失效模式分析.ppt68.ppt

1、An analytical tool for identifying Potential Failures in a product or process so that corrective action can be taken before the failures can reach the customer.,FMEA是一種識別產品或過程的潛在失效,以便在這些失效影響客戶之前 採取措施的分析工具,An FMEA is a Structured Approach to: FMEA是結構式的方法,Identifying the ways in which a design or proc

2、ess can fail to meet the critical customer requirements 識別設計或過程可能以何種方式失效而不能滿足客戶重要需求 Estimating the risk of specific causes with regard to these failures 估計產生這些失效的特殊原因的風險 Evaluating the current controls for preventing these failures 評估現有控制手段對這些失效的預防 Prioritizing the actions that must be taken to impr

3、ove the design or the process 給那些用以改進設計和過程的措施排序,FMEA History 歷史,First used in the 1960s during the Apollo Moon Missions. 最早被用於上世紀六十年代的阿波羅登月計劃. In 1974 MIL-STD-1629 was developed by the Navy for using FMEAs. 1974年海軍為FMEA的應用制定了MIL-STD-1629. In the late 1970, adapted by the auto industry in response to

4、 higher liability costs and higher quality demands by customers. 在二十世紀七十年代末, 為滿足客戶更高的責任成本和質量需求而被用於自動化工業中.,FMEA is proactive, not reactive. Dont wait for the customer to complain if you can avoid it! FMEA是預防性 的，不是反應性的。應當儘量避免失效，而不是等著顧客提出申訴！,FMEA reduces the chance that a customer will see a failure FM

5、EA通過以下措施減少顧客遇到失效的情況: By defining failure in terms of what the customer wants and expects. 針對顧客的要求和期望確定失效 By showing where measures need to be taken to prevent failure. 指出爲了防止失效，需要在哪方面採取措施,Types of FMEAs 類型,Design used to analyze product designs before they are released to production 設計 - 用於在產品投產前對設計

6、的分析 Process used to analyze manufacturing processes 過程 - 用於分析製程 System used to analyze systems in the early concept and design stages 系統 用於分析早期的概念和設計階段的系統,Summary 概要,Identifies known and potential failure modes; 識別已知和潛在的失效模式 Identifies the causes and effects of each failure mode; 識別每一種失效模式的原因和後果 Pri

7、oritizes the failure modes (using the RPN); 利用風險序數 （RPN）給失效模式排序 Should initiate corrective action where needed. 必要時提出糾正措施,Timing of an FMEAFMEA的時機,FMEAs should be initiated when preliminary drawings of the design or process are available 當初步的設計圖紙和工藝被制定出來時應開始做FMEA Updated as identified issues are res

8、olved 當被發現的問題解決後要更新FMEA Can be used on existing products to improve quality 可用於現有的產品以提高質量,System系統 Wiring harness 線束 Electronic module 電控模塊 Assembly 總成,System FMEA treats system as a“functional schematic” 系統FMEA從“功能關係圖”入手來考慮,SFMEA,An analytical tool used to identify system-level failure modes, and i

9、dentify corrective actions to be taken. 是一種分析工具用來識別系統失效模式,It is similar to a Design FMEA, but focuses on the circuit schematic instead of physical failure of components. 同DFMEA相類似, 系統FMEA側重於回路設計而不是元件的物理失效。,Example: 舉例： Failure mode at electrical system level 電氣系統失效模式 Open circuit at ckt A 回路A出現開路 Ca

10、use: 原因： Terminal unseated 端子脫出 Terminal unseated becomes a failure mode at the component level. 端子脫出 是電氣元件的失效模式。,Rules of Design FMEA設計FMEA規則,Tool for design engineers and project team to improve the design in a preemptive manner (before failure occur) 是設計工程師和項目小組的工具用來提高設計的前瞻性(在問題發生前) Used to estab

11、lished Critical to Quality features that effect the performance of the product 用與那些影響產品性能的重要質量特性 Used to establish Critical to Life features that effect the life of the product 用於確定影響產品壽命的重要壽命特性 Used to establish Critical to safety features 用於確定重要安全特性,Purpose of Design FMEA設計FMEA的用途,Establishes crit

12、ical features that must be controlled in manufacturing to satisfy customer requirements 確定那些必須在生產中進行控制的特性以滿足客戶要求 Identifies deficiencies in the product design and associated action items 找出產品設計中的不足和相應的措施 Helps evaluate the risk of design changes 幫助評價設計變更的風險,Purpose of Design FMEA設計FMEA的用途,Identifies

13、 process development needs 確定開發工藝流程的需求 Dynamic document documents design alternatives and associated risks 動態的文件 記錄可選擇的設計方案和相應的風險 Establishes bases for manufacturing and quality control plan 建立製造和品質控制計劃的基礎,Design FMEA Inputs and Outputs 設計FMEA的輸入和輸出,Product drawings 產品圖紙 Product models 產品模型 Product

14、specification 產品規格,Identified Critical to Quality failures 確定的重要質量特性 Actions to prevent the causes of failures 防止失效原因的措施 Actions to detect failure modes 發現失效模式的措施 History of actions and Responsibilities 措施和責任人的記錄,Design 设计 Components 元件 Elements 设计要素,Design FMEA looks at physical failure modes of co

15、mponents and design elements 设计FMEA着眼于元件及设计要素 的物理失效模式,DFMEA,Rules of Process FMEA過程FMEA規則,Tool for process engineers and project team to improve the manufacturing process in a preemptive manner 是工藝工程師和項目小組的工具,用來提高製造工藝的前瞻性 Used to prioritize actions to ensure attention to critical processes that effe

16、ct customers 用與區分先後順序以確保那些影響客戶的重要工藝 Used to document process improvements 用於工藝改進 Dynamic document for continuous improvement 持續改進的動態文件,Purpose of Process FMEA過程FMEA的用途,Assists in the analysis of new manufacturing process 幫助分析新的製造工藝 Establishes the bases for manufacturing process instructions and con

17、trol sheets 建立製造工藝文件和控制文件的基礎 Identifies new manufacturing process needs 確定新製造工藝的需求 Helps evaluate the risk of process changes 幫助評估工藝更改的風險,Process 过程 Manufacturing 制造 Assembling 装配,Process FMEA looks at product failures caused by the process failing to meet requirements 过程FMEA着眼于因加工過程不符合要求所造成的产品 失效,P

18、FMEA,FMEA Team 小組,Team approach is necessary. 需要團隊的方式 Responsible for Design FMEA Design Engineer 設計工程師負責設計FMEA Responsible for Process FMEA Manufacturing Engineer 製造工程師負責過程FMEA Recommended representatives: 推薦人選: Design / 設計 Manufacturing Engineers / 製造工程師 Quality Engineers / 質量工程師 Reliability / 可靠性

19、 Materials / 原材料 Suppliers / 供應商,Definition of Terms 術語,Failure Mode The way in which a specific input requirement fails and if not detected, corrected or removed will cause an Effect to occur. 失效模式 一個特殊的輸入要求失敗的方式或者由於未被發覺,糾正或消除而帶來的後果 Effect Impact on customer requirements 後果 對客戶要求的影響,Definition of T

20、erms 術語,Cause Source(s) of process variation that causes the Failure Mode to occur. 原因 造成失效模式發生的過程變差的起源 Current Control (proposed controls) 當前的控制 (建議的控制) Design elements that ensure function 確保功能的設計要素 Mistake proofing, automated controls, set up instructions, gauges 防錯,自動化控制,機器設定指導書,量具 Audits, check

21、lists, inspections, PM, etc. 稽核,檢查表,檢驗,設備維護,等,Linking Failure Modes to Effects 失效模式和後果之間的聯繫,Failure Mode 1,Failure Mode 2,Effect 1,Failure Mode 1,Effect 2,Effect 1,Failure Mode 1,Failure Mode 2,Effect 1,Note that the relationship between the Failure Mode and Effect is not always 1-to-1 請注意失效模式和後果之間的

22、關係不總是一對一,Effect 2,Risk Priority Number 風險序數,The output of a FMEA is the “Risk of Priority Number” - RPN 一個FMEA的輸出是“風險序數”-RPN The RPN is a calculated number based on information provided regarding RPN是根據下面的資料計算出來的 The potential failure modes, 潛在失效模式 The effects, and 後果 The current or planned ability

23、to detect the failure before it reaches the customer 現有的和已計劃的能力可以在影響客戶前覺察失效,Risk Priority Number 風險序數,It is calculated as the product of three quantitative rating 它是用三個級數計算出來的 RPN = Severity * Occurrence * Detection 風險序數 = 嚴重度 * 發生頻度 * 探測度 The RPN is not sacred RPN不是神聖的 Scaling for Severity, Occurre

24、nce, and Detection are locally developed嚴重度,發生頻度,探測度的尺度由自己制定 Other categories may be added to suit need 根據需要可以加上其他類型 High Risk Priority Numbers are significant to the success of the product design - actions must be taken to prevent failures 高風險序數對產品設計的成功來講很重要 - 需要採取措施來防止失效,Definition of RPN Terms RP

25、N術語,Severity (of effect) Importance to customer, may involve function, safety, reliability, or life of product (1= not severe, 10 = very severe) 嚴重度(後果的) 對客戶的重要程度, 可包括功能,安全,可靠性, 產品壽命等方面. (1=不嚴重, 10=很嚴重) Occurrence (of cause) Frequency with which a given Cause may occur (1= not likely to occur, 10= v

26、ery likely to occur) 發生頻度 (原因的) 一個特定的原因可能發生的頻度 (1= 不可能發生, 10= 很可能發生) Detection (Capability of current or planned Controls) Ability to detect the cause (1= likely to be detected, 10= not likely to be detected) 探測度 (現有的或已計劃的控制能力) 覺察原因的能力 (1= 有可能發覺, 10= 不可能發覺),Rating Scales 評分尺度,Rating Scales 評分尺度,Rati

27、ng Scales 評分尺度,Examples of Occurrence scale 發生率評分的例子,Examples of Detection scale 探測度評分的例子,What is the input? 輸入是 甚麼?,What can go wrong with the input? 輸入會出 甚麼錯?,What is the Effect on the output? 輸出的 後果是 甚麼?,What are the causes? 原因是 甚麼?,How well? 程度如何?,How can this be found? 怎樣才 可以 發現?,How often? 頻繁程

28、度,What can be done? 可以做甚麼?,How well? 程度如何?,FMEA Model 模式,Prevention/預防,Prevention/預防,Prevention/預防,Cause/原因,Effect/後果,Failure Mode/ 失效模式,Controls/控制,Material or process input/原料或過程輸入,Process Step/工序,External customer or downstream process step/外部客戶或下一工序,General Steps in the DFMEA/一般步驟,Select design

29、FMEA team 組建設計FMEA小組 List customer requirements 列出客戶的要求 For each customer requirement list the key design elements that satisfy the customer requirements 針對客戶的每一個要求列出滿足該要求的關鍵設計要素 For each key design element list ways that the design element could vary, Potential Failure Modes 列出每一個關鍵設計要素的變化,潛在的失效模式

30、List Effects of each Failure mode on the customer requirement 列出每個失效模式的對客戶要求的影響 List Causes for each failure Mode 列出失效模式的原因,General Steps in the DFMEA/一般步驟,List current controls for each cause 列出每個原因的現有控制手段 Assign Severity, Occurrence, and Detection ratings to each cause 給每個原因的嚴重度,頻度,可探測度評分 Calculat

31、e RPNs 計算風險序數 Recommend actions to reduce high RPNs 提出降低風險序數的措施 Take appropriate action 採取適當的措施 Recalculate RPNs 重新計算風險序數,A schematic representation, with 一種圖示法, 其中 Components (or features) shown as blocks, 用方塊表示各元件(或特性) Interactions between components shown as lines, 用直線表示各元件之間的關係 At the appropriat

32、e level of detail 詳細到恰當的程度,Develop a Functional Block Diagram of The Product繪制產品功能結構圖,Block Diagram 結構圖,Examples例如,Dont forget auxiliary functions as well a primary functions 主要功能和輔助功能都要考慮 Often, components work together to perform a function 經常是幾個零件共同實現一個功能 Hint: Use the Block Diagram! 提示: 利用結構圖,Li

33、st The Function(s) of Each Component列出每個要素的功能,A defect, flaw, or other unsatisfactory condition in the product that is caused by a design weakness 由於設計缺陷造成的產品缺陷,瑕疵或其它令人不滿意的情況,Typical Failure Modes: 典型的失效模式 - Breaks - Cracks 破碎 裂紋 - Corrodes - Sticks 腐蝕 粘結 - Deforms/melts 變形/熔化,Start with the previou

34、s two steps: 從前両個步驟入手: Functions 功能 Quality requirements 質量要求,In your own descriptive words, write down the following scenarios，用自己的語言描述下列假設： Failure = No function， 失效 = 無功能 Failure = Not enough function， 失效 = 功能不足 Failure = Too much function， 失效 = 功能過強 Similarly,同樣： Failure = No quality requirement

35、 失效 = 未達到質量要求,An effect can be ，後果可能是： Complete loss of function，功能完全喪失 Degradation of performance or quality 性能或質量下降 Many failure modes have more than one effect! 許多失效模式不止有一個後果！ Effects of failure often show up as a chain of events, from immediate effect to the ultimate effect on the customer 失效模式的

36、後果經常表現為對客戶的一連串的影響,包括直接的後果和最終的後果,Determine Potential Cause(s) of Each Failure Mode確定每種失效模式的潛在原因,A cause of failure is a design weakness that leads to the failure mode 造成失效的原因是由於設計缺陷 引起 Inherent in the way the product was designed 是產品設計所固有的 Relative to the usage of the product 與產品的使用方法有關 Many failure

37、modes have multiple causes! 許多失效模式有多個起因！,If the design as-is were to go into production. 如果依據現有設計進行生產的話 Use historical data，利用歷史資料 Take improvements into account，參考已有的改進 Consider the lifespan of the product，考慮產品的壽命 Use reliability models and comparison with similar products，利用可靠性模型並與類似產品比較,Assess Th

38、e Likelihood of Occurrence of Each Cause評估每種原因發生的可能性,There are three types of design controls: 設計控制有三種類型： (1) Those that prevent the cause of failure; 預防產生失效的原因； (2) Those that detect the cause(s) of failure; 覺察產生失效的原因； (3) Those that detect the failure mode(s) 檢測失效模式,Detection Rating (D): 探測度評分 9-1

39、0Remote chance of detecting failure 察明失效的可能性極小 7-8Very low chance，可能性很小 5-6Low to moderate chance，可能性不大 2-4Good chance，可能性較大 1Will almost certainly detect failure (If it passes this, it will not fail) 失效幾乎都可以被査到(如果通過這樣的檢查就不會有失效),To reduce severity - design change to control the effect 降低嚴重度 通過設計更改來控

40、制後果 To reduce occurrence - design change to control the cause 減少發生頻度 -通過設計更改來控制原因 To improve detection - improved testing or simulation methods 增強探測度 改進測試和模擬方法 Special Attention if Severity = 9 or 10 當嚴重度為9或10時要特別注意,General Steps in the PFMEA/一般步驟,Select process FMEA team 組建過程FMEA小組 Develop a Proces

41、s Map and identify all process steps 做一個流程圖確定過程的所有步驟 List all the Key Process Outputs to satisfy internal and external customer requirement 列出所有的滿足內部和外部客戶要求的關鍵過程輸出 For each process step, list Key Process Input Variables 列出每一步的關鍵過程輸入變量 For the Process Define C&E matrix relating Key Outputs to Key Pro

42、cess Input Variable 用因果圖分析關鍵過程輸入和關鍵輸出的聯繫 Rank the KPIVs according to importance 根據重要程度給關鍵過程輸入變量分級 Start the process FMEA 開始做過程FMEA,General Steps in the PFMEA/一般步驟,For each process input, list ways that it can vary (failure Modes) and identify associated effects 對每一個過程的輸入,列出其可能的變化和相應的後果 List all Caus

43、es for each Failure Mode 列出失效模式的所有原因 List the current Controls for each cause 列出每個原因的現有控制手段 Assign Severity, Occurrence, and Detection ratings to each cause 給每個原因的嚴重度,頻度,可探測度評分 Calculate the RPN for each potential Failure Mode scenario 計算每個潛在失效模式的風險序數 Determine recommended actions to reduce High RPN

44、s 提出降低風險序數的措施 Take appropriate actions 採取適當的措施 Recalculate RPNs 重新計算風險序數,Use the Process Flow Diagram format 適用流程圖的格式 Identifies fabricate, move, store and inspect operations 識別四種作業類型,製造,移動,儲存,檢驗 Identifies Key Characteristics 識別關鍵特性 A function is what the operation does 功能系指該操作所起的作用 State the funct

45、ion as /说明功能为：Verb + Object + Qualifier 动词+宾语+修饰词 Mold part /成型零件 Crimp terminal onto cable /電線上壓接端子 Form bend in part /零件彎曲成形,A customer want or desire 顧客的希望或要求 Could seriously affect customer perception 有可能嚴重影響顧客的看法 Could lead to a customer complaint 有可能導致顧客投訴 A defect, flaw, or other unsatisfacto

46、ry condition in the product that occurs when the process fails to meet the process requirements 由於過程未達到要求而導致的産品缺陷、瑕疵等不良狀態 Failure modes should be written in terms of the condition of the product 失效模式體現在産品上,Typical Failure Modes /幾種典型失效模式 Diameter out of spec. /直径超差 Missing seal /漏裝密封墊 Cut strands /切

47、破線皮 Miss-oriented part /部件方向錯 Insufficient solder /焊劑不足 Too much solder /焊劑過量 NFO, Flash /未充滿,飛邊 The ramifications of failure/後果是失效模式的衍生事件 The effect can be on /可能影響 The ultimate customer /最終用戶 Or intermediate customer (OEM, etc.) /中間用戶 A government regulation /政府法規 The next process step /下工序,Custom

48、er complaints are a useful source of information 顧客抱怨是非常有用的資訊來源 An effect can be /後果可能是 Complete loss of function /功能完全喪失 Degradation of performance or quality /質量或性能下降 Damage of process equipment /設備受損 Injury to an operator /員工受傷 Shut-down of an assembly line /停線 Effects of failure often show up as

49、 a chain of events, from immediate effect to the ultimate effect on the customer /失效的後果 通常表現爲從對顧客的直接影響到最終影響等一系列連鎖反應 It is recommended that these chains be developed for each failure mode and recorded on the FMEA form /建議針對每一種失效模式找出這些連鎖反應，並記錄在FMEA表上,A cause of failure is how the failure can occur in

50、the process 失效原因就是過程爲何會失效 Should be written in terms of something in the process that can be corrected and controlled 應表述爲可糾正或可控制的因素 Consider human error, wear-out of tools, ambient conditions, and interactions of factors 如人的過失，工裝磨損、環境條件以及因素間的相互作用,Effects on the process /對過程的影響 9-10May endanger mach

51、ine or operator /可能導致設備或人員受損 6-8Scrap /報廢 4-5Sort and rework /篩選和返工 2-3Rework on-line /在線返工 1No effect /無影響,Consider Also the Effects on the Customer 还要考虑对顾客的影响,Use historical data (as a baseline) /利用歷史資料 Take improvements into account 考慮改進 9-10Failure almost inevitable /失效幾乎不可避免 7-8Similar processe

52、s that have often failed in the past 以前類似過程常常失效 4-6Similar processes that have occasional failures 類似過程偶爾失效 1-3Similar processes that have experienced isolated failures /類似過程僅有過個別失效,Cause-and-Effect Chain 因果鏈,Tool Is Worn 夾具磨損,Tool Not Replaced 夾具未更換,Lack of Maintenance Procedure/沒有保養程序,Clamp Cracks

53、 at Bend夾子在彎曲處裂紋,Bundle Falls Out 線束散開,Rattling Noise 卡嗒聲噪音,CAUSE chain 原因鏈,EFFECT chain 後果鏈,Radius Out Of Spec 半徑超差,Crossed Wire 交叉的電線,No Function 沒有 功能,Causes Tree/原因樹,Effects Tree/後果樹,Fire in Plant 工廠 起火,Operator Injury 員工受傷,Damaged Equip 設備損壞,Must Repair Vehicle 必需維修車輛,Poor Instruction 指導書 不足,Not Trained 未培訓,Operator Error 操作員 錯誤,Board Error 電路板 錯誤,Operator Tired 操作人員疲勞,Crossed Wire 交叉的電線,Process controls catch the defect before the product reaches the customer /程序控制當在産品到達顧客前發現缺陷! There are thre