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1、FAILUREMODEandEFFECTSANALYSIS失效模式及其影响分析 PhilipsCFTAsiaPacificInnovation IndustrialSupportJAYTAN FMEACourseSchedule Day29 00Real lifeP FMEAexercise con tReview10 30Tea break10 45D FMEA12 00Lunch1 00OrganizationAspectofFMEA3 00Tea break3 30MaturityGrid Day19 00IntroductionIntrotoFMEAProcessFMEA10 30Te
2、a break10 45Process FMEA con t 12 00Lunch1 00Real lifeP FMEAexercise3 30Tea break3 45Real lifeP FMEAexercise con t 1INTRODUCTIONTOFMEA Car2 NoMajorBreakdowns非主要的破损Fewfailures很少的失效 Car1 FrequentBreakdowns频繁地破损Manyminorcomponentsfailures许多的小部件失效 Areliabilityprogram Whynecessary 一个可靠性的计划 为什么必须 Customer
3、Satisfaction 顾客满意 Customersatisfactionmeans Neverhavingtosayyou resorry 顾客满意意味着 决不要说对不起 QUALITYENGINEERINGTOOLS TOOLS1DesignReview27QCTools3New7QCTools4StatisticalProcessControl5DesignofExperiments6QualityFunctionDeployment7FailureModeandEffectsAnalysis APPLICATIONDesignQualityAssuranceDataanalysis
4、Problem solvingBusinessProcessMgt QFPHoldingtheimprovementQualitybreakthroughsMeetingcustomerrequirementFool proofDesign processes WhatisaFMEA Astructured disciplinedprocesstosystematicallyandcomprehensively identifyanddocumentpotentialproblemsandweaknessesinadesignorprocesssothatdesignchangescanbem
5、adeorothercorrectiveactionstakentopreventactualoccurrenceoffailure 一个结构化和专业化的过程 它能系统和综合地找出并记录在设计和工艺过程中潜在的问题和缺点并由此作出设计改变或采取其它的改正措施以防止失效的实际发生 EffectofFMEAonProcessandDesignchanges DesignStart Development ProductionRelease Production Time NoofEngineeringChanges Traditionalapproach FMEAapproach TYPESofF
6、MEA TYPEALIASESDESCRIPTIONProductDesignFMEA Focusontheproductitself reviewFMEAD FMEAsystems parts componentsProcessProductionFMEA Focusonthemanufacturingprocess FMEAP FMEArevieweachprocessstepApplicationDownstreamcustomer s Focusoncustomer sprocessFMEAManufacturingFMEA Primarilyinterestedincompatibi
7、litybetweenyourproduct customer sprocessService FocusonfieldserviceFMEA Concernedwithreliability productapplication maintainability ObjectiveofFMEA FailureMode EffectAnalysis FMEA isusedtoimproveproductreliability consideringusage environment lifetimeetc qualityof purchased parts incl hidden functio
8、nsofapart reproducibilityoftheproduct reductionoffalloff repairsinassembly reproducibilityoftheproductionprocess handling transportetc FocusontechnicalproblemsLinkwithMaturityGridandRiskManagement TypesofRisks MarketRiskshavingtherightproductontherighttimeTechnicalRisksachievingtheproductspecquality
9、 reproducibilityProjectRisksprojectorganisation teamaspects resources MarketRisks TechnicalRisks ProjectRisks Planning Specification Know how capacity UseofFMEA A ReliabilityEngineering Reliabilityimprovements B ProducibilityAnalysis Lessrepairsandscrapduringmanufacturing ImprovementoftheZero HourQu
10、ality C ProductionProcessAnalysis Lessrepairsandscrap Determinationofprocesscontrolpoints Processrelease AandBduringdevelopmentphase Cduringworkpreparationphase 100 1 10 1 1 1 PRODUCTDESIGN PROCESSDESIGN PRODUCTION IMPROVEPRODUCT PAYBACKS LOWVISIBILITY REWARD HIGHVISIBILITY REWARD TIME 500 1 CONCEPT
11、DESIGN QualityLever ReliabilityInvestigationbyMeansofFMEA Premises ThenormalfunctioningoftheproductQuestion Whatistheinfluenceof use timeandenvironmentoneachcomponentPossibilities a wear b rust c materialfatigue d contamination e deformationunderload creep f ageing g processfailures Whatistheeffecto
12、nproductfunctions ProducibilityAnalysisbyMeansofFMEA Premises Measuringtoolis egFOR ppmActions ActionsasoutcomeoftheProcessQualityControl Analysis Focusedonfailureswhicharemadeandnoticedduringtheproductionprocess 2PROCESSFMEA FMEAfortheProductionProcess SubjectforAnalysis flowchartandscenarioofthepr
13、oductionprocessFocusedon manipulationsoftheoperator wrong deviations material process equipment transport storage Failuremode RPN2 SO2D2 Controls Cause1 RPNn SOnDn Controls Cause1 DevelopmentofaProcessFMEA AnOverview Processstep Purpose RPN1 SO1D1 Controls Cause1 Effects Severity S Occurrence On Det
14、ection Dn ProcessFMEAProcedure 5Steps EstablishtheProcessFlowAnalyzetheProcessEstablishpurposeofeachoperationandthepossiblefailuremodesDefinetheweakpointsoftheProcessEstablishactionsandresponsibilities Step1 EstablishProcessFlow Takeintoaccountthe SpecificationformanufacturingSystemStructure manufac
15、turingstrategy manual automaticetc technologies processes equipment line factorylayout suppliers transport materialflowSystemoperation controlandmaintenanceSystemenvironmentalconditionsTesting qualitycontrolMakeoftheassemblyprocessa PROCESSFLOWCHART ProcessFlowChart eg Mountpart Handlingprocess Glue
16、part Adjustmentprocess Testing Mountsubassy Handlingprocess Mountpart Testing Station1 Station2 Station3 Station4 ProcessFlowChart eg Equipments Lightpencarrier Lightpencarrier Press ontool Lightpencarrier Mountingfixture Electricscrewdriver Screwdispenser LDGUcutting insertionmachine Lightpencarrier Solderingequipment Gratingadjustment machine Gluedispenserand curingunit Mountactuatr installspringclip Mount secureflex assembly CutLDGUleads mountLDGUinto Lightpenhousing Solderactuatorand LDGUtof
