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(bào)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(yīng)用選擇和其它工具關(guān)聯(lián)。PerformaFMEA執(zhí)行一個(gè)FMEA。2失效模式及其影響分析研究報(bào)告第2頁FMEA:FailureModesandEffectsAnalysisFMEAisasystematicapproachusedtoexaminepotentialfailuresandpreventtheiroccurrence.Itenhancesourabilitytopredictproblemsandprovidesasystemofranking,orprioritization,sothemostlikelyfailuremodescanbeaddressed. FMEA是用來檢驗(yàn)潛在失效和預(yù)防它再次發(fā)生系統(tǒng)性方法.它增強(qiáng)了我們預(yù)測(cè)問題能力,并提供了一個(gè)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(yīng)用在工藝及產(chǎn)品設(shè)計(jì)早期，自由討論決定潛在失效模式、原因、嚴(yán)重度及發(fā)生可能性。在6S中，我們應(yīng)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(gè)在失效縮小管理任務(wù)有價(jià)值工具。FMEA3失效模式及其影響分析研究報(bào)告第3頁DefinitionofFMEA定義recognizeandevaluate

thepotentialfailuremodesandcausesassociatedwiththedesigningandmanufacturingofanewproductorachangetoanexistingproduct.

認(rèn)識(shí)和評(píng)定新產(chǎn)品設(shè)計(jì)和制造時(shí)或?qū)ΜF(xiàn)有產(chǎn)品做出改變時(shí)相關(guān)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(jī)會(huì)行動(dòng)document

theprocess.

使過程形成文件FMEAisa

systematic

designevaluationprocedurewhosepurposeisto:是系統(tǒng)設(shè)計(jì)評(píng)定程序4失效模式及其影響分析研究報(bào)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(yīng)用錯(cuò)誤AFailureModeis...失效模式是……5失效模式及其影響分析研究報(bào)告第5頁FMEAUsebyBlack/Brown/GreenBeltsToidentifypotentialfailuremodesandratetheseverityoftheireffectsToidentifycriticalcharacteristicsandsignificantcharacteristicsTorankpotentialdesignandprocessdeficienciesTohelpallofusfocusoneliminatingproductandprocessconcernsandpreventproblemsfromrecurringReducetheproductdevelopmenttimingandcost6失效模式及其影響分析研究報(bào)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(bào)告第7頁NASAusedFMEAtoidentifySinglePointFailuresonApolloproject(SPF=noredundancy&lossofmission).Howmanydidtheyfind?420andwethoughtwehadproblems!8失效模式及其影響分析研究報(bào)告第8頁TypesofFMEA’sSYSTEMDESIGNPROCESSSystemFMEAisusedtoanalyzesystemsandsubsystemsintheearlyconceptanddesignstages.DesignFMEAisusedtoanalyzeproductsbeforetheyarereleasedtoproductionProcessFMEAisusedtoanalyzemanufacturing,assemblyandadministrativeprocesses9失效模式及其影響分析研究報(bào)告第9頁WhenistheFMEAStarted?“Dothebestyoucanwithwhatyouhave”ASEARLYASPOSSIBLE!Guideline:10失效模式及其影響分析研究報(bào)告第10頁WhentoStart???Whennewsystems,productsandprocessesarebeingdesignedWhenexistingdesignsandprocessesarebeingchangedWhencarry-overdesignsorprocesseswillbeusedinnewapplicationsorenvironmentsAftercompletingaProblemSolvingStudy,topreventrecurrenceofaproblem11失效模式及其影響分析研究報(bào)告第11頁BeginningandEnd12失效模式及其影響分析研究報(bào)告第12頁EffectofFMEAonProcessandDesignchangesDesignStartDevelopmentProductionReleaseProductionTimeNoofEngineeringChangesTraditionalapproachFMEAapproach13失效模式及其影響分析研究報(bào)告第13頁P(yáng)rocessFMEAForm14失效模式及其影響分析研究報(bào)告第14頁JLExample15失效模式及其影響分析研究報(bào)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(bào)告第16頁P(yáng)rocessFailureModeThepotentialfailuremodeisthemannerinwhichtheprocesscouldfailtoperformitsintendedfunction.Thefailuremodeforaparticularoperationcouldbeacauseinasubsequent(downstream)operationoraneffectassociatedwithapotentialfailureinaprevious(upstream)operation.FAILUREMODEEFFECTPREVIOUSOPERATIONCAUSENEXTOPERATION17失效模式及其影響分析研究報(bào)告第17頁P(yáng)rocessCauses

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

Occurrencex Severityx DetectionOSD

xx=RPN21失效模式及其影響分析研究報(bào)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(bào)告第22頁Severity23失效模式及其影響分析研究報(bào)告第23頁Occurance24失效模式及其影響分析研究報(bào)告第24頁Detection25失效模式及其影響分析研究報(bào)告第25頁Itisconductedonatimely

basisand

Itisappliedbyaproduct

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

EFFECTCAUSESBasicSteps30失效模式及其影響分析研究報(bào)告第30頁BasicSteps1.DevelopaStrategy2.Reviewthedesign/process3.ListfunctionsDevelopaStrategyReviewthedesign/processListfunctions31失效模式及其影響分析研究報(bào)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(bào)告第32頁1.DevelopaStrategy2.Reviewthedesign/process3.Listfunctions4.Brainstormpotentialfailuremodes5.OrganizepotentialfailuremodesBasicStepstopictopicAffinityDiagram33失效模式及其影響分析研究報(bào)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(bào)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(bào)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(bào)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(bào)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(bào)告第38頁TestingtheRelationshipsIFTHENHOWDOIKNOW?CAUSEFAILUREMODEEFFECT39失效模式及其影響分析研究報(bào)告第39頁ActionsThedesignorprocessmustbeimprovedbasedontheresultsoftheFMEAstudy.Awell-developedFMEAwillbeoflimitedvaluewithoutpositiveandeffectivecorrectiveactions.40失效模式及其影響分析研究報(bào)告第40頁ModuleObjectivesDescribeFMEAprinciplesandtechniques.Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.PerformaFMEA41失效模式及其影響分析研究報(bào)告第41頁DescribeFMEAprinciplesandtechniques.Summarizetheconcepts,definitions,applicationoptionsandrelationshipswithothertools.PerformaFMEAModuleObjectives…...42失效模式及其影響分析研究報(bào)告第42頁OrganizationalLearningandSystemsThinking組織學(xué)習(xí)和系統(tǒng)思維AManagementSystem43失效模式及其影響分析研究報(bào)告第43頁BuildingOrganizationalMemoryEyelashLearningCurveABILITYTODOJOBTIMEOLDEMPLOYEELEAVESWITHKNOWLEDGENEWEMPLOYEEBEGINSThereisnoorganizationalmemorytoallowpeopletostartwheretheirpredecessorsleftoffNothinginplacetocapturetheneworimprovedmethodsthatproduceresults*44失效模式及其影響分析研究報(bào)告第44頁RapidLearningCurveABILITYTODOJOBTIMENEWEMPLOYEECOMESONANDPICKSUPALMOSTWHEREPREVIOUSEMPLOYEELEFTOFFOrganizationcontinuestoadvanceitsknowledgebypreservingthelessonseachlearnsRapidlearning=lesswaste,lesscomplexity,highercustomervalue,lowercosts*45失效模式及其影響分析研究報(bào)告第45頁HowDoWeCreateRapidLearning?Twokeyingredients:1.Havingbestknownmethodsdocumented2.TrainingpeopleonwhatthosemethodsareWhototrain?

NewemployeesManagersExperiencedemployees*SixSigma46失效模式及其影響分析研究報(bào)告第46頁P(yáng)rosandConsofStandardMethodsAdvantages:優(yōu)點(diǎn)Customerprogressismorevisibleandcanbetrackedovertime 用戶進(jìn)步更可見而且能夠隨時(shí)間跟蹤C(jī)aptureandsharelessonslearned

吸收和分享教訓(xùn)Systemitselfdoesnotbecomeasourceofvariation

系統(tǒng)本身不會(huì)成為變異起源Leadstoefficientpractices造成有效率實(shí)踐

*47失效模式及其影響分析研究報(bào)告第47頁P(yáng)rosandConsofStandardMethodsDisadvantages:缺點(diǎn)Stiflecreativityandleadtostagnation 抑制創(chuàng)造力造成停滯不前Interferewithcustomerfocus干涉客戶焦點(diǎn)Addbureaucracyandredtape助長官僚作風(fēng)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(bào)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(bào)告第49頁EffectiveStandardization有效標(biāo)準(zhǔn)Companiesthatusestandardizationeffectivelyoperateverydifferently:ThecompanyknowswhyitisdevelopingstandardsandhowtheycontributetoitsoverallpurposeManagementusesbest-knownmethodsthemselvesandstronglysupportsandchecksusageEmployeesunderstandhowdifferentfacetsoftheirworkaffecttheproductsandservices

Employeesknowwhichelements/functionsarecriticaltoproducinghigh-qualityoutput50失效模式及其影響分析研究報(bào)告第50頁CreateStandardsJudiciously明智地創(chuàng)造標(biāo)準(zhǔn)LeveragePoint:Aplacewherealittlechangehasagreatimpact支點(diǎn)：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(bào)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(bào)告第52頁LeveragePointThinking-HowDoYouTurntheShip?

KnowingtheleveragepointsiscriticalfordeterminingprioritiesandstrategiesforimprovementVitalFewTrivialManyParetoPrinciple80%oftheproblemsarecausedbyonlyabout20%ofthecontributingfactors*53失效模式及其影響分析研究報(bào)告第53頁54失效模式及其影響分析研究報(bào)告第54頁What’stheConnection?聯(lián)絡(luò)Companiesrunintotroublebecausetheychangetheirmethodsbeforetheyunderstandwhythemethodsarethereinthefirstplace.陷入麻煩企業(yè)是因?yàn)樗麄冊(cè)诓涣私猬F(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(bào)告第55頁Resistthetemptationtochangeuntilwedetermine:

?Arethedocumentedstandardsthebest?

?Whatistheimpactontherestofthesystem?

?Arethemethodsactuallybeingfollowed?

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

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

了解標(biāo)準(zhǔn)Outputmustbemeasurablewithimmediatefeedbackonperformance.Don’tbevagueorrequireinterpretation(i.e.wordslikeflat,smooth,etc.)57失效模式及其影響分析研究報(bào)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(bào)告第58頁CAP-Do-DeterminetheNeedforStandardization1.CheckMakesureweknowwhytheworkisbeingdone

SeeifthepurposeisclearlydocumentedCompareactualpracticewithdocumentedmethodsIfnodocumentedmethodsexi