-范围CConstructing Boundary Diagrams创建界限图Constructing Boundary DiagramsBoundar

8、y Diagram Example界限图-范例Headlamp Assembly前灯装配Boundary Diagram Example界限图Interface Matrix接口矩阵Recommended robustness tool that acts as an input to a Design FMEA 接口矩阵是推荐的作为设计FEMA输入的稳健工具Identifies and quantifies the strength of system interactions by: 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 whether the relation

9、ship is necessary or adverse 显示系统间的关系是互利的还是不利的Identifying the type of relationship 确定关系的类型Interface Matrix接口矩阵Recommend P: Physically touching I: Information exchange P E I M E: Energy transfer M: Material exchange Interaction is necessary for function Interaction is beneficial, but not absolutely n

10、ecessary for functionality Interaction does not affect functionality Interaction causes negative effects but does not prevent functionality Interaction must be prevented to achieve functionality Numbers in each corner represent the above interface types, with values denoting the following: +2 +1 0 -

11、 1 - 2 Example Interface Matrix接口矩阵的范例 P: Physically touching I: Information exchange P E I M E: Energy transfer M: Material exchange Interaction is necessary for function Interaction is beneficial, but not absolutely necessary for functionality Interaction does not affect functionality Interaction

12、causes negative effects but does not prevent functionality Interaction must be prevented to achieve functionality Numbers in each corner represent the above interface types, with values denoting the following: +2 +1 0 - 1 - 2 P: Physically touching I: InfExample Interface Matrix 接口矩阵的范例 P: Physicall

13、y touching I: Information exchange P E I M E: Energy transfer M: Material exchange Interaction is necessary for function Interaction is beneficial, but not absolutely necessary for functionality Interaction does not affect functionality Interaction causes negative effects but does not prevent functi

14、onality Interaction must be prevented to achieve functionality Numbers in each corner represent the above interface types, with values denoting the following: +2 +1 0 - 1 - 2 Example Interface Matrix 接口矩阵P-DiagramP图Recommended structured tool to identify intended inputs and outputs for a function P图

15、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 noise factors, control factors, ideal function, and error states 描述噪音因素，控制因素，理想的功能和误差状态Assists in the identification of: 有助于识别：Potential Causes for failure 潜在的失效原因Failure Modes 失效模式Potential Effects of failure 潜在的失效后果Current Controls 目前的控制方法Recommended Actions 建

16、议的措施P-DiagramP图Recommended structExample P-DiagramP图的范例Example P-DiagramP图的范例Header Information表头信息Complete each field 完成每一区域：System, Subsystem or Component Name and 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 Number FMEA编号Prepared By 准备

17、人FMEA Date FMEA日期Header Information表头信息CompletDetermine Function确定功能Determine Function确定功能What is Function?功能是什么？Design intent or engineering requirement 设计意图或工程要求Written in verb-noun measurable format 书面的，可以测量的动名词格式Representation of all wants, needs and requirements, both spoken and unspoken for al

18、l customers and systems 描述所有顾客和系统的所有需要，需求和要求What is Function?功能是什么？DesignVerb 动词Indicates action, occurrence, beingGenerate产生Control控制Dispense分配Retain保持Prevent防止Noun 名词Indicates what the action relates 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Verb 动词Indicates action, occurBrai

19、nstorming头脑风暴Exercise in creative thinking Method to generate ideas通过创造性思维找到解决办法的练习Brainstorming头脑风暴Exercise in Function Trees 功能树Provide an organized approach to identify the essential features of a product (or process sometimes) 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 ensure that unspoken and spoken requi

20、rements are defined 有助于确保所有的要求已经确定Provide a graphical representation of functions to ensure clear, total team understanding 提供功能的图示描述，以确保全体小组清楚地理解Function Trees 功能树Provide an First Level第一层Second Level第二层Constructing Function Trees建立功能书Third Level第三层HOW ?如何做？WHY ?为什么？First LevelSecond LevelConstruAd

21、justHeadlamp调整前灯Vertical Trimmer Function Tree 垂直调整片的功能树HOW ?如何做？Permit / Maintain HorizontalAdjustment通过/维持水平调整Permit / Maintain Vertical Adjustment通过/维持垂直调整Adjust Light Beam Y调整Y方向的光Locate Headlamp Horizontally 前灯水平方向的定位Adjust Light Beam Z调整Z方向的光Locate Headlamp Vertically 前灯垂直方向定位WHY ?为什么？AdjustVe

22、rtical Trimmer FunctioGuidelines 指南Brainstorm all functions (VERB - NOUN) 集体讨论所有的功能Document individual functions by asking “HOW is function achieved?” 通过提问“如何达到功能？”文件化各自的功能Repeat left to right, until actionable level 不断从左到右重复，直至到达可执行的层次Use worksheet to check that actionable level is measurable 使用工作表

23、检查可执行的层次是可以测量的Work right to left and check structure by asking “WHY is function 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Guidelines 指南Brainstorm all Design FMEA Functions设计FMEA的功能Function 3Function nFunction 2Function 1Function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-

24、Sub-Function子功能的子功能Sub-Sub-Function子功能的子功能Design FMEA Functions设计FMEA的功Design FMEA Path/Step 设计FMEA 路径/步骤Step2DFMEA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Recommended Actions 建议的措施Design FMEA Path/Step 设计FMEA Design FMEA Path/Step 设计FMEA-步骤/步骤Design FMEA

25、 Path/Step 设计FMEPotential Failure Modes潜在失效模式Function 1功能1Potential Failure Modes:潜在失效模式：No function没有起作用Partial/Over Function/Degraded Over Time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Function 2功能2Function 3功能3Function 4功能4Function N功能nPotential Failure Modes潜在失效模式Failure Mode

26、s - 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 in one direction Degraded Over Time朝一个方向调整部分/全部的功能降低Intermittent functionAdjustment sometimes and 功能的间歇性中断not at others (not in cold) 有时调整Unintended functionNone known非预期的功能不知道Function: Adjust Light Be

27、am Y功能：调整Y方向的光Failure Mode Type Potential Failure Mode失效模式的类型 潜在的失效模式Failure Modes - Vertical TrimEffects of Failure Modes失效模式的后果Effects of Failure Modes失效模式的Effects of Failure Modes失效模式的后果Potential Effects of Failure Modes:潜在失效模式的后果：Part / Sub-component 零件/分部件Next Higher Assembly 更高层的装配System 系统Veh

28、icle 车辆Government Regulations 政府法规Customer (Internal and End User)顾客（内部的和最终用户）Effects of Failure Modes失效模式的Design FMEA Severity设计FMEA-严重度Design FMEA Severity设计FMEA-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

29、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 6Suggested Severity Evaluation 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

30、有缺陷 很轻微 配合和外观/尖响和卡嗒响等项目不舒服， 2 25%顾客感觉有缺陷 无 无影响 1Suggested 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 Vertical Trimmer/垂直调整片Retains SettingPotential Effects of Failure 潜在失效后果Part: May be stripped during adjustment(7) 零件：可能在调整过程中丢失 Next Higher Assembly: Headlamp cannot be adjusted (6) 更高层的装配

31、：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-compliance (10) 政府法规： 不符合 Customer: Impaired night/ fog (7) 顾客：减少夜晚/雾天行驶10DFMEA Severity Rating ExampleDFMEA严重度等级的范例SEVItem 条款Function 功能Potential Failure Mode潜在失效模式Does not mai

32、ntain adjustment不用继续调整Potential Effects of Failure 1YCS=9 S=10Design FMEA 设计FMEAIdentify Potential Special Characteristics识别潜在的特殊特性YCS=9Design FMEA Identify PoteDFMEA - Recommended ActionsDFMEA - 建议的措施DFMEA - Recommended ActionsDFCauses Occurrence 原因-发生率Special Characteristics 特殊特性Actions 措施 Design

33、Controls 设计控制Assessing Risk 评估风险Actions 措施Design FMEA Paths/Steps 设计FMEA 路径/步骤Step3DFMEA的完成Causes OccurrenceDesign FMEADesign FMEA Path/Step 2设计FMEA 路径/步骤2Design FMEA Path/Step 2设计FMEAPotential Cause of Failure潜在失效原因 An indication of a design weakness, the consequence of which is the failure mode 潜在

34、失效原因是由设计缺陷引起的，其结果就是失效模式。 Potential Cause of Failure潜在失What Might Cause Failure?可能导致失效的原因？Item is manufactured and assembled within engineering specifications 工程规范中已经制造并装配的零件Design may include a deficiency that may cause unacceptable 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

35、造，误差等）Two Assumptions for Cause .两种假定的原因What Might Cause Failure?可能导致Manufacturing Misbuilds 制造的错误构造Due to Design Deficiencies由设计缺陷引起的+-+-Manufacturing Misbuilds 制造的错误Manufacturing Misbuilds 制造的错误构造Due to Design Deficiencies由设计缺陷引起的+-+-Manufacturing Misbuilds 制造的错误Use a Fishbone Diagram使用鱼刺图Causes o

36、f Failure失效的原因No Adjustment没有调整Thread SeizureBroken Bracket有故障的支架Interface not Understood by User用户没有理解接口Thermostat GeometryThread FusionMaterial PropagationScrew Thread Specification Oversize螺旋的螺纹太大Support Area too Small支持范围太窄Use a Fishbone DiagramCauses oCauses of Failure - Why Ladder失效原因-梯形为什么Mat

37、erial crackedPartBends零件弯曲Support area too small支持范围太窄WHY?为什么？WHY?为什么？WHY?为什么？Level 3第3层Level 2第2层Level 1第1层Broken Bracket有故障的支架Causes of Failure - Why LaddeSentencing Technique判断的技巧FailureMode失效模式Could result in可能导致Effect后果Cause原因Leads to引起TIME 时间Due to由于Sentencing Technique判断的技巧FailSentencing Tech

38、nique Example判断技巧的范例No Adjustment没有调整Could result in可能导致Misaligned Beams方向偏离的光线Due to由于Thread Seizure螺纹咬死Leads to导致 TIME 时间Sentencing Technique Example判Causes of Failures失效的原因Function1功能1Failure Mode 1失效模式1Failure Mode 2失效模式2Failure Mode n失效模式nWHY?为什么？M E P E MCauses of Failures失效的原因FunctiDesign FME

39、A Occurrence设计FMEA-发生率Design FMEA Occurrence设计FME失效发生的可能性 可能的失效率 频度数很高：持续性失效 100个 每1000辆车/项目 10 50个 每1000辆车/项目 9高：经常性失效 20个 每1000辆车/项目 8 10个 每1000辆车/项目 7中等：偶然性失效 5个 每1000辆车/项目 6 Suggested Occurrence Evaluation Criteria建议的发生率评价准则失效发生的可能性 可能的失效率 频度数Suggested Occurrence Evaluation Criteria建议的发生率评价准则失效发

40、生的可能性 可能的失效率 频度数中等：偶然性失效 2个 每1000辆车/项目 5 1个 每1000辆车/项目 4低：相对很少 0.5个 每1000辆车/项目 3 发生的失效 0.1个 每1000辆车/项目 2极低：失效不太 0.010个 每1000辆车/项目 1 可能发生Suggested Occurrence EvaluatioYCYSS=9 S=10S=5-8O=4-10Design FMEA设计FMEAIdentify Potential Special Characteristics识别潜在特殊特性YCYSS=9S=5-8Design FMEAIdentifRecommended Ac

41、tions建议的措施Recommended Actions建议的措施DFMEA - Design ControlsDFMEA-设计控制Type 1Prevention: Prevent the cause/mechanism or failure mode/effect from occurring, or reduce the rate of occurrence类型1 预防：预防失效原因/机理或者失效模式/后果，或减少发生度Type 2Detection: Detect the cause/mechanism or failure mode, either by analytical or physical methods, before the item is released to production类型2 探测：在零件生产之前，用分析或物理方法探测失效原因/机理或失效模式DFMEA - Design ControlsDFMEA-Design FMEA Detection设计FMEA-探测度Design FMEA Detection设计FMEASuggested De