FMEA失效模式及其影响分析(3).pptx
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FMEA失效模式及其影响分析(3).pptx
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FailureModeandEffectAnalysis失效模式及其影响分析,1,ModuleObjectives课程目的,DescribeFMEAprinciplesandtechniques.描述FMEA的法则及技巧。
Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.摘要概念、定义、应用的选择和其他工具的关联。
PerformaFMEA执行一个FMEA。
2,FMEA:
FailureModesandEffectsAnalysisFMEAisasystematicapproachusedtoexaminepotentialfailuresandpreventtheiroccurrence.Itenhancesourabilitytopredictproblemsandprovidesasystemofranking,orprioritization,sothemostlikelyfailuremodescanbeaddressed.FMEA是用来检查潜在失效和预防它再次发生的系统性方法.它增强了我们预测问题的能力,并提供了一个排序或区分优先次序的系统,因而使得最可能的失效模式得以确定.FMEAisgenerallyappliedduringtheinitialstagesofaprocessorproductdesign.Brainstormingisusedtodeterminepotentialfailuremodes,theircauses,theirseverity,andtheirlikelihoodofoccurring.InSixSigma,weapplyFMEAtoknowfailuremodes.Ourmaininterestsarethecauseandlikelihoodofoccurrence,forwhichwehaveactualdataanddonotneedtorelyonbrainstorming.FMEA通常应用在工艺及产品设计的初期,自由讨论决定潜在失效的模式、原因、严重度及发生的可能性。
在6S中,我们应用FMEA去了解失效的模式。
我们主要感兴趣的是原因及发生的可能性。
FMEAisalsoavaluabletoolformanagingtasksduringdefect/failurereductionprojects.FMEA也是一个在失效缩小的管理任务的有价值的工具。
FMEA,3,DefinitionofFMEA定义,recognizeandevaluatethepotentialfailuremodesandcausesassociatedwiththedesigningandmanufacturingofanewproductorachangetoanexistingproduct.认识和评估新产品的设计和制造时或对现有产品做出改变时相关的潜在失效模式和原因identifyactionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring,确定消除或减少潜在失效发生机会的行动documenttheprocess.使过程形成文件,FMEAisasystematicdesignevaluationprocedurewhosepurposeisto:
是系统的设计评估程序,4,Failuretoperformadefinedfunction执行既定功能的失效Somethingoccurringthatyoudontexpect,orwant发生了你不希望或不想要的事情Wrongapplication应用错误,AFailureModeis.失效模式是,5,FMEAUsebyBlack/Brown/GreenBelts,ToidentifypotentialfailuremodesandratetheseverityoftheireffectsToidentifycriticalcharacteristicsandsignificantcharacteristicsTorankpotentialdesignandprocessdeficienciesTohelpallofusfocusoneliminatingproductandprocessconcernsandpreventproblemsfromrecurringReducetheproductdevelopmenttimingandcost,6,Background,Developedinearly60sbyNASAto“fail-proof”Apollomissions.Adoptedinearly70sbyUSNavy.Bylate80s,automotiveindustryhadimplementedFMEAandbeganrequiringsuppliersdothesame.Liabilitycostswerethemaindrivingforce.Usedsporadicallythroughoutindustryduring1980s.AdoptedbyMSIin?
SixSigmaisthecatalyst.,7,NASAusedFMEAtoidentifySinglePointFailuresonApolloproject(SPF=noredundancy&lossofmission).Howmanydidtheyfind?
420andwethoughtwehadproblems!
8,TypesofFMEAs,SYSTEM,DESIGN,PROCESS,SystemFMEAisusedtoanalyzesystemsandsubsystemsintheearlyconceptanddesignstages.,DesignFMEAisusedtoanalyzeproductsbeforetheyarereleasedtoproduction,ProcessFMEAisusedtoanalyzemanufacturing,assemblyandadministrativeprocesses,9,WhenistheFMEAStarted?
“Dothebestyoucanwithwhatyouhave”,ASEARLYASPOSSIBLE!
Guideline:
10,WhentoStart?
Whennewsystems,productsandprocessesarebeingdesignedWhenexistingdesignsandprocessesarebeingchangedWhencarry-overdesignsorprocesseswillbeusedinnewapplicationsorenvironmentsAftercompletingaProblemSolvingStudy,topreventrecurrenceofaproblem,11,BeginningandEnd,12,EffectofFMEAonProcessandDesignchanges,DesignStart,Development,ProductionRelease,Production,Time,NoofEngineeringChanges,Traditionalapproach,FMEAapproach,13,ProcessFMEAForm,14,JLExample,15,ElementsofFMEA,FailureModeAnywayinwhichaprocesscouldfailtomeetsomemeasurableexpectation.EffectAssumingafailuredoesoccur,describetheeffects.Listseparatelyeachmaineffectonbothadownstreamoperationandtheenduser.SeverityUsingascaleprovided,ratetheseriousnessoftheeffect.10representsworstcase,1representsleastsevere.CausesThisisthelistofcausesand/orpotentialcausesofthefailuremode.OccurrenceThisisaranking,onascaleprovided,ofthelikelihoodofthefailureoccurring.10representsnearcertainty;1represents6sigma.InthecaseofaSixSigmaproject,occurrenceisgenerallyderivedfromdefectdata.CurrentControlsAllmeansofdetectingthefailurebeforeproductreachestheenduser,arelistedundercurrentcontrols.DetectionTheeffectivenessofeachcurrentcontrolmethodisratedonaprovidedscalefrom1to10.A10impliesthecontrolwillnotdetectthepresenceofafailure;a1suggestsdetectionisnearlycertain.,16,ProcessFailureMode,Thepotentialfailuremodeisthemannerinwhichtheprocesscouldfailtoperformitsintendedfunction.Thefailuremodeforaparticularoperationcouldbeacauseinasubsequent(downstream)operationoraneffectassociatedwithapotentialfailureinaprevious(upstream)operation.,FAILUREMODE,EFFECT,PREVIOUSOPERATION,CAUSE,NEXTOPERATION,17,ProcessCauses,ProcessFMEAconsidersprocessvariabilitydueto:
18,CurrentControls,Assessmentoftheabilityofthecontroltodetectthefailurebeforetheitemleavesthemanufacturingareaandshipstothecustomer.Capabilityofallcontrolsintheprocesstopreventescapes,SPC,ProcessCapability,GageR&R,Sampling,Testing,DOE,19,TypesofMeasures,SEVERITYAsitappliestotheeffectsonthelocalsystem,nextlevel,andenduserOCCURRENCELikelihoodthataspecificcausewilloccurandresultinaspecificfailuremodeDETECTIONAbilityofthecurrent/proposedcontrolmechanismtodetectandidentifythefailuremode,Typically,threeitemsarescored:
20,RiskPriorityNumber,RPN=OxSxDOccurrencexSeverityxDetection,O,S,D,x,x,=RPN,21,ShortcomingsofRPN,A84396B48396,SAMERESULT,FailureMode,Severity,Occurrence,Effectiveness,RPN,22,Severity,23,Occurance,24,Detection,25,ItisconductedonatimelybasisandItisappliedbyaproductteamandItsresultsaredocumented,FMEAisMostEffectiveWhen,26,WhatIsAGoodApplication?
InvolvenewtechnologyHavechangedfrompreviousArechronicallyintroubleHaveahighdegreeofoperatorcontrolHaveahighdegreeofvariation,Choosedesignsorprocesseswhich.,27,FMEAProcess,ManufacturingEngineer,Buyer,ProcessOperator,ProcessKnowledge,PreviousExperience,PastProblems,ChronicProblems,ReliabilityEngineer,ProcessFunctions,PotentialFailureModes,Effects,Causes,CurrentControls,ActionPriority,ActionstoEliminateorReduceFailureMode,WarrantyClaims,28,BasicSteps,1.DevelopaStrategy,29,1.DevelopaStrategy2.Reviewthedesign/process,BasicSteps,30,BasicSteps,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions,31,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes,BasicSteps,BasicSteps:
1.Developastrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes,32,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes,BasicSteps,topic,topic,AffinityDiagram,33,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes,BasicSteps,34,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority,BasicSteps,35,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority8.Takeactiontoreducerisk,BasicSteps,36,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority8.Takeactiontoreducerisk9.CalculateresultingRPNs,BasicSteps,O*S*D=RPN,37,1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority8.Takeactiontoreducerisk9.CalculateresultingRPNs10.Followup,BasicSteps,38,TestingtheRelationships,IF,THEN,HOWDOIKNOW?
CAUSE,FAILUREMODE,EFFECT,39,Actions,ThedesignorprocessmustbeimprovedbasedontheresultsoftheFMEAstudy.,Awell-developedFMEAwillbeoflimitedvaluewithoutpositiveandeffectivecorrectiveactions.,40,ModuleObjectives,DescribeFMEAprinciplesandtechniques.Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.PerformaFMEA,41,DescribeFMEAprinciplesandtechniques.Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.PerformaFMEA,ModuleObjectives.,42,OrganizationalLearningandSystemsThinking组织学习和系统思维,AManagementSystem,43,BuildingOrganizationalMemory,EyelashLearningCurve,ThereisnoorganizationalmemorytoallowpeopletostartwheretheirpredecessorsleftoffNothinginplacetocapturetheneworimprovedmethodsthatproduceresults,*,44,RapidLearningCurve,ABILITYTODOJOB,TIME,NEWEMPLOYEECOMESONANDPICKSUPALMOSTWHEREPREVIOUSEMPLOYEELEFTOFF,OrganizationcontinuestoadvanceitsknowledgebypreservingthelessonseachlearnsRapidlearning=lesswaste,lesscomplexity,highercustomervalue,lowercosts,*,45,HowDoWeCreateRapidLearning?
Twokeyingredients:
1.Havingbestknownmethodsdocumented2.TrainingpeopleonwhatthosemethodsareWhototrain?
NewemployeesManagersExperiencedemployees,*,SixSigma,46,ProsandConsofStandardMethods,Advantages:
优点Customerprogressismorevisibleandcanbetrackedovertime顾客进步更可见而且可以随时间跟踪Captureandsharelessonslearned吸取和分享教训Systemitselfdoesnotbecomeasourceofvariation系统自身不会成为变异的来源Leadstoefficientpractices导致有效率的实践,*,47,ProsandConsofStandardMethods,Disadvantages:
缺点Stiflecrea
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