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1、FMEA 失效模式及后果分析OVERVIEW OF THE CHRYSLER/FORD/GM POTENTIAL FAILURE MODE AND EFFECTS ANALYSISREFERENCE MANUAL 克莱斯勒, 福特,通用的潜在失效模式及效果分析参考手册概述1FMEA失效模式及后果分析ADDITIONAL ASSISTANCE 其他帮助来源Chrysler 克莱斯勒 Procurement and Supply(Supplier Development)采购和供应(供应商开发).Ford 福特 Customer Division Supplier Technical Assist
2、ance(STA)客户部供应商技术支持.GM 通用 Procuring Division Supplier Development contact采购部供应商开发For specific technical questions, contact the appropriate responsible engineer (work with your customer).如有特殊问题, 可以与相应的工程师(与你们顾客一起工作的)联系.2FMEA失效模式及后果分析History 历史May 1991-Supplier Quality Requirements Task Force Supplier
3、 Advisory Council identified several tools that would benefit from standardization. 在1991年5月, 供应商质量要求行动小组供应商顾问委员会明确了几种工具, 并通过标准化使大家受益.Supplier Quality Requirements Task Force assessed feasibility and selected several projects for communization, including FMEA. 供应商质量要求行动小组评估了其可行性并选择了几个项目以便沟通, 其中包括FME
4、A.FMEA Work Group completed Reference Manual in Dec. 1992 在1992年12月, FMEA工作小组完成了参考手册的编写.Early 1993-FMEA Reference Manual approved 在1993年年初, FMEA参考手册被认可.Mid 1993-Training developed1993年中期, 建立了相关培训. Phased in during 3rd quarter 1993, according to individual customer requirements.根据个别顾客要求, 在1993年第三季度逐步
5、执行.February 1995 updated and reissued1995年2月更新并再版.3 FMEA失效模式及后果分析PLEASE NOTE 请注意FMEA training offered by Ford(Fairlane Training & Development Center) is not in conflict with and is in fact complimentary to this standardized FMEA training/ FMEA guideline.由福特(Fairlane培训和开发中心)提供的FMEA培训与这种标准化的FMEA培训/FME
6、A指导并不矛盾, 实际上是一种有益的补充.4FMEA失效模式及后果分析Objectives 目的Attendance at this overview course should enable participants to :参加这个概述课程, 将会使与会者学会: Describe how to prepare FMEAs using the Reference Manual.运用参考手册, 描述怎样去准备FMEAs. Understand the format of the Reference Manual.了解参考手册的格式. Know where to go to receive ad
7、ditional assistance.知道到哪里可以得到额外的支持.5DFMEA设计失效模式及后果分析DESIGN POTENTIAL FMEA 潜在的设计失效模式及效果分析Analytical technique and systemized group of activities.分析技术和系统化的小组活动.Utilized primarily by Design Responsible Engineer/Team它主要被具有设计责任的工程师/小组会所运用.6DFMEA设计失效模式及后果分析DESIGN POTENTIAL FMEA BENEFITS 潜在的设计失效模式及后果分析的益处:
8、Helps assure potential failure modes and their effects have been addressed.可帮助确认潜在失效模式和它们的影响后果.Identifies associated causes/mechanisms可识别相关的起因/机理Identifies actions to reduce or eliminate the chance of the failure occurring.可标识出降低或消除失效出现机会的措施.Aids in objective evaluation of design requirements and al
9、ternatives.有助于在设计要求和选择中的目标评估.Aids in initial design for manufacturing and assembly requirements.有助于在初始设计过程中满足制造和装配的要求.Increase probability that failure modes and effects have been considered during design phase.在设计阶段可增加考虑到失效模式及其影响后果的机率.Aids in design test and development programs有助于实验设计和项目开发. (TO BE
10、 CONTINUED 待续)7DFMEA设计失效模式及后果分析DESIGN POTENTIAL FMEA BENEFITS (CONTINUED)潜在的设计失效模式及效果分析的益处:(接续)Failures assessed from customers point of view.从顾客观点角度去评估失效.Allows tracking and documenting risk-reducing actions 可对降低风险措施进行追踪和文件记录.Excellent reference for future analysis and designs对于将来的分析和设计, 是非常好的参考.Do
11、cuments the Design FMEA process.使DFMEA过程文件化.8PFMEA过程失效模式及后果分析Process Potential FMEA 过程潜在失效模式及效果分析Analytical technique and systemized group of activities.分析技术和有组织的小组活动.Utilized primarily by a Manufacturing Responsible Engineer/Team 它主要被具有制造责任的工程师/小组会所运用9PFMEA过程失效模式及后果分析Process Potential FMEA Benefits
12、过程潜在失效模式及效果分析的益处Helps assure product-related process failure modes and their effects have been addressed.可帮助确认与生产相关的过程失效模式和它们的影响效果所在的位置Identifies associated causes/mechanisms.可识别相关联的起因/机理Identifies actions to reduce or eliminate the chance of the failure occurring.可标识出降低或消除失效出现机会的措施. Identify potent
13、ial manufacturing or assembly process causes of failure.可鉴别在制造或装配过程中失效的潜在起因Identify process variables that, if controlled, can reduce occurrence or improve detection of failure conditions.可鉴别过程变量, 如果此变量受控, 可以降低出现频率或提高失效条件的发现度.Helps prioritize corrective actions有助于纠正措施的优化排序.Excellent in-process refer
14、ence.在过程方面是非常优秀的参考.Documents the Process FMEA process.使PFMEA过程文件化.10FMEA失效模式及后果分析CUSTOMER 顾客For purposes of preparing FMEAs, the definition of “customer” includes: 对于准备FMEAs的目的来讲, “顾客”的定义包括:The end user最终用户Design responsible engineers/teams of vehicle and higher level assemblies.车型设计和更高一级装配过程设计的工程师们
15、/设计小组Process responsible engineers/teams in activities such as在如下活动中, 负有过程责任的工程师们/小组 Manufacturing 生产 Assembly 装配 Service 售后服务Subsequent downstream manufacturing, assembly, or service operation.下一道生产,装配工序,或服务.11FMEA失效模式及后果分析Other Definitions in Glossary (Appendix) 其他的术语其他的术语(附录附录)Design Intent 设计目的
16、Design of Experiments(DOE) 实验设计 Design Validation/Verification(DV) 设计验证/审核 Process Change 过程更改 Pareto 帕雷托图 QFD 质量功能分解Control plan 控制计划 Process 过程 Special Product Characteristic 产品特殊特性Design life 设计寿命12FMEA失效模式及后果分析Who should prepare the FMEA? 谁来做FMEA?“the responsible engineer is expected to directly
17、 and actively involve representatives from all affected areas.”“ 希望负有责任的工程师能够直接地,主动地联系所有相关部门的代表.”Team Effort 团队的努力 Product Design 产品设计 Reliability 可靠性 Assembly 装配 Purchasing 采购 Manufacturing 生产 Testing 测试 Materials 材料 Service 售后服务 Quality 质量 Suppliers 供应商 Sales 销售 Legal Department 法律部门Design area re
18、sponsible for next assembly下一级装配的设计责任部门.Others as appropriate 其他视情况.13DFMEA设计失效模式及后果分析Sources of Information 资料来源Team brainstorming 小组的集思广义Design and Engineering Specifications 设计和工程规范Manufacturing/Process specifications 制造/过程规范Control Plans 控制计划Warranty Data 保修记录Reliability Data 可靠性数据Recall Data 召回
19、记录Quality Function Deployment studies 质量功能配置研究 Quality Surveys 质量审查Test Reports 检测报告Teardown Reports 破坏性报告.Other FMEAs 其他的FMEAs etc. 等14DFMEA设计失效模式及后果分析When?什么时间?Design FMEA should be initiated before or at design concept finalizationDFMEA 应在概念设计完成之前开始.Process FMEA should be initiated before or at t
20、he feasibility stage, prior to tooling for productionPFMEA应在可行性研究阶段时或之前, 在生产工装开发之前开始.FMEAs are “living documents” FMEAs 是动态文件 . FMEAs should be continually updated as changes occur and new information is obtained.只要出现更改和莸得新的信息, FMEAs 文件就得更新. ( To be continued 待续)15FMEA失效模式及后果分析When? ( Continued) 什么时
21、间?(接续)FMEAs should be performed before failure modes are unknowingly designed in确保FMEAs工作在一些失效模式被无意地包括在设计中之前完成.Upfront time can alleviate late-change crises.早期开展可以避免后期更改.Properly applied, FMEA is an interactive, never-ending process.适当的运用, FMEA是一个相互作用的, 永不终止的过程.16DFMEA设计失效模式及后果分析Development of a Des
22、ign FMEA 设计FEMA的开发Assemble team 成立小组Assign Responsibilities分配责任 Leader 组长 Data-Gathering 采集数据 Recorder 记录员17DFMEA设计失效模式及后果分析Prepare Block Diagram制作框图 Helps with understanding function 帮助对功能的了解 Helps with understanding scope 帮助对范围的了解 Should be included with FMEA documents 应当包括在FEMA文件中Begin FMEAFEMA开始
23、18DFMEA设计失效模式及后果分析PLEASE REFER TO THE SAMPLE FMEA ON PAGE 8 OF THE POTENTIAL FAILURE MODE AND EFFECTSANALYSIS REFERENCE MANUAL请参阅潜在失效 模式及后果分析参考手册中 第八页的FEMA示例19DFMEA设计失效模式及后果分析FMEA REFERENCE MANUALFEMA参考手册(1) FMEA Number FMEA编号(2) Systems, Subsystem, or Component Name and Number 系统、子系统或零部件的名称、编号(3) D
24、esign Responsibility 设计责任 OEM 整车厂 Department/Group 部门/小组 Supplier(if known) 供应商(如果知道)20DFMEA设计失效模式及后果分析(4) Prepared by 编制者(5) Model year(s)/Vehicle(s) 年型/车型(6) Key Data 关键日期 Initial FMEA due date 初始FMEA完成日期 Should not exceed scheduled design release date 不应超过计划的生产设计发布的日期(7) Date 日期21DFMEA设计失效模式及后果分析
25、FMEA REFERENCE MANUALFMEA参考手册(8) Core Team 核心小组 all individuals involved 所有参与的个人 include a distribution list with address/phone #s包括一张记录参加人员 地址/电话的分发表(9) Item/Function 项目/功能 Enter name/number 填入名称/号码 Enter all functions 填入所有的功能 Consider functions for all part features one at a time一次性考虑到所有零件的特点功能22D
26、FMEA设计失效模式及后果分析(10) Potential Failure Mode 潜在失效模式 “the manner in which a component, subsystem, or system could potentially fail to meet the design intent.”“零部件，子系统或系统有可能未达到设计意图的形式“。 Use physical terms,not symptoms noticed by customer.应用规范化的术语，而不同于顾客所见的现象。 Review various pieces of documentation for i
27、deas 运用各种方法评审不同的文件 Brainstorm脑力激荡23DFMEA设计失效模式及后果分析FMEA REFERENCE MANUALFMEA参考手册(11) Potential Effect(s)of Failure 潜在失效后果 Effect on function对系统功能的影响 As perceived by customer如顾客感受的一样24DFMEA设计失效模式及后果分析(12)Severity (S)The seriousness of the effect of the potential failure mode.A reduction in Severity R
28、anking can only occur as a result of a design change.Suggested Evaluation Criteria:Effect criteria : Severity of Effect RankingHazardous Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves without warning: noncompliance with government regulation w
29、ithout warning. 10Hazardous with Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves warning: noncompliance with government regulation with warning. 9.Etc.Please refer to page 13 of the FMEA Manual25DFMEA设计失效模式及后果分析 (12)严重度 (S)潜在失效模式影响后果的严重程度。要减少失效
30、的严重度级别数值，只能通过修改设计来实现。推荐的评价准则：(请参考FMEA手册中第13页)Effect criteria : Severity of Effect RankingHazardous Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves without warning: noncompliance with government regulation without warning. 10Hazardous with Very
31、high severity ranking when a potential failure mode affects safe vehicle operation and/or involves warning: noncompliance with government regulation with warning. 9.Etc.26DFMEA设计失效模式及后果分析Suggested Evaluation Criteria推荐的评价准则This is the suggested criteria 这是推荐的准则The team should agree on an evaluation
32、criteria and ranking system, which is consistent, even if modified for individual product analysis设计小组对评定准则和分级规则应意见一致，即使因为个别产品分析作了修改也应一致。 have your customers concurrence 取得顾客的同意 include the revised criteria in your documentation在文件中包括已修改的准则 be consistent throughout the analysis 在分析中保持一致性 27DFMEA设计失效
33、模式及后果分析(13) Classification 分级 Used to classify any special product characteristic for component, subsystem or system characteristics that may require additional process controls. 可用于对零件、子系统或系统的产品特性分级，它们可能还需要附加的过程控制。Safety and/or Government-Regulated Characteristics安全性和/或政府法规特性 Safety Item安全条款 Critic
34、al Characteristic 关键特性 Safety/Compliance 安全/符合 Key Product Characteristic 关键产品特性28DFMEA设计失效模式及后果分析Important Performance, Fit, or Appearance Characteristics重要性能，安装或外观特性 Critical Characteristic关键特性 Critical Verification关键确认 Significant Characteristic重要特性 Fit/Function Key Product Characteristic配合/功能关键产
35、品特性Use your customers methods 应用顾客的方法29 DFMEA设计失效模式及后果分析(14) Potential Causes/Mechanism(s) of Failure 潜在失效的起因/机理Indication of a design weakness设计薄弱部分的迹象Consequence is failure mode 结果就是失效模式List every conceivable cause/mechanism of failure列出每个可以想到的失效起因/机理30 DFMEA设计失效模式及后果分析(15) Occurrence(O)The likeli
36、hood that a specific cause/mechanism of failure will occurCan only be reduced by a design change that removes or contros a cause/mechanism of failureSuggested Evaluation Criteria:Probability of Failure Possible Failure Rates RankingVery high: Failure is almost inevitable 1 in 2 10 1 in 3 9High: Repe
37、ated failures 1 in 8 8 1 in 20 7Moderate: Occasional failures 1 in 80 6 1 in 400 5 1 in 2,000 4Low: Relatively few failures 1 in 15,000 3 1 in 150,000 2 Remote: Failure is unlikely 1 in 1,500,000 1Please refer to page 17 of the FMEA MANUAL31DFMEA设计失效模式及后果分析 (15) 频度 (O)指某一特定失效起因或机理出现的可能性。通过设计更改来消除或控制
38、一个或更多的失效起因或机理是降低频度数的唯一途径。推荐的评价准则：(请参考FMEA手册的第17页)Probability of Failure Possible Failure Rates RankingVery high: Failure is almost inevitable 1 in 2 10 1 in 3 9High: Repeated failures 1 in 8 8 1 in 20 7Moderate: Occasional failures 1 in 80 6 1 in 400 5 1 in 2,000 4Low: Relatively few failures 1 in 1
39、5,000 3 1 in 150,000 2 Remote: Failure is unlikely 1 in 1,500,000 132DFMEA设计失效模式及后果分析(16)Current Design Control 现行设计控制Validation/Verification activities which will assure adequacy of design 设计确认/验证将保证该设计的结果是恰当的Initial occurrence and detection rankings are based on these current controls最初的频度或不易探测度数取
40、决于现行的控制方法“Current” is based on same or similar designs“现行”取决于相同或相似的设计Remember: these are tests performed before part is released for production切记：这些试验是在零件被批准生产之前进行的 33DFMEA设计失效模式及后果分析There are three types of Design Controls/Features to consider; those that:有三种设计控制方法可考虑，它们是： 1) Prevent the cause/mech
41、anism or failure mode/effect from occurring, or reduce their rate of occurrence 防止起因/机理或失效模式/后果的出现，或减少它们出现率 2) Detect the cause/mechanism and lead to corrective actions 查出起因/机理并导致找到纠正措施 3) Detect the failure mode 查明失效模式34DFMEA设计失效模式及后果分析(17)Detection (D)Ability of a Current Design Control to identif
42、y a potential causeSuggested Evaluation Criteria :Detection Criteria: likelihood of Detection by Design Control RankingAbsolute Design Control will not and/or can not detect a potential cause/ 10Uncertainty mechanism and subsequent failure mode;or there is no Design Control.etc Please refer to page
43、19 of the FMEA MANUAL.35DFMEA设计失效模式及后果分析 (17) 不易探测度(D)用现行设计控制方法来探测潜在失效原因能力的评价指标推荐的评价准则：(请参考FMEA手册的第19页)Detection Criteria: likelihood of Detection by Design Control RankingAbsolute Design Control will not and/or can not detect a potential cause/ 10Uncertainty mechanism and subsequent failure mode;or
44、 there is no Design Control.etc 36DFMEA设计失效模式及后果分析(18) Risk Priority Number (RPN) 风险顺序数(RPN) RPN = S * O * D风险顺序数是严重度数(S),频度数(O),和不易探测度数(D)的乘积 Used as a guide to help rank process concerns用来对过程中所担心的事项排序 Golf score concept (Lower is better)就象高尔比赛得分那样,数值越小越好 There are no “ threshold ”values没有标准分值 Spec
45、ial attention should be given when severity is high (as defined by the team, including the Customer)由可行性小组(包括顾客)所定义的严重度高时要给予特别关注37DFMEA设计失效模式及后果分析(18) 风险顺序数(RPN)0 0100100200200300300 Like the chart,sort the RPN, and take corrective actions to reduce the higher ones; 就象图表所示,先排列出所有的风险顺序值,然后优先解决高分值问题38
46、DFMEA设计失效模式及后果分析(19) Recommended Action(s) 建议措施Intent is to reduce Severity, Occurrence, and/or Detection rankings 目的是为了减少严重度，出现频次，和/或不易探测度Examples 例如 DOE 试验设计 Revised Test Plan 修改试验计划 Revised Design 修改设计 Revised Material Specification 修改材料性能要求39DFMEA设计失效模式及后果分析(20) Responsibility/ Target Date 责任/目标
47、日期(21) Actions Taken 采取的措施(22) Resulting RPN 纠正后的RPN40PFMEA过程失效模式及后果分析 Development of a Process FMEA 过程FMEA的开发Assemble Team 成立小组Assign Responsibilities 职责分配 leader 组长 data-gathering 数据收集 recorder 记录员Process flow diagram is valuable at this point在这个时候, 过程流程图是非常有用的.Begin FMEA开始FMEA工作41PFMEA过程失效模式及后果分析
48、 Header Information 前面的信息Items (1) through (8) 从(1)至(8)项Essentially the same as Design FMEA 内容基本上与DFMEA一样.42PFMEA过程失效模式及后果分析 (9) Process Function/Requirements 过程功能/要求 Enter description and purpose 输入功能描述和目的. Be as concise as possible 尽可能简要.(10) Potential Failure Mode 潜在失效模式 “ the manner in which the
49、 process could potentially fail to meet the process requirements and/or design intent.”“ 是指过程可能发生的不满足过程要求和/或设计意图的形式. A description of non-conformance是对不符合的一个描述. Assume incoming parts are correct假定提供的部件都是合格的. Remember to consider subsequent operations.记得要考虑下道工序.43PFMEA过程失效模式及后果分析 (11) Potential Effec
50、t(s) of Failure 潜在失效后果 Effect of failure mode based on what customer might notice/experience 失效模式后果是依据顾客可能注意到的或所经历的. Includes subsequent process operations应包括下道工序操作.(12) Severity 严重度 The seriousness of the effect of the potential failure mode是指潜在失效模式后果的严重程度. Suggested Evaluation Criteria (Please ref