DFMEA---失效模式与后果分析.pptx
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DFMEA---失效模式与后果分析.pptx
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DFMEA-失效模式与后果分析(DesignFailureMode&EffectAnalysis),Marian(Shenzhen)Co.,Ltd编制:
曹喜元FormationBy:
JackCao日期:
Date:
1-Feb-2013,主要内容Maincontent,1.DFMEA介绍4.DFMEA关键参数DFMEAPresentationDFMEAKeyParameter2.DFMEA职责5.DFMEA表单填写说明DFMEAResponsibilityDFMEAFormFillingExplanation3.DFMEA制作流程6.DFMEA案例DFMEAMakeProcessDFMEAExample,一、DFMEA的介绍DFMEAPresentation,DFMEA是FMEA中的一种,FMEA分为:
DFMEA和PFMEADFMEAisintheFMEAonetype,FMEAContain:
DFMEA&PFMEADFMEA是由负责设计的工程师或小组,在产品设计阶段尽可能的范围内预估产品在设计上可能发生的缺点.DFMEAisEngineerorgrouptoresponsiblescheme,Asfaraspossiblewithinthescopeoftheestimatedproductdesignonthepossiblefaultsintheproductdesignstage.PFMEA是由负责制造装配的工程师或小组,预估产品在生产过程阶段或之前可能会发生的缺点.PFMEAisPEorgrouptoresponsiblescheme,Asfaraspossibletheestimatedproductpossiblefaultsintheproductiveprocessorbefore.本章节重点讲述DFMEAThischapterfocusesonDFMEA.,DFMEA的形成DFMEAFormation,DFMEA是由负责设计的工程师或小组,在尽可能的范围内预估产品在设计上可能发生的缺点,衡量该项缺点或可能造成的影响,并拟定为防止或检测该缺点应改善的设计控制,并推动其标准化作业,且必须配合设计发展之程序反复执行.DFMEAisEngineerorgrouptoresponsiblescheme,Asfaraspossiblewithinthescopeoftheestimatedproductdesignonthepossiblefaultsintheproductdesignstage,Measurethefaultsorcancauseinfluence,andplantopreventortestingthedefectshouldbeimproveddesigncontrol,andpromotethestandardizedoperation,andmustfitinwiththedevelopmentofdesignprogramandimplementation.最终成品及其所有相关的系统、子系统都应纳入评估.DFMEA是设计小组,即公司工程,运用设计,工程经验或分析方法等而形成的.Thefinalandallrelatedsystem,subsystemshouldbeincludedinassessment.DFMEAisthedesignteam,namelythecompanyproject,theuseofdesign,engineeringexperienceoranalysismethodsandform.,DFMEA必备条件DFMEAEssentialCondition,确认已知及潜在的失效模式;Confirmtheknownandthepotentialfailuremode.确认每一个失效模式的效应和原因;Confirmeachfailuremodeeffectandreasons.风险优先评估(严重性、发生频率、难检度);Riskpriorityevaluation(severity,occurrencefrequencyanddifficulttocheckdegree)提供问题的数据及改善行动;Provideproblemofdataandimprovementaction.,DFMEA的动态链DFMEATrendsCatenation,DFMEA是个循环过程,在设计方案最终形成之时或之前开始.DFMEAisacyclicprocess,thedesignschemeoffinalformorbeforethestart.在产品开发各阶段中,当设计有变化或得到其他信息时,应及时,不断地修改,最终在产品加工图样完成之前全部结束。
Ineverystageofproductdevelopment,whenthedesignchangeorgetotherinformation,shouldbeprompt,constantlymodified,finally,inproductprocessingpatternuntilallover.,二、DFEMA职责DFMEAResponsibility,工程经理:
DFMEA总体负责人,负责组建DFMEA团体,提出DFMEA实施计划,并组织召开DFMEA会议,分配团队人员任务组织DFMEA评审,DFMEA审核.Projectmanager:
generalmanager,responsibleforDFMEA,thispaperputsforwardaDFMEAgroupDFMEAimplementationplan,andorganizeaDFMEAmeeting,distributionteampersonneltaskOrganizationDFMEAreview,DFMEAaudit.工程师:
负责主导DFMEA文件编写、修改和升级.Engineer:
responsibleforleadingDFMEAdocumentpreparation,modificationandupgrade.,二、DFEMA职责DFMEAResponsibility,工程助理:
负责客户投诉问题,研发、试产、量产中问题的收集,及时反馈到DFMEA团体负责人处,并参与O,S,D参数评估,提供量产CPK数据.Projectassistant:
responsibleforcustomercomplaintproblem,researchandtrialproduction,thequantityofcollection,andrenderWhenthefeedbacktoDFMEAgroupplace,andparticipateinO,S,Dparameterevaluation,SupplyvolumeproductionCPKdata.试样工程师:
负责研发产品测试过程中所出现问题点的收集并及时反馈到DFMEA负责人处,参与O,S,D参数评估.Sampleengineer:
responsibleforresearchanddevelopmentintheprocessofproducttestingproblemspointcollectionandtimelyfeedbacktotheDFMEAchiefplace,participateinO,S,Dparameterevaluation.,二、DFEMA职责DFMEAResponsibility,CQE:
负责客户需求信息归纳整理,DFMEA建议措施监督实施、追踪,实施效果反馈,根据DFMEA和客户需求等信息制定控制计划,并参与O,S,D参数评估.CQE:
Beresponsibleforthecustomerdemandinformationsummary,DFMEAsuggestedmeasuressupervisionandimplementation,trackingandeffectfeedback,accordingtotheDFMEAandrequirementsforinformationsuchascontrolplan,andparticipateinO,S,Dparameterevaluation.,三、DFMEA制作流程DFMEAMakeprocess,注:
团队制定目标,使团队清楚新产品或以改善为目标,并需要了解客户需求。
Note:
Theteamsetgoals,maketheteamclearnewproductsortoimproveasthegoal,andneedtounderstandcustomerneeds.使用方法;Methodofapplication.客户要求的设计/工程SPEC;Customerrequestedproject&EngineeringSPEC.产品信赖;ProductTrust.制程、生产、装配要求;Process,ProductionAssembleofRequirement.品质目标.QualityDestination.,组成DFMEA团队ConstituteDFMEATeam,确定目标ConfirmDestination,三、DFMEA制作流程DFMEAMakeprocess,产品设计及类似产品设计的问题及原因;Productdesignandsimilarproductdesignproblemsandreasons制造工艺及类似产品制程中常及的不良原因;Manufacturingprocessandsimilarproductsinprocessandbadreason.类似产品的制程能力及原因;Similarproductsofprocesscapabilityandthereason.类似产品的客诉及原因;Similarproductsofcustomercomplaintandthereason.类似产品的依赖性失效及原因;Similarproductsthedependenceofthefailureandthereason.类似产品的管理性问题;Similarproductsofmanagerialproblems.,资料收集DataCollection,三、DFMEA制作流程DFMEAMakeprocess,使用维修;UseMaintain.环境.Environment.表格格式TableFormat.分层层次DelaminationAdministrativelevels.失效定义FailureDefinition.成果整合AchievementIntegration.时机Opportunity.,资料收集DataCollection,制订执行方案FormulateimplementPlan,三、DFMEA制作流程DFMEAMakeprocess,分析制程特性AnalysisProcessCharacter,定义制造流程DefinitionproductionProcess,分析产品特性AnalysisProductCharacter,分析失效原因AnalysisFailureCause,分析现行控制方法AnalysisControlMethod,分析失效效应AnalysisFailureEffect,分析发生率AnalysisOccurrenceRate,分析难检度AnalysisDetection,分析严重度AnalysisSeverity,计算风险优先数CalculatedRiskPriorityNumber,分析制程特性AnalysisProcessCharacter,三、DFMEA制作流程DFMEAMakeprocess,决定优先改善的失效模式DecideAmeliorativeFailureMode,建议改善措施RecommendationImprovementMeasures,改善实施ImprovementImplement,结果确认有效ResultNotarizeEffective,四、DFMEA关键参数DFMEAKeyParameter,严重度、发生率、难检度、风险优生数Severity,Occurrence,Detection,RPN,严重度Severity-S发生率Occurrence-O难检度Detection-D风险优生数RiskPriorityNumber-RPNRPN=S*O*D,四、DFMEA关键参数DFMEAKeyParameter,严重度Severity,衡量失效的影响程度.Assessmentfailureincidence失效影响产品或制程,某一失效会对产品外观、结构、功能、性能稳定性、可靠性的影响;或对下一个制程,使用者和设备的影响;或对最终客户,政府法规、安全、环保等的违及.Failureaffectproductorprocess,afailuretoproductappearance,structure,function,performancestabilityandreliabilityoftheinfluence;Ortothenextprocess,theuserandtheinfluenceoftheequipment;Ortoendcustomers,governmentregulations,safety,andenvironmentalprotection,andadefault.,四、DFMEA关键参数DFMEAKeyParameter,严重度Severity,严重度的划分标准-主观判定SeverityClassificationStandard-SubjectivityDecide其大小由失效模式的影响程度而定,以1至10表示等级.Itssizeofthefailuremodeoftheinfluencedegreetodecide,be1to10showlevel.1级最轻微,10级最严重.1Levelbestslight,10Levelbestgrave.1级-几乎不会有什么影响.1Level-Almosthasnoinfluence.10级-违反安全和法规.10Level-Violationofsafetyandregulations.,四、DFMEA关键参数DFMEAKeyParameter,严重度分类SeverityClassify,耐火性、自然性、UL、RHoS&HFFireResistance,Naturalness,UL,RHoS&HF一、危险特性Catastrophic工业标准(无法满足而不能销售)IndustryStandardIncapableConnotMarket.客户要求CustomerRequest内部工程需要由Critical测量项目InternalENGneedforcriticalmeasureproject,四、DFMEA关键参数DFMEAKeyParameter,严重度分类SeverityClassify,客户及供应商共同制定特性;CustomerandSuppliertogetherformulatefeatures.二、重大特性Significant或客户指定特性,如导电或绝缘;(满足而不能销售给指定客户)Orcustomerappointfeatures,ForinstanceEC&Insulation.ContentConnotMarket设计工程指定的特性;DesignationCustomerDEappointfeatures.行业标准.Industrialstandard.,四、DFMEA关键参数DFMEAKeyParameter,严重度分类SeverityClassify,可靠性测试,如拉拔力测试;.ReliabilityTesting,Forexampledrawingforcetest.三、主要特性Major产品制程不良率及分析Productprocessrejectratioandanalysis.,四、DFMEA关键参数DFMEAKeyParameter,严重度等级标准SeverityRankStandard,四、DFMEA关键参数DFMEAKeyParameter,严重度等级标准SeverityRankStandard,四、DFMEA关键参数DFMEAKeyParameter,严重度等级标准SeverityRankStandard,四、DFMEA关键参数DFMEAKeyParameter,发生率Occurrence,某一原因而导致失效发生的几率.Areasontotheoddsoffailure.划分标准:
依据不良品出现的机率来定,以1至10表示等级.Thedivisionstandard:
accordingtotheprobabilityofbadproductappearedtodecide,be1to10showlevel.1级最轻微,10级最严重.1Levelbestslight,10Levelbestgrave.1级-几乎不会发生.1Level-Almostwonthappen.10级-肯定会发生.10Level-Willhappen,四、DFMEA关键参数DFMEAKeyParameter,发生率Occurrence,划分标准-CPK、主观判定、统计资料DivideStandard-CPK,Subjectivejudge,statisticalinformation,四、DFMEA关键参数DFMEAKeyParameter,发生率Occurrence,划分标准-CPK、主观判定、统计资料DivideStandard-CPK,Subjectivejudge,statisticalinformation,四、DFMEA关键参数DFMEAKeyParameter,难检度Detection,在现行的控制措施下,侦测失效发生的能力.Inthecurrentcontrolmeasures,theabilitytodetectfailurehappened.划分标准:
依据失效模式检验的难易程度来定,以1至10表示等级.Thedivisionstandard:
Accordingtothefailuremodeofthetestdifficultytoset,be1to10showlevel.1级最容易,10级为几乎不可能发现.1Levelbesteasy,10LevelforAlmostimpossibilityfind.1级-用有效的手段完全可以检测出来1Level-Witheffectivemeanscompletelycanbedetected.10级-无任何手段可以检测出来.10Level-Nomeanscanbedetected.,四、DFMEA关键参数DFMEAKeyParameter,难检度Detection,划分标准-主观判定、统计资料DivideStandard-Subjectivejudge,statisticalinformation,四、DFMEA关键参数DFMEAKeyParameter,风险系数RiskPriorityNumber,RPN=S*O*D风险系数RPN排出次序后,RPN越大越优先解决.RPN在100以上必须解决;50RPN100应尽可能解决,不能解决必须加严控制;RPN50可不加控制.当严重度(S)很高或发生率(O)很高时,不管RPN大小如何,都必制定相应改善或控制措施,并指定责任人和改善完成日期.RiskcoefficientRPNdischargeorder,thebiggertheRPNpriority.RPNinmorethan100mustbesolved;50RPN100shouldasfaraspossibletosolve,cantsolvemustbetightenedcontrol;RPN50dontaddcontrol.Whentheseverity(S)orhighincidence(O)isveryhigh,nomatterhowRPNsizewillbeformulatethecorrespondingimprovementorcontrolmeasures,andappointresponsiblepersonsandimprovethecompletiondate.,如何制定改善措施Howtomaketheimprovementmeasures,针对预防/纠正措施,以降低评价等级的内容顺序为:
严重度、发生率及侦测度;Aimingatpreventing/correctivemeasures,inordertoreducethecontentoftheevaluationgradeorder:
(S),(O),(D).通过设计变更来消除或控制一个或多个失效模式的起因机理,能降低严重度等级;Throughthedesignchangetoeliminateorcontroloneormoreofthecauseofthefailuremodemechanism,canreducetheseveritylevel;透过设计变更,去除或管制某一或多个影响失效模式的原因或设备,只能降低发生率的等级.Throughthechangeofthedesign,removeorcontroloneormoreofthecauseofthefailuremodeeffectorequipment,canreducetheincidenceofgrade.增加设计验证,修改测试计划,修改原物料规格,只可降低难检度.Toincreasethedesignverification,modifyingthetestplan,modifytheoriginalmaterialspecifications,canonlyr
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