FMEA第五版表格資料

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,,,,,,ProcessFailureModeandEffectsAnalysis(ProcessFMEA),,,,,,,,,,,,,,,,,,,,,,,,,

,SCOPEDEFINITION(Step1),,,,,,,,,,,,,,,,,,,,,,,,,,,,,,

,CompanyName:,NameofcompanyresponsibleforPFMEA,,,Subject:,NameofPFMEAproject,,,,System/sub-system/component/part:,Nameofsystemelement,,,,,,,,,,,,,,,,,,,,

,PlantLocation:,Geographicallocation,,,PFMEAStartDate:,DatePFMEAprojectstarted,,,,PFMEAIDNumber:,Determinedbythecompany,,,,,,,,,,,,,,,,,,,,

,CustomerName:,Nameofcustomer(s)or[productfamily],,,PFMEARevisionDate:,Dateofmostrecentchange,,,,ProcessResponsibility:,NameofPFMEAowner,,,,,,,,,,,,,,,,,,,,

,ModelYear/Platform:,Customerapplicationorcompanymodel/style,,,Cross-FunctionalTeam:,TeamRosterneeded,,,,ConfidentialityLevel:,"[BusinessUse,Confidential,Propriotary,etc.]",,,,,,,,,,,,,,,,,,,,

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,STRUCTUREANALYSIS(Step2),,,FUNCTIONANALYSIS(Step3),,,FAILUREANALYSIS(Step4),,,,RISKANALYSIS(Step6),,,,,,,OPTIMIZATION(Step6),,,,,,,,,,,Remarks,,CONTINUOUSIMPROVEMENT

,"1.

ProcessItem

System,Subsystem,PartElementorNameofProcess","2.

ProcessStep

StationNo.andNameofFocusElement","3.

ProcessWorkElement

[Man,Machine,Material(Indirect),Milieu(Environment),etc.]","1.

FunctionoftheProcessItem

[In-plant,Shiptoplant,ProcessItem,VehicleEnduser,whenknown]","2.

FunctionoftheProcessStepandProductCharacteristic

(Quantitativevalueisoptional)","3.

FunctionoftheProcessWorkElementandProcessCharacteristic","1.

FailureEffects(FE)

[In-plant,shiptoplant,processitem,vehicleenduser,whenknow]",OriginalSeverity(S)ofFE,"2.

FailureMode(FM)oftheProcessElement","3.

FailureCause(FC)oftheWorkElement",CurrentPreventionControl(PC)ofFC,Occurrence(O)ofFC,CurrentDectectionControls(DC)ofFCorFM,Detection(D)ofFC/FM,ActionPriority(AP),SpecialProductChar,FilterCode(optional),PreventionAction,DetectionAction,ResponsiblePerson,TargetCompletionDate(TCD),"Status:

Open,Completed,Discarded",ActionTakenwithPointertoEvidence,CompletionDate,Severity(S),Occurrence(O),Detection(D),ActionPriority(AP),,,History/ChangeAuthorization(AsApplicable)

,"Thenameoftheprocessbeinganalyzede.g.electricalmotorassemblylinewhichistheendresultofallsuccessfullycompletedprocesssteps

mayalsobeanon-directmanufacturingprocesse.g.shipping",TheoperationorstationtobeanalyzedthatproducestheProcessIteme.g.OP30SinteredbearingPress-inprocess,"Usethe4M'stoidentitytypesofvariationthathaveaninfluenceontheoperationorstationbeinganalyzed

4MTypes:

Man,Machine,Material(indirect),Milieu(Environment)

Listasingle""M""foreachline.

Typesmayvarybycompany","AdescriptionofwhattheProcessItemisexpectedtoachievebrokendownintoseveralcategories

SomecategoriesmaybeunknownandlistedasNotApplicable(NA)

TheseexpectationscanbereferredtowhencompletingFailureEffects(FE)

TheseexpectedresultsmayapplyfortheentireProcessIteme.g.electricalmotorassemblyline

In-plant：Avoidreworkandscrap

ShiptoplantInstallationofwindowlifterelectricalmotortovehicledoor

ProcessItem.：Shaftinstalledintopolehouseassembly

Vehicle.：Windowraisesandlowers","Adescriptionofwhattheoperationorstationmustachievee.g.Axialpositionsinteredbearinginpolehousing

ThisisthepositiveProductCharacteristicandmustbedetectableintheproduct

TheFailureModeorFailureModeswillbethenegativeornegativesofthepositiveProductCharacteristic.

TheProductCharacteristiccanbewrittenstatingtheentirepositiveProductCharacteristic,egwithingaptolerance,orusingseparatelines,consideringoverandundertolerance,eg,notgreaterthenmaxtolerance,notlessthanmintolerance.ItmayalsoconsidermagnitudeofouttotoleranceifiteffectstheFailureEffectse.g.gapnotgreaterthenmaxtoleranceby0~3mmorgapnotgreaterthenmaxtolerance-Morethan3mm","Apositivedescriptionofhowtheworkiscompletedincludingthepositiveprocesscharacteristicrelatedtoeach4M

ThenegativeofthesepositiveswillbeusedfortheFailureCausecolumnThemoredetailusedherewillproducemoreFailureCausei.e.eachlineisauniquepositiveproducingauniquenegative,i.e.aFailureCause

Insteadof“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,SystemorSubsystemcouldfailtoperformtheFunctiondescribedattheNextHigherlevel

WhenconsideringEffects,consideritemslistedin“FunctionoftheProcessItem”andthe""FailureMode”endhowtheycanEffectthe3areasbeingconsidered(In-Plant,Shiptoplant.ProcessItem,VehicleEndUser)

Includepotentialeffectstothevehicle(EndUser)levelendregulations.asapplicable

ItisrecommendedtolisttheSeverityRanknexttoeachofthe3areasbeingconsideredandusethehighestRankfortheSeverityRank.Onearea,suchasEndUser.maynotalwayshavethehighestSeverityRank",1~10,"Failuremodemustbedetectableintheproduct(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)andleadtotheFailureMode

NewFailureCauses-Whileconsidering“FailureCauses”,new'FunctionoftheProcessWorkElementandProcessCharacteristic”,“ProductCharacteristicandmaybegenerated,i.e.listing.“Scratchedtopsurfacewhilepickingpartfromrack”cangenerate“Pickpartfrompartrackwithoutscratchingthetopsurface”,maygenerateandanew“ProductCharacteristics”,“Topsurfacescratchtree”andanewFailureMode“Topsurfacescratched”

FailureAnalysiscanbeginwiththeFM.FForFCaslongasthereisanaccurateFailureChain",InitialState-Pastcontrolsprovenand/orcontrolscommittedto,1~10,InitialState-Pastcontrolsprovenand/orcontrolscommittedto,1~10,"H,M,L,NA",,LL,AdditionalActionsneededtoreduceOccurrence,AdditionalActionsneededtoimproveDetection,"Name,nottitleordepartment",mmyyorddmmyy,"Optional:

Decisionpending,Implementationpending","Descriptionofactiontakenanddocumentnumber,reportnameanddate,etc.",mmyyorddmmyy,1~10,1~10,1~10,"H,M,L,NA",ForPFMEAteamuse,,"Examples:

Adesignchange:DCN0983885

Amanagementreview:

MR07-NOV-2017

Acustomerreview:

CR02-FEB-2018"

,ElectricalMotor,[OP30]Sinteredbearingpress,Operator,"ProcessItem:Convertelectricalenergyintomechanicalenergy(acc.controlsignal)

InPlant:Assemblyofcomponentswithincycletime,withoutscraporrework

ShiptoPlant:Assemblyofmotortovehicledoorwithoutlinestoppage,sortorcontainment

EndUserWindowraisesandlowers",Pressinsinteredbearingtoachieveaxialpositioninpolehousingtomaxgapperprint,Operatortakescleansinteredbearingfromchuteandpushitontothepress-inshaftuntiltheupperstop,"ProcessItem:Lossofmechanicalenergybecauseoftoomuchfrictionbetweenbearingandshaft,innerdiameterofthebearingdeformedbecauseofftoomuchseatingstress

InPlant:None

ShiptoPlantNone

EndUser:Windowraisesandlowerswithdifficulty",8,"Axialpositionofsinteredbearingisnotreached,gaptoosmall",Operatorinsertsasinteredbearingwhichwasdroppedtothegroundfloorbefore(contaminatedwithdirt),NoPreventioncontrol,10,LotreleaseProtectobjective(effectiveity100%)VisualGaugeinspectionofaxialgapofbearingtopolehousingeatbyoperator(checkthechecker:N/A)Dectectionindicator:OK/NOK(RED/GREENarea)andoperatorseparatetheNOKpart,2,H,CC,,"Thedefinitionofaworkinstructionandaworkinstructionfor""fallingcomponents""andcontentsoftheregular

Trainingcurriculartheoperatorandfinishingstaff",,JohnDoe(ProductionEngineer),DD.MM.YYYY,In-progress,,,8,3,2,L,,,

,ElectricalMotor,[OP30]Sinteredbearingpress,Machine(pressmachine),"ProcessItem:Convertelectricalenergyintomechanicalenergy(acc.controlsignal)

InPlant:Assemblyofcomponentswithincycletime,withoutscraporrework

ShiptoPlant:Assemblyofmotortovehicledoorwithoutlinestoppage,sortorcontainment

EndUserWindowraisesandlowers",Pressinsinteredbearingtoachieveaxialpositioninpolehousingtomaxgapperprint,Machinehastopressinthesinteredbearingintothepolehousingseatuntilthedefinedaxialposition,"ProcessItem:Lossofmechanicalenergybecauseoftoomuchfrictionbetweenbearingandshaft,innerdiameterofthebearingdeformedbecauseofftoomuchseatingstress

InPlant:None

ShiptoPlantNone

EndUser:Windowraisesandlowerswithdifficulty",8,"Axialpositionofsinteredbearingisnotreached,gaptoosmall",Machinestopsbeforereachingfinalposition(toolessforce),Selectedpresswithforcemonitoringandpositioncontrolsensor,3,LotreleaseProtectobjective(effectiveity100%)VisualGaugeinspectionofaxialgapofbearingtopoleho