失效模式及其影響分析研究報告

FailureModeandEffectAnalysis

失效模式及其影響分析1失效模式及其影響分析研究報告第1頁ModuleObjectives課程目DescribeFMEAprinciplesandtechniques.描述FMEA法則及技巧。Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.摘要概念、定義、應用選擇和其它工具關聯(lián)。PerformaFMEA執(zhí)行一個FMEA。2失效模式及其影響分析研究報告第2頁FMEA:FailureModesandEffectsAnalysisFMEAisasystematicapproachusedtoexaminepotentialfailuresandpreventtheiroccurrence.Itenhancesourabilitytopredictproblemsandprovidesasystemofranking,orprioritization,sothemostlikelyfailuremodescanbeaddressed. FMEA是用來檢驗潛在失效和預防它再次發(fā)生系統(tǒng)性方法.它增強了我們預測問題能力,并提供了一個排序或區(qū)分優(yōu)先次序系統(tǒng),因而使得最可能失效模式得以確定.FMEAisgenerallyappliedduringtheinitialstagesofaprocessorproductdesign.Brainstormingisusedtodeterminepotentialfailuremodes,theircauses,theirseverity,andtheirlikelihoodofoccurring.InSixSigma,weapplyFMEAtoknowfailuremodes.Ourmaininterestsarethecauseandlikelihoodofoccurrence,forwhichwehaveactualdataanddonotneedtorelyonbrainstorming.FMEA通常應用在工藝及產(chǎn)品設計早期，自由討論決定潛在失效模式、原因、嚴重度及發(fā)生可能性。在6S中，我們應用FMEA去了解失效模式。我們主要感興趣是原因及發(fā)生可能性。FMEAisalsoavaluabletoolformanagingtasksduringdefect/failurereductionprojects.FMEA也是一個在失效縮小管理任務有價值工具。FMEA3失效模式及其影響分析研究報告第3頁DefinitionofFMEA定義recognizeandevaluate

thepotentialfailuremodesandcausesassociatedwiththedesigningandmanufacturingofanewproductorachangetoanexistingproduct.

認識和評定新產(chǎn)品設計和制造時或對現(xiàn)有產(chǎn)品做出改變時相關潛在失效模式和原因identify

actionswhichcouldeliminateorreducethechanceofthepotentialfailureoccurring,

確定消除或降低潛在失效發(fā)生機會行動document

theprocess.

使過程形成文件FMEAisa

systematic

designevaluationprocedurewhosepurposeisto:是系統(tǒng)設計評定程序4失效模式及其影響分析研究報告第4頁Failuretoperformadefinedfunction 執(zhí)行既定功效失效Somethingoccurringthatyoudon‘texpect,orwant 發(fā)生了你不希望或不想要事情Wrongapplication

應用錯誤AFailureModeis...失效模式是……5失效模式及其影響分析研究報告第5頁FMEAUsebyBlack/Brown/GreenBeltsToidentifypotentialfailuremodesandratetheseverityoftheireffectsToidentifycriticalcharacteristicsandsignificantcharacteristicsTorankpotentialdesignandprocessdeficienciesTohelpallofusfocusoneliminatingproductandprocessconcernsandpreventproblemsfromrecurringReducetheproductdevelopmenttimingandcost6失效模式及其影響分析研究報告第6頁BackgroundDevelopedinearly60’sbyNASAto“fail-proof”Apollomissions.Adoptedinearly70’sbyUSNavy.Bylate80’s,automotiveindustryhadimplementedFMEAandbeganrequiringsuppliersdothesame.Liabilitycostswerethemaindrivingforce.Usedsporadicallythroughoutindustryduring1980’s.AdoptedbyMSIin?

SixSigmaisthecatalyst.7失效模式及其影響分析研究報告第7頁NASAusedFMEAtoidentifySinglePointFailuresonApolloproject(SPF=noredundancy&lossofmission).Howmanydidtheyfind?420andwethoughtwehadproblems!8失效模式及其影響分析研究報告第8頁TypesofFMEA’sSYSTEMDESIGNPROCESSSystemFMEAisusedtoanalyzesystemsandsubsystemsintheearlyconceptanddesignstages.DesignFMEAisusedtoanalyzeproductsbeforetheyarereleasedtoproductionProcessFMEAisusedtoanalyzemanufacturing,assemblyandadministrativeprocesses9失效模式及其影響分析研究報告第9頁WhenistheFMEAStarted?“Dothebestyoucanwithwhatyouhave”ASEARLYASPOSSIBLE!Guideline:10失效模式及其影響分析研究報告第10頁WhentoStart???Whennewsystems,productsandprocessesarebeingdesignedWhenexistingdesignsandprocessesarebeingchangedWhencarry-overdesignsorprocesseswillbeusedinnewapplicationsorenvironmentsAftercompletingaProblemSolvingStudy,topreventrecurrenceofaproblem11失效模式及其影響分析研究報告第11頁BeginningandEnd12失效模式及其影響分析研究報告第12頁EffectofFMEAonProcessandDesignchangesDesignStartDevelopmentProductionReleaseProductionTimeNoofEngineeringChangesTraditionalapproachFMEAapproach13失效模式及其影響分析研究報告第13頁ProcessFMEAForm14失效模式及其影響分析研究報告第14頁JLExample15失效模式及其影響分析研究報告第15頁ElementsofFMEAFailureMode Anywayinwhichaprocesscouldfailtomeetsomemeasurableexpectation.Effect

Assumingafailuredoesoccur,describetheeffects.Listseparatelyeachmaineffectonbothadownstreamoperationandtheenduser.Severity

Usingascaleprovided,ratetheseriousnessoftheeffect.10representsworstcase,1representsleastsevere.Causes

Thisisthelistofcausesand/orpotentialcausesofthefailuremode.Occurrence

Thisisaranking,onascaleprovided,ofthelikelihoodofthefailureoccurring.10representsnearcertainty;1represents6sigma.InthecaseofaSixSigmaproject,occurrenceisgenerallyderivedfromdefectdata.CurrentControls

Allmeansofdetectingthefailurebeforeproductreachestheend user,arelistedundercurrentcontrols.Detection Theeffectivenessofeachcurrentcontrolmethodisratedonaprovidedscalefrom1to10.A10impliesthecontrolwillnotdetectthepresenceofafailure;a1suggestsdetectionisnearlycertain.16失效模式及其影響分析研究報告第16頁ProcessFailureModeThepotentialfailuremodeisthemannerinwhichtheprocesscouldfailtoperformitsintendedfunction.Thefailuremodeforaparticularoperationcouldbeacauseinasubsequent(downstream)operationoraneffectassociatedwithapotentialfailureinaprevious(upstream)operation.FAILUREMODEEFFECTPREVIOUSOPERATIONCAUSENEXTOPERATION17失效模式及其影響分析研究報告第17頁ProcessCauses

ProcessFMEAconsidersprocessvariabilitydueto:OPERATORSET-UPMACHINEMETHODENVIRONMENTMEASUREMENT18失效模式及其影響分析研究報告第18頁CurrentControlsAssessmentoftheabilityofthecontroltodetectthefailurebeforetheitemleavesthemanufacturingareaandshipstothecustomer.CapabilityofallcontrolsintheprocesstopreventescapesSPCProcessCapabilityGageR&RSamplingTestingDOE19失效模式及其影響分析研究報告第19頁TypesofMeasuresSEVERITYAsitappliestotheeffectsonthelocalsystem,nextlevel,andenduserOCCURRENCELikelihoodthataspecificcausewilloccurandresultinaspecificfailuremodeDETECTIONAbilityofthecurrent/proposedcontrolmechanismtodetectandidentifythefailuremodeTypically,threeitemsarescored:20失效模式及其影響分析研究報告第20頁RiskPriorityNumberRPN=OxSxD

Occurrencex Severityx DetectionOSD

xx=RPN21失效模式及其影響分析研究報告第21頁ShortcomingsofRPN

A 8

4 3 96 B 4

8 3 96SAMERESULTFailureModeSeverityOccurrenceEffectivenessRPN22失效模式及其影響分析研究報告第22頁Severity23失效模式及其影響分析研究報告第23頁Occurance24失效模式及其影響分析研究報告第24頁Detection25失效模式及其影響分析研究報告第25頁Itisconductedonatimely

basisand

Itisappliedbyaproduct

teamandItsresultsaredocumentedFMEAisMostEffectiveWhen26失效模式及其影響分析研究報告第26頁WhatIsAGoodApplication?InvolvenewtechnologyHavechangedfrompreviousArechronicallyintroubleHaveahighdegreeofoperatorcontrolHaveahighdegreeofvariationChoosedesignsorprocesseswhich...InvolvenewtechnologyHavechangedfrompreviousArechronicallyintroubleHaveahighdegreeofoperatorcontrolHaveahighdegreeofvariationChoosedesignsorprocesseswhich...27失效模式及其影響分析研究報告第27頁FMEAProcessManufacturingEngineerBuyerProcessOperatorProcessKnowledgePreviousExperiencePastProblemsChronicProblemsReliabilityEngineerProcessFunctions,PotentialFailureModesEffects,Causes,CurrentControlsActionPriorityActionstoEliminateorReduceFailureModeWarrantyClaims28失效模式及其影響分析研究報告第28頁BasicSteps1.DevelopaStrategy29失效模式及其影響分析研究報告第29頁1.DevelopaStrategy2.Reviewthedesign/process

EFFECTCAUSESBasicSteps30失效模式及其影響分析研究報告第30頁BasicSteps1.DevelopaStrategy2.Reviewthedesign/process3.ListfunctionsDevelopaStrategyReviewthedesign/processListfunctions31失效模式及其影響分析研究報告第31頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.BrainstormpotentialfailuremodesBasicStepsBasicSteps:1.Developastrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes32失效模式及其影響分析研究報告第32頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.OrganizepotentialfailuremodesBasicStepstopictopicAffinityDiagram33失效模式及其影響分析研究報告第33頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.AnalyzepotentialfailuremodesBasicSteps34失效模式及其影響分析研究報告第34頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.EstablishriskpriorityVITALFEWTRIVIALMANYBasicSteps35失效模式及其影響分析研究報告第35頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority8.TakeactiontoreduceriskBasicSteps36失效模式及其影響分析研究報告第36頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority8.Takeactiontoreducerisk9.CalculateresultingRPN’sBasicStepsO*S*D=RPN37失效模式及其影響分析研究報告第37頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.Organizepotentialfailuremodes6.Analyzepotentialfailuremodes7.Establishriskpriority8.Takeactiontoreducerisk9.CalculateresultingRPN’s10.FollowupBasicSteps38失效模式及其影響分析研究報告第38頁TestingtheRelationshipsIFTHENHOWDOIKNOW?CAUSEFAILUREMODEEFFECT39失效模式及其影響分析研究報告第39頁ActionsThedesignorprocessmustbeimprovedbasedontheresultsoftheFMEAstudy.Awell-developedFMEAwillbeoflimitedvaluewithoutpositiveandeffectivecorrectiveactions.40失效模式及其影響分析研究報告第40頁ModuleObjectivesDescribeFMEAprinciplesandtechniques.Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.PerformaFMEA41失效模式及其影響分析研究報告第41頁DescribeFMEAprinciplesandtechniques.Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.PerformaFMEAModuleObjectives…...42失效模式及其影響分析研究報告第42頁OrganizationalLearningandSystemsThinking組織學習和系統(tǒng)思維AManagementSystem43失效模式及其影響分析研究報告第43頁BuildingOrganizationalMemoryEyelashLearningCurveABILITYTODOJOBTIMEOLDEMPLOYEELEAVESWITHKNOWLEDGENEWEMPLOYEEBEGINSThereisnoorganizationalmemorytoallowpeopletostartwheretheirpredecessorsleftoffNothinginplacetocapturetheneworimprovedmethodsthatproduceresults*44失效模式及其影響分析研究報告第44頁RapidLearningCurveABILITYTODOJOBTIMENEWEMPLOYEECOMESONANDPICKSUPALMOSTWHEREPREVIOUSEMPLOYEELEFTOFFOrganizationcontinuestoadvanceitsknowledgebypreservingthelessonseachlearnsRapidlearning=lesswaste,lesscomplexity,highercustomervalue,lowercosts*45失效模式及其影響分析研究報告第45頁HowDoWeCreateRapidLearning?Twokeyingredients:1.Havingbestknownmethodsdocumented2.TrainingpeopleonwhatthosemethodsareWhototrain?

NewemployeesManagersExperiencedemployees*SixSigma46失效模式及其影響分析研究報告第46頁ProsandConsofStandardMethodsAdvantages:優(yōu)點Customerprogressismorevisibleandcanbetrackedovertime 用戶進步更可見而且能夠隨時間跟蹤Captureandsharelessonslearned

吸收和分享教訓Systemitselfdoesnotbecomeasourceofvariation

系統(tǒng)本身不會成為變異起源Leadstoefficientpractices造成有效率實踐

*47失效模式及其影響分析研究報告第47頁ProsandConsofStandardMethodsDisadvantages:缺點Stiflecreativityandleadtostagnation 抑制創(chuàng)造力造成停滯不前Interferewithcustomerfocus干涉客戶焦點Addbureaucracyandredtape助長官僚作風Makeworkinflexibleandboring 使工作欠缺靈活性，使人輕易感到厭煩Onlydescribetheminimalacceptableoutput

只描述最小可接收輸出48失效模式及其影響分析研究報告第48頁FindingaBalance尋找平衡Thedifficultywefaceis....theargumentsforandagainststandardizationarebothtrue公說公有理，婆說婆有理Toachieveabalance,developstandardsjudiciously-whereitmattersthemostWheneffectivelymanaged,standardsprovidethefoundationforimprovement

49失效模式及其影響分析研究報告第49頁EffectiveStandardization有效標準Companiesthatusestandardizationeffectivelyoperateverydifferently:ThecompanyknowswhyitisdevelopingstandardsandhowtheycontributetoitsoverallpurposeManagementusesbest-knownmethodsthemselvesandstronglysupportsandchecksusageEmployeesunderstandhowdifferentfacetsoftheirworkaffecttheproductsandservices

Employeesknowwhichelements/functionsarecriticaltoproducinghigh-qualityoutput50失效模式及其影響分析研究報告第50頁CreateStandardsJudiciously明智地創(chuàng)造標準LeveragePoint:Aplacewherealittlechangehasagreatimpact支點：小小改變就能有巨大影響地方。三兩撥千斤？“....everyjob,everyprocess,haswithinithigh-leveragepointsthatwemuststandardizeifwewanttoachieveconsistentlyhighperformance,andlow-leveragepointswherestandardizationissuperfluous,servingonlytorestrictflexibility.”51失效模式及其影響分析研究報告第51頁KnowWhatIsandWhatIsNotImportant“Knowledgeaboutwhatisnotimportantisalmostasvaluableasknowledgeaboutwhatisimportant.Itfreesourattentiontobetterfocusonthefewthingsthatmakeadifference.”

“Thiskindofflexibilityshowsupinalljobs.”

“Asaruleofthumb,keepthedegreeofstandardizationaslowaspossiblebutdo

notneglectanyleveragepoints.”52失效模式及其影響分析研究報告第52頁LeveragePointThinking-HowDoYouTurntheShip?

KnowingtheleveragepointsiscriticalfordeterminingprioritiesandstrategiesforimprovementVitalFewTrivialManyParetoPrinciple80%oftheproblemsarecausedbyonlyabout20%ofthecontributingfactors*53失效模式及其影響分析研究報告第53頁54失效模式及其影響分析研究報告第54頁What’stheConnection?聯(lián)絡Companiesrunintotroublebecausetheychangetheirmethodsbeforetheyunderstandwhythemethodsarethereinthefirstplace.陷入麻煩企業(yè)是因為他們在不了解現(xiàn)有方法存在原因之前就盲目改變它。Theyeliminatesafetynetsintheirprocesseswithoutcontrollingthefactorsthatmadethemessential.55失效模式及其影響分析研究報告第55頁Resistthetemptationtochangeuntilwedetermine:

?Arethedocumentedstandardsthebest?

?Whatistheimpactontherestofthesystem?

?Arethemethodsactuallybeingfollowed?

What’stheConnection?56失效模式及其影響分析研究報告第56頁EmployeeResponsibility員工責任Beforeanyonecanbeheldresponsibleforthequalityoftheirownwork,theymust:1.Knowthejob

了解工作Isthejobclearlydocumented?Aregoalsandtargetsvisible?Hasadequatetrainingbeendone?Doworkersknowhowproductisused?2.Knowthestandard

了解標準Outputmustbemeasurablewithimmediatefeedbackonperformance.Don’tbevagueorrequireinterpretation(i.e.wordslikeflat,smooth,etc.)57失效模式及其影響分析研究報告第57頁EmployeeResponsibility(cont)3.Havetheabilitytoregulate

擁有調(diào)整能力Whenthejobdoesnotmeetthestandard,aretherereactionprocedures?Arebestpracticesleveraged?Musthaveall3-inorder!(SeeAppendixAforChecklist)58失效模式及其影響分析研究報告第58頁CAP-Do-DeterminetheNeedforStandardization1.CheckMakesureweknowwhytheworkisbeingdone

SeeifthepurposeisclearlydocumentedCompareactualpracticewithdocumentedmethodsIfnodocumentedmethodsexi