03806-pfmea Potential Failure Mode and Effects Analysis.pdf
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1、Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 1, Printed: 10/12/98 Failure Mode and Effects Analysis Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 2, Printed: 10/12/98 Dont Let This Happen To YO
2、U! Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 3, Printed: 10/12/98 Potential Failure Mode and Effects Analysis Process Failure Mode And Effects AnalysisLow - High Process: Outside Suppliers Affected:Engineer:1 - 10 Primary Process Responsibilit
3、y:Model Year/Vehicle(s):Part Number: Other Div. Or People Involved:Scheduled Production Released:PFMEA Date:Rev. Approvals:Quality Assurance ManagerQuality Assurance Engineer Operations ManagerSenior Advisor Part Name Operation NumberProcess Function Potential Failure Mode Potential Effects Of Failu
4、rePotential Cause Of FailureCurrent Controls Occured Severity Detection RPN Recommended Actions And Status Actions Taken Occured Severity Detection RPN Responsible Activity SIRTake TPPEWrong MaterialFragmented ContainerInsufficient Supplier ControlMaterial Certification 19218 ContainerMaterial Held
5、InUnpredictable DeploymentImproper HandlingRequired With Each 1Storage AreaMisidentified MaterialShipment Release Verification Out Of SpecFragmented ContainerSupplier Process ControlPeriodic Audit Of 310390 MaterialUnpredictable DeploymentSupplier Material ContaminatedFragmented ContainerOpen BoxesV
6、isual Inspection 19763 MaterialUnpredictable Deployment MaterialFragmented ContainerEngineering ChangeRelease Verification 110770 CompositionUnpredictable DeploymentSupplier ChangeGreen “OK“ Tag ChangeCustomer Notification 2Move ToUnreleasedFragmentationUntrained LTOCheck For Green “OK“ 510150 Appro
7、vedUntrained PersonnelTag At Press StorageTrace Card Check List Training Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 4, Printed: 10/12/98 Potential Failure Mode and Effects Analysis Cayman Systems Revision N 980815 (513) 777-3394 Potential Fail
8、ure Mode and Effects Analysis Slide 5, Printed: 10/12/98 Course Goals To understand the role and function of the FMEA To understand the concepts and techniques of Design FMEA and how to apply it To understand the concepts and techniques of Process FMEA and how to apply it To understand the role and
9、function of FTA To understand the concepts of Zero Quality Control or Mistake-Proofing (e.g. Poka-Yoke) and its implications for FMEA Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 6, Printed: 10/12/98 Liability Issues Cayman Systems Revision N 980
10、815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 7, Printed: 10/12/98 How FMEA Fits With Elements of TQM Customer Requirements Engineering Specifications System and Components Specifications Process and Supplier Requirements and Control Develop System Design and Process FMEA Eli
11、minate Potential Failures Improve Upon Design and Process Design is The Critical Element Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 8, Printed: 10/12/98 What Is An FMEA? An Advanced Quality Planning tool used to evaluate potential failure modes
12、 and their causes. Prioritizes Potential Failures according to their Risk and drives actions to eliminate or reduce their likelihood of occurrence. Provides a discipline/methodology for documenting this analysis for future use and continuous process improvement. By its self, an FMEA is NOT a problem
13、 solver. It is used in combination with other problem solving tools. The FMEA presents the opportunity but does not solve the problem. Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 9, Printed: 10/12/98 FMEAs Have Failure Modes? The team developing
14、 the FMEA turns out to be one individual. The FMEA is created to satisfy a customer or third party requirement, NOT to improve the process. The FMEA is developed too late in the process and does not improve the product/process development cycle. The FMEA is not reviewed and revised during the life o
15、f the product. It is not treated as a dynamic tool. The FMEA is perceived either as too complicated or as taking too much time. Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 10, Printed: 10/12/98 Origins FMECA Failure Mode Effects and Criticality
16、Analysis 1950s Origin - Aerospace person who uses the product Use Failure This can help in Repair manuals person who uses the product More in the DFMEA section herein. Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 51, Printed: 10/12/98 CAUTION! Do
17、 NOT mix up: Design Failures or there is no Design Control. 10 Very Remote Very remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. 9 Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. 8 Very
18、Low Very low chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. 7 Low Low chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. 6 Moderate Moderatechance the Design Control will detect a potential cause/mechanism an
19、d subsequent failure mode. 5 Moderately High Moderately high chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. 4 High High chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. 3 Very High Very high chance the Desi
20、gn Control will detect a potential cause/mechanism and subsequent failure mode. 2 Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subsequent failure mode. 1 Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 6
21、8, Printed: 10/12/98 Design Controls Design controls are those actions taken as a normal part of the development process that are designed into the process to minimize the occurrence of failure or to detect specific failure modes. Design controls should directly relate to the Prevention and/or Detec
22、tion of specific causes of failures. Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 69, Printed: 10/12/98 Design Control Examples Reliability Tests / Prototype Testing Design Reviews Worst Case Stress Analysis Robust Design Environmental Stress Tes
23、ting Designed Experiments Finite Element Analysis Variation Simulation FT Analysis Component Derating (60% to 80%) 100,000 Mile Pilot Test Consider Interpretation of Data Cayman Systems Revision N 980815 (513) 777-3394 Potential Failure Mode and Effects Analysis Slide 70, Printed: 10/12/98 Recommen
24、ded Actions When the failure modes have been ranked by their RPN, corrective actions should be first directed at the highest ranked concerns and critical items identified. The intent of any recommended action is to reduce one or more (or all) of the occurrence, severity and/or detection rankings. On
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