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1、FMEA & (S)PC training module,This training module is based upon and should be studied together with the AIAG reference manuals.Change authority for this document: Quality manager BG MDS Fons Sieben,ChapterContents1Acknowledgement / References2Potential Failure Mode and Effect Analysis3Process consid
2、erations & the need for process control4Stages in SPC and process analysis (QMAPS)5Control Charts & Out of Control Conditions6From FMEA thru Control Planning to SPC - Process documentation7Terminology and abbreviations: CRIT / SIGN / KEY / NORMAL8Flow diagram STATISTICAL PROCESS CONTROL9Statistical
3、methods / calculation of control limits10Capability Indices and formulas11Cpk interpretation and relation to PPM,2000-10-31,updated,2000-07-11UZW-B0/H100-13,This training module is related to:FMEA & (S)PC procedureUZW-B0/H100-13,Acknowledgement / References,Potential Failure Mode & Effect Analysis,A
4、n FMEA is a systemized group of activities, intended to:Recognize and evaluate the potential failure of a product/process and its effects.Identify actions which could eliminate or reduce the chance of the potential failure occurring.Document the process.It is complementary to the design process of d
5、efining positively what a design must do to satisfy the customer,Ref: FMEA Reference manual (AIAG),2000-07-11,Brainstorming,Potential Failure Mode & Effect Analysis,Ref: FMEA Reference manual (AIAG),2000-07-11,Brain storming Team effortRisk analysis toolPreventive / On Time = BEFORE THE EVENT!,Poten
6、tial Failure Mode & Effect Analysis: Process overview,Ref: FMEA Reference manual (AIAG),2001-03-23,Describe:Function of parts or process stepsPotential Failure modePotential effects of Failure,Describe and Plan recommended actions Predict RPN,Close the loop / continuous improvementWork on next probl
7、em in the priority rowLearn from problem solving / previous designsReflect the learnings in documentation: FMEA / Control Plans / Design rules / learning modules etc,Working formats Design FMEA (preferred format),Ref: FMEA Reference manual (AIAG)UZW-B0/H100-13,2000-12-29,Working formats Process FMEA
8、 (Preferred format),Ref: FMEA Reference manual (AIAG)UZW-B0/H100-13,2000-12-29,D/PFMEA : Some practical implications,Ref: FMEA Reference manual (AIAG)UZW-B0/H100-13,2001-03-23,Steps wrt improvement actions:Establish initial FMEA, and select the items for actions.Identify the recommended actions, and
9、 at the same time estimate the predicted RPN (register at the right side under Actions results).Note: When the recommended actions are - for the time being - an investigation, this new estimated RPN is of course identical to the original, pending the result of the investigation.When actions have bee
10、n completed, the resulting RPN is again to be established.This new situation becomes now the new current . controls, and is to be moved towards these related columns.,Living documents & learning: Above implies that the FMEA list reflects only the best current knowledge, and history is not documented
11、.Where it is considered to be necessary to keep the history for learning reasons, a front page should be considered to keep record of the important historical events.,Working formats FMEA (Old format / see previous pages for preferred formats),Ref: FMEA Reference manual (AIAG)UZW-B0/H100-13,2001-03-
12、23,Old format: Do not use anymore!,Working formats Control Plan,Ref: FMEA Reference manual (AIAG)UZW-B0/H100-13,2000-12-29,Form: PROCESS STEP CONTROL PLAN (Preferred version)(for product specific control plans: see proc Test specs: UZW-B0/H100-39),Working formats Control Plan,Ref: FMEA Reference man
13、ual (AIAG)UZW-B0/H100-13,2001-03-23,Form: PROCESS STEP CONTROL PLAN: (Old format / see previous pages for preferred version),Old format: Do not use anymore!,Considerations around PROCESS,Processes are important!,Almost all quality gurus and almost all management gurus agree that : processes must be
14、defined, the most important processes must be identified and given special attention, all processes must be managed, all processes must be improved.,Of course, it may be easier to manage departments or functions.,Ref: PD Components Foundation training for Breakthrough Champions /Mr Caulcutt,2000-12-
15、29,Considerations around PROCESS,Deming on processes,William Edwards Deming suggested thatstakeholders will benefit if managers: focus on processes, understand variability, develop a learning culture, value people.,See “The new economics” (1993) W E Deming, Harvard U P,Ref: PD Components Foundation
16、training for Breakthrough Champions /Mr Caulcutt,2000-12-29,Considerations around PROCESS,What is a process?,EFQM definition:A process is a sequence of steps which adds value by producing required outputs from a variety of inputs.,A better definition:A process is a network of interdependent componentsthat work together to achieve benefits for thestakeholders.,
