失效模式及其影响分析讲座(英文版)

What is the influence of : use - time and environment on each component
Possibilities: fatigue,
(creep)
a. wear,
b. rust,
c. material
d. contamination, e. deformation under load
systems, parts & components
* Focus on the product itself, D-FMEA
Process
Production FMEA
* Focus on the manufacturing
w each process step
1
INTRODUCTION TO
FMEA
A reliability program ? Why necessary?
一 个 可 靠 性 的 计 划？
为 什 么 必 须？
Car 1: • Frequent Break downs • 频繁地破损 • Many minor components failures • 许多的小部件失效
FMEA approach
Traditional approach
Design Start
Development
Production Production Release
Time
TYPES of FMEA
TYPE
ALIASES
DESCRIPTION
Product
Design FMEA
review
FMEA
Failure Mode & Effect Analysis - Process
Subject :
D at e:
No Process step / Purpose Potential Potential Effect S Potential O Current D RPN Gravity Recommended
Focused on: - manipulations of the operator - wrong (deviations) material - process - equipment - transport - storage
Development of a Process FMEA : An Overview
Car 2: • No Major Break downs • 非主要的破损 • Few failures • 很少的失效
Customer Satisfaction－ 顾 客 满 意
Customer satisfaction means: Never having to say you’re sorry !
失效模式及其影响分析 讲座(英文版)
2021/7/11
FMEA Course Schedule
Day 1
9.00 Introduction Intro to FMEA Process FMEA
10.30 Tea-break
10.45 Process -FMEA (con’t) 12.00 Lunch 1.00 Real-life P-FMEA exercise 3.30 Tea-break 3.45 Real-life P-FMEA exercise -con’t
5 Design of Experiments
6 Quality Function Deployment
What is a FMEA?
A structured, disciplined process to systematically and comprehensively, identify and document potential problems and weaknesses in a design or process so that design changes can be made or other corrective actions taken to prevent actual occurrence
Technical
Risks
Planning
Project Risks
• Project Risks project organisation, team aspects, resources
Know-how, capacity
Use of FMEA
A. Reliability Engineering - Reliability improvements.
Service
* Focus on field service
Objective of FMEA
Failure Mode & Effect Analysis (FMEA) is used to improve
• product reliability (considering usage, environment, lifetime etc.) • quality of (purchased) parts (incl. ‘hidden’ functions of a part) • reproducibility of the product (reduction of fall off & repairs in
Focused on failures which are made and noticed during the production process.
2 PROCESS FMEA
FMEA for the Production Process
Subject for Analysis: - flow chart and scenario of the production process
4 ~ Reject at 1 32 adjustment stn
3 ~Weekly 4 96 maintenance
3 Mount and secure flex ESD assy = > Assemble Flex Assy
Application process
FMEA compatibility
Downstream customer’s * Focus on customer’s Manufacturing FMEA * Primarily interested in
between your product &customer’s process
PAYBACKS
TIME
10 : 1
HIGH VISIBILITY/ REWARD
1:1
IMPROVE PRODUCT
Reliability Investigation by Means of FMEA
Premises: The normal functioning of the product
Question:
con’t 10.30
12.00 FMEA
Day 2
9.00 Real-life P-FMEA exercise Review
Tea-break 10.45 D-FMEA Lunch 1.00 Organization Aspect of
3.00 Tea-break 3.30 Maturity Grid
顾 客 满 意 意 味 着： 决 不 要 说 对 不 起 ！
QUALITY ENGINEERING TOOLS
TOOLS 1 Design Review 2 7 QC Tools 3 New 7 QC Tools 4 Statistical Process Control
APPLICATION
Design Quality Assurance Data analysis/Problem-solving Business Process Mgt, QFP Holding the improvement Quality breakthroughs Meeting customer requirement Fool-proof Design & processes
Failure Mode on Failure
causes on
Control
Factor Action
Failure
1 Mount actuator and install Difficulty in ~Long cycle time 8 ~ Handling 8 ~Production 4 256
of failure
一 个 结 构 化 和 专 业 化 的 过 程，它 能 系 统 和 综 合 地 找 出 并记录在设计和工艺过程中潜在的问题和缺点并由此 作出设计改变或采取其它的改正措施以防止失效的实
际发生
No of Engineering Changes
Effect of FMEA on Process and Design changes
spring clip = > Hold assembling
required to
Monitoring
actuator in place
spring clip
orientate clip Chart, Opr
skill chart
Owner Completion Action
Date
Taken
/Result
assembly) • reproducibility of the production process (handling, transport etc.)
Focus on technical problems Link with Maturity Grid and Risk Management!
f. ageing,
g. process failures.
What is the effect on product functions ?
Producibility Analysis by Means of FMEA
Premises: Actions:
Analysis:
Measuring tool is: eg FOR/ppm Actions as outcome of the Process Quality Control (P.Q.C.)
Evolution Factor
2 Cut LDGU , Mount LDGU Lens and ~Fail Grating
to line pen housing = > grating
Adjustment
Assemble LDGU
contamination
8 ~Handling
~ Cutting machine dirty
Types of Risks
• Market Risks having the right product on the right time
Market Risks
• Technical Risks
Specification
achieving the product spec
quality, reproducibility
A and B during development phase. C during work preparation phase.
Quality Lever
CONCEPT DESIGN
500 : 1
PRODUCT DESIGN
PROCESS DESIGN
PRODUCTION
100 : 1
LOW VISIBILITY/ REWARD
Process step
Purpose
Failure mode
Effects
Severity, S
Cause 1 Controls RPN1 = SO1D1
Cause 1 Controls RPN2 = SO2D2
Occurrence, On Detection, Dn
Cause 1 Controls RPNn = SOnDn
B. Producibility Analysis - Less repairs and scrap during manufacturing. - Improvement of the Zero- Hour Quality.
C. Production Process Analysis - Less repairs and scrap. - Determination of process control points. - Process release.