FMEA第五版表格(带实例)--2019.8.17.xls
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FMEA第五版表格(带实例)--2019.8.17.xls
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ProcessFailureModeandEffectsAnalysis(ProcessFMEA)SCOPEDEFINITION(Step1)CompanyName:
NameofcompanyresponsibleforPFMEASubject:
NameofPFMEAprojectSystem/sub-system/component/part:
NameofsystemelementPlantLocation:
GeographicallocationPFMEAStartDate:
DatePFMEAprojectstartedPFMEAIDNumber:
DeterminedbythecompanyCustomerName:
Nameofcustomer(s)orproductfamilyPFMEARevisionDate:
DateofmostrecentchangeProcessResponsibility:
NameofPFMEAownerModelYear/Platform:
Customerapplicationorcompanymodel/styleCross-FunctionalTeam:
TeamRosterneededConfidentialityLevel:
BusinessUse,Confidential,Propriotary,etc.STRUCTUREANALYSIS(Step2)FUNCTIONANALYSIS(Step3)FAILUREANALYSIS(Step4)RISKANALYSIS(Step6)OPTIMIZATION(Step6)RemarksCONTINUOUSIMPROVEMENT1.ProcessItemSystem,Subsystem,PartElementorNameofProcess2.ProcessStepStationNo.andNameofFocusElement3.ProcessWorkElementMan,Machine,Material(Indirect),Milieu(Environment),etc.1.FunctionoftheProcessItemIn-plant,Shiptoplant,ProcessItem,VehicleEnduser,whenknown2.FunctionoftheProcessStepandProductCharacteristic(Quantitativevalueisoptional)3.FunctionoftheProcessWorkElementandProcessCharacteristic1.FailureEffects(FE)In-plant,shiptoplant,processitem,vehicleenduser,whenknowOriginalSeverity(S)ofFE2.FailureMode(FM)oftheProcessElement3.FailureCause(FC)oftheWorkElementCurrentPreventionControl(PC)ofFCOccurrence(O)ofFCCurrentDectectionControls(DC)ofFCorFMDetection(D)ofFC/FMActionPriority(AP)SpecialProductCharFilterCode(optional)PreventionActionDetectionActionResponsiblePersonTargetCompletionDate(TCD)Status:
Open,Completed,DiscardedActionTakenwithPointertoEvidenceCompletionDateSeverity(S)Occurrence(O)Detection(D)ActionPriority(AP)History/ChangeAuthorization(AsApplicable)Thenameoftheprocessbeinganalyzede.g.electricalmotorassemblylinewhichistheendresultofallsuccessfullycompletedprocessstepsmayalsobeanon-directmanufacturingprocesse.g.shippingTheoperationorstationtobeanalyzedthatproducestheProcessIteme.g.OP30SinteredbearingPress-inprocessUsethe4Mstoidentitytypesofvariationthathaveaninfluenceontheoperationorstationbeinganalyzed4MTypes:
Man,Machine,Material(indirect),Milieu(Environment)ListasingleMforeachline.TypesmayvarybycompanyAdescriptionofwhattheProcessItemisexpectedtoachievebrokendownintoseveralcategoriesSomecategoriesmaybeunknownandlistedasNotApplicable(NA)TheseexpectationscanbereferredtowhencompletingFailureEffects(FE)TheseexpectedresultsmayapplyfortheentireProcessIteme.g.electricalmotorassemblylineIn-plant:
AvoidreworkandscrapShiptoplantInstallationofwindowlifterelectricalmotortovehicledoorProcessItem.:
ShaftinstalledintopolehouseassemblyVehicle.:
WindowraisesandlowersAdescriptionofwhattheoperationorstationmustachievee.g.AxialpositionsinteredbearinginpolehousingThisisthepositiveProductCharacteristicandmustbedetectableintheproductTheFailureModeorFailureModeswillbethenegativeornegativesofthepositiveProductCharacteristic.TheProductCharacteristiccanbewrittenstatingtheentirepositiveProductCharacteristic,egwithingaptolerance,orusingseparatelines,consideringoverandundertolerance,eg,notgreaterthenmaxtolerance,notlessthanmintolerance.ItmayalsoconsidermagnitudeofouttotoleranceifiteffectstheFailureEffectse.g.gapnotgreaterthenmaxtoleranceby03mmorgapnotgreaterthenmaxtolerance-Morethan3mmApositivedescriptionofhowtheworkiscompletedincludingthepositiveprocesscharacteristicrelatedtoeach4MThenegativeofthesepositiveswillbeusedfortheFailureCausecolumnThemoredetailusedherewillproducemoreFailureCausei.e.eachlineisauniquepositiveproducingauniquenegative,i.e.aFailureCauseInsteadof“Getcorrectsinteredbearingfrompartrackandplaceintofixture”Use“Getcorrectsinteredbearing”and“Fullyplacebearingintofixture”ThisidentifiesoftwoseparateFailureCauses,i.e.“wrongpartpicked”“Bearingnotfullysetintofixture”Themoredetailused,themoreCausescanbecapturedinthedocumentedforriskanalysis.Otherpossiblepositiveprocesscharacteristic-“Pickpartfrompartrackwithoutscratchingthetopsurface”,“Placepartintofixturewithoutusingtoomuchforce”.Applytorquetoboltuntilgreenlightappears.Applytorquetoboltuntilgreenlightappearsbutnotbeyond.“Pickcorrectlubrication”.“Applycorrectvolumeoflubrication”NewProductCharacteristicandFailureModes-Whileconsidering“FunctionoftheProcessWorkElementandProcessCharacteristic”new“ProductCharacteristics”.“FailureCauses”and“FailureModes”maybegenerated,i.e.listing.“Pickpartfrompartrackwithoutscratchingthetopsurface”,maygenerateanewFailureCause.“Scratchedtopsurfacewhilepickingpartfromrack”andanew“ProductCharacteristics”,“Topsurfacescratchfree”andnewFailureMode“Topsurfacescratched”HowtheVehicle,SystemorSubsystemcouldfailtoperformtheFunctiondescribedattheNextHigherlevelWhenconsideringEffects,consideritemslistedin“FunctionoftheProcessItem”andtheFailureMode”endhowtheycanEffectthe3areasbeingconsidered(In-Plant,Shiptoplant.ProcessItem,VehicleEndUser)Includepotentialeffectstothevehicle(EndUser)levelendregulations.asapplicableItisrecommendedtolisttheSeverityRanknexttoeachofthe3areasbeingconsideredandusethehighestRankfortheSeverityRank.Onearea,suchasEndUser.maynotalwayshavethehighestSeverityRank110Failuremodemustbedetectableintheproduct(defect)TheFailureModewillbethenegativeornegativesofthepositiveProductCharacteristic.ConsideringeachsideofthespecificationofProductCharacteristicifspecificationofProductCharacteristichasarange,listFailureModeforeachsideofthespecification,i.e.,“TorqueBolttospec”,theFailureModeswillbe“Torquelossthenspec”,“Torquemorethanspec”EachmayhaveadifferentSeverityRank.ConsideringmagnitudeofoutofspecificationIfthemagnitudeofoutofspecificationcanaffecttheSeverityRank.Itshouldhelisted,i.e.,“Nostampingcracks”,theFailureModescouldbecrack0-10mmlong”,SeverityRank4.“Crackgreaterthan10mmbutlessthan20mmlong”.SeverityRank7.“Crack20mmorgreater”SeverityRank10.EachwillhaveitsownOccurrenceRanks.Controls,etc.WhenusingaspreadsheettoperformtheFailureAnalysisitisrecommendedtobeginwithFailureModesthenidentifyFailureEffectsandCauses.TheFailureCauseisthenegativeofthepositivelistedin“FunctionoftheProcessWorkElementandProcessCharacteristic”Causemustbedetectableintheprocess(error)andleadtotheFailureModeNewFailureCauses-Whileconsidering“FailureCauses”,newFunctionoftheProcessWorkElementandProcessCharacteristic”,“ProductCharacteristicandmaybegenerated,i.e.listing.“Scratchedtopsurfacewhilepickingpartfromrack”cangenerate“Pickpartfrompartrackwithoutscratchingthetopsurface”,maygenerateandanew“ProductCharacteristics”,“Topsurfacescratchtree”andanewFailureMode“Topsurfacescratched”FailureAnalysiscanbeginwiththeFM.FForFCaslongasthereisanaccurateFailureChainInitialState-Pastcontrolsprovenand/orcontrolscommittedto110InitialState-Pastcontrolsprovenand/orcontrolscommittedto110H,M,L,NALLAdditionalActionsneededtoreduceOccurrenceAdditionalActionsneededtoimproveDetectionName,nottitleordepartmentmmyyorddmmyyOptional:
Decisionpending,ImplementationpendingDescriptionofactiontakenanddocumentnumber,reportnameanddate,etc.mmyyorddmmyy110110110H,M,L,NAForPFMEAteamuseExamples:
Adesignchange:
DCN0983885Amanagementreview:
MR07-NOV-2017Acustomerreview:
CR02-FEB-2018ElectricalMotorOP30SinteredbearingpressOperatorProcessItem:
Convertelectricalenergyintomechanicalenergy(acc.controlsignal)InPlant:
Assemblyofcomponentswithincycletime,withoutscraporreworkShiptoPlant:
Assemblyofmotortovehicledoorwithoutlinestoppage,sortorcontainmentEndUserWindowraisesandlowersPressinsinteredbearingtoachieveaxialpositioninpolehousingtomaxgapperprintOperatortakescleansinteredbearingfromchuteandpushitontothepress-inshaftuntiltheupperstopProcessItem:
Lossofmechanicalenergybecauseoftoomuchfrictionbetweenbearingandshaft,innerdiameterofthebearingdeformedbecauseofftoomuchseatingstressInPlant:
NoneShiptoPlantNoneEndUser:
Windowraisesandlowerswithdifficulty8Axialpositionofsinteredbearingisnotreached,gaptoosmallOperatorinsertsasinteredbearingwhichwasdroppedtothegroundfloorbefore(contaminatedwithdirt)NoPreventioncontrol10LotreleaseProtectobjective(effectiveity100%)VisualGaugeinspectionofaxialgapofbearingtopolehousingeatbyoperator(checkthechecker:
N/A)Dectectionindicator:
OK/NOK(RED/GREENarea)andoperatorseparatetheNOKpart2HCCThedefinitionofaworkinstructionandaworkinstructionforfallingcomponentsandcontentsoftheregularTrainingcurriculartheoperatorandfinishingstaffJohnDoe(ProductionEngineer)DD.MM.YYYYIn-progress832LElectricalMotorOP30SinteredbearingpressMachine(pressmachine)ProcessItem:
Convertelectricalenergyintomechanicalenergy(acc.controlsignal)InPlant:
Assemblyofcomponentswithincycletime,withoutscraporreworkShiptoPlant:
Assemblyofmotortovehicledoorwithoutlinestoppage,sortorcontainmentEndUserWindowraisesandlowersPressinsinteredbearingtoachieveaxialpositioninpolehousingtomaxgapperprintMachinehastopressinthesinteredbearingintothepolehousingseatuntilthedefinedaxialpositionProcessItem:
Lossofmechanicalenergybecauseoftoomuchfrictionbetweenbearingandshaft,innerdiameterofthebearingdeformedbecauseofftoomuchseatingstressInPlant:
NoneShiptoPlantNoneEndUser:
Windowraisesandlowerswithdifficulty8Axialpositionofsinteredbearingisnotreached,gaptoosmallMachinestopsbeforerea
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- FMEA 第五 表格 实例 2019.8 17