防錯(cuò)培訓(xùn)經(jīng)典教材

1、Error Proofing 防錯(cuò) Topics - Error Proofing Training Duration 時(shí)間區(qū)間時(shí)間區(qū)間 Start 開始時(shí)間開始時(shí)間 Error Proofing 防錯(cuò)防錯(cuò) Objective of the Training & Expectations0:158:00 AM 培訓(xùn)的目標(biāo)及預(yù)期目的0:158:00 AM What and Why or Error Proofing - Exercise 11:008:15 AM 什么是防錯(cuò)，為什么進(jìn)行防錯(cuò)-練習(xí)11:008:15 AM Coffee Break中間休息中間休息0:159:15 AM Applic

2、ation of Error Proofing - Overview Exercise 2 1:009:30 AM 2 防錯(cuò)應(yīng)用-總體練習(xí)21:009:30 AM Identify Opportunities for Errors & PFEMA, Exercise 31:0010:30 AM 識(shí)別防錯(cuò)及PFEMA良機(jī),練習(xí)31:0010:30 AM Error Proofing Options0:3011:30 AM 防錯(cuò)方案1:0010:30 AM Lunch Break 午休午休0:4512:00 PM Error Proofing Options (continue) Exercise

3、 41:0012:45 PM 防錯(cuò)方案(續(xù))練習(xí)41:0012:45 PM Activities 措施措施 Topics主題 Objectives of the Training 培訓(xùn)的目的 What and Why of Error Proofing 什么是防錯(cuò)，怎樣進(jìn)行防錯(cuò) Application of Error Proofing 防錯(cuò)應(yīng)用 Identify Opportunities for Errors 防錯(cuò)時(shí)機(jī)的確定 Overview of Failure Mode and Effects Analysis (FMEA) 失效模式和效果分析總括 Error Proofing Opt

4、ions 防錯(cuò)的選擇 Prevention & Detection Through Poka Yoke Devices 通過Poka Yoke進(jìn)行預(yù)防與探測(cè) Move to The Next Level 轉(zhuǎn)入下一級(jí) A Benchmark Within Eaton 伊頓內(nèi)部標(biāo)準(zhǔn) Summary 概要 Objectives of the Training 培訓(xùn)的目的 Understand What Is Error Proofing and What It Can Do 了解什么是防錯(cuò)和防錯(cuò)能做什么 Understand the Principles of Error Proofing 了解防錯(cuò)

5、的原理 Learn How to Apply Error Proofing to Products and Processes 了解怎樣對(duì)產(chǎn)品及工藝過程應(yīng)用防錯(cuò) Learn About the Poka Yoke Devices and Systems 了解Poka Yoke裝置和系統(tǒng) Learn the Process of Implementation and Continuous Improvements 了解實(shí)施防錯(cuò)的過程和持續(xù)改進(jìn)的過程 What Are Your Expectations? 你們的期望是什么？ What and Why of Error Proofing 什么是防錯(cuò)

6、以及為什么要防錯(cuò) Definition 定義 Error Proofing Is a Systematic Approach for Anticipating and Detecting Potential Defects and Preventing Them From Reaching the Customer (Internal or External) 防錯(cuò)是一種預(yù)測(cè)及探測(cè)潛在缺陷以及阻止缺陷影響客戶 的體系方法(內(nèi)部防錯(cuò)和外部防錯(cuò)) Error Proofing by Other Names 以其他名稱進(jìn)行防錯(cuò) Fool Proofing防止愚蠢行為 Idiot Proofing防止

7、白癡行為 Mistake Proofing防止錯(cuò)誤行為 Fail Safing安全失效 Poka Yoke Zero Quality Control (Zero Defects) 零質(zhì)量控制（零缺陷） Design for Manufacture and Assembly 制造和裝配的設(shè)計(jì) Let Us Not Argue the Merits of These Names Let Us Decide What We Want to Achieve 我們不要爭(zhēng)論這些名稱,讓我們決定想要完成什么? Demoralizing Terms 防錯(cuò)防錯(cuò) 術(shù)語(yǔ)術(shù)語(yǔ) Characteristics of E

8、rror Proofing 防錯(cuò)的特點(diǎn) Proactive Identification and Prevention前期識(shí)別及預(yù)防 Prevent First首先進(jìn)行防錯(cuò) Do Not Allow Defect From Going Further 其次不準(zhǔn)許缺陷進(jìn)一步發(fā)展 Intentionally Designed, Not Happenstance 設(shè)計(jì)錯(cuò)誤,非偶然錯(cuò)誤. At the Source - Close to the Origination 錯(cuò)誤的來(lái)源_接近發(fā)源地. Inexpensive First 首先成本不高 Transparent to the Operator 操

9、作者很容易發(fā)現(xiàn) Absolutely Reliable 錯(cuò)誤根源查找絕對(duì)準(zhǔn)確 A Means to Achieve Zero Defect Product 一種達(dá)到0缺陷產(chǎn)品的方法 Defects and Errors 缺陷和錯(cuò)誤 Defects in Products Are the Imperfections (or Faults, or Flaws, or Blemishes, or Shortcomings, or Failings, or Deficiencies) 缺陷缺陷是指產(chǎn)品里的不完整性(或者故障,或者裂紋,或者瑕疵，或者短處，或者過 失 ，或者不足) Resulting F

10、rom Errors 錯(cuò)誤產(chǎn)生的結(jié)果 Errors Are Human Oversights (or Faults, or Blunders, or Boo-boos, or Slip-ups, or Inaccuracies or Miscalculations) That Cause Defects in Products 錯(cuò)誤錯(cuò)誤是人為疏忽(或者過錯(cuò),或者失誤,或者低級(jí)錯(cuò)誤，或者失敗，或者精度失誤或者計(jì) 算 失誤)，這些引起產(chǎn)品的缺陷。 SO, Errors Cause Defective Products! 所以,錯(cuò)誤導(dǎo)致有缺陷的產(chǎn)品產(chǎn)生! Why Are Errors Made 為什

11、么會(huì)導(dǎo)致錯(cuò)誤 Any Product Is a Result of Numerous Decisions Made and Actions Taken by Human Beings, During: 任何產(chǎn)品都可以在下述一系列人為行為中產(chǎn)生錯(cuò)誤： Product Design 產(chǎn)品設(shè)計(jì) Process Design 過程設(shè)計(jì) Equipment Design 設(shè)備設(shè)計(jì) Component Fabrication Processes 零件加工過程 Product Assembly Processes 產(chǎn)品裝配過程 Inspection Processes 檢驗(yàn)過程 Paperwork Gene

12、ration 程序行程過程 Etc.等等 And Human Beings are Fallible or Imperfect 人是容易犯錯(cuò)或不完美的 SOME Examples of Defects 屬于缺陷的一些例子 Wrong or Inappropriate Material 錯(cuò)誤或不適合的材料 Wrong or Non-functioning Components 錯(cuò)誤或者沒有功能的零件 Wrong Dimensions or Tolerances 尺寸或公差錯(cuò)誤 Missing Components 零件漏裝 Foreign Matters, Contamination 雜質(zhì)物質(zhì),

13、污穢物 Damaged Product or Components 受損產(chǎn)品或零件 Wrong Paperwork, or Wrong Product Shipped 程序錯(cuò)誤或者運(yùn)輸了錯(cuò)誤的產(chǎn)品 Non-functioning or Malfunctioning Product 沒有功能的產(chǎn)品或者是故障產(chǎn)品 Wrong Shipping, or Wrong Billing 運(yùn)輸錯(cuò)誤或者是填單錯(cuò)誤 SOME Examples of Causes of Defects 導(dǎo)致缺陷的一些例子 Poor Design Decisions 設(shè)計(jì)比較乏味 Omitted or Wrong Processi

14、ng 過程疏忽或過程錯(cuò)誤 Missing / Extra Parts or Wrong Parts 漏裝/多裝了錯(cuò)誤的零件 Omitted or Wrong Adjustment / Testing 遺漏調(diào)整/測(cè)試或調(diào)整/測(cè)試過程錯(cuò)誤 Wrong Equipment Setup or Loss of Setup 設(shè)備設(shè)置錯(cuò)誤或沒有進(jìn)行設(shè)備設(shè)置 Wrong Material, Components or Assemblies 材料，零件或者裝配錯(cuò)誤 Wrong Communication, Instructions, Procedures, or Methods 錯(cuò)誤的信息，指令，程序，或者方法

15、 Inexperience, Lack of Training, Wrong Training, Lack of Retraining 缺乏經(jīng)驗(yàn)，缺乏培訓(xùn)，培訓(xùn)錯(cuò)誤，缺少再培訓(xùn) SOME Examples of Results of Defects 缺陷導(dǎo)致的結(jié)果示例 Malfunction or Non-functioning Product 有故障或者缺乏機(jī)能的產(chǎn)品 Inconvenience, Discomfort, Injury, Death 麻煩，不便，傷害，死亡 Delays, Cancellations 延期，取消 Financial Losses 財(cái)政損失 Loss of Us

16、e or Productivity 效用或者生產(chǎn)力的缺乏 Damage to Customers Property 損害客戶的利益 Liabilities and Law Suites 負(fù)債和法律問題 Loss of Reputation and Business 名譽(yù)和業(yè)務(wù)受損 SOME Causes of Human Errors 導(dǎo)致人們犯錯(cuò)誤的一些原因 Forgetfulness, Loss of Concentration, Lack of Attention or Diverted Attention 健忘，不集中，缺乏注意力或者轉(zhuǎn)移注意力 Misunderstanding or

17、Lack of Understanding 誤會(huì)或者缺乏理解 Lack of or Improper Experience / Training 缺乏經(jīng)驗(yàn)/培訓(xùn)或者不正確的經(jīng)驗(yàn)/培訓(xùn) Lack of Standardization 缺乏標(biāo)準(zhǔn) Intentional or Willful Error 有意圖的或者惡意的錯(cuò)誤 Wrong or Delayed Decision 決定錯(cuò)誤或拖延 Limited or Lack of Sensory Capability (e.g., Smell, Color, Touch) 有限的或者沒有感官能力（例如，嗅覺，色彩，觸覺） Lack of Appli

18、cation of Common Sense 缺乏運(yùn)用常識(shí)判斷的能力 Error Proofing in a Few Words 預(yù)防錯(cuò)誤的一些方法 “ occurrence of defect was the result of some condition or action, and that it would be possible to eliminate defects entirely by pursuing the cause. The causes of defects lie in worker errors, and defects are the results of

19、neglecting those errors. It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehand.” 缺陷的產(chǎn)生是一些環(huán)境或者行為導(dǎo)致的結(jié)果，但是完全有可能通過查 找原因排除缺陷。缺陷原因在于工人，缺陷是因?yàn)楣と撕鲆曞e(cuò)誤而產(chǎn) 生的。如果工人能及時(shí)的發(fā)現(xiàn)錯(cuò)誤并且消除錯(cuò)誤，就不會(huì)導(dǎo)致缺陷的 產(chǎn)生。 Shigeo Shingo Why Error Proof? 為什么防錯(cuò)？ 99.9% Error Free Could Resul

20、t in 99.9%沒有錯(cuò)誤導(dǎo)致什么結(jié)果 2,000,000 Documents Lost by IRS IRS缺少2，000，000檔案 16,000 Pieces of Mail Lost Every Day 每天丟失16，000郵件 22,000 Wrongly Debited / Credited Checks Per Hour 每個(gè)小時(shí)都會(huì)發(fā)生22，000寫錯(cuò)借方和貸方的支票 1,314 Wrongly Connected Phone Calls Per Minute 每個(gè)小時(shí)都會(huì)發(fā)生1，314起電話占線 20,000 Incorrect Drug Prescriptions Per

21、 Year 每個(gè)小時(shí)都會(huì)發(fā)生20，000起用錯(cuò)藥物的情況 12 Newborn Babies Given to Wrong Parents 12個(gè)小孩被父母抱錯(cuò) 2 Unsafe Landings Every Day at OHare Airport 每天都會(huì)有2起飛機(jī)不安全著陸 32,000 Missed Heartbeats Per Person Each Year 每年每個(gè)人都會(huì)有32，000 Is 99.9% Good Enough? 99.9% 夠不夠好? The Errors That Became Headlines 錯(cuò)誤變成頭條 Titanic Sinking 泰坦尼克號(hào)的沉沒

22、 Challenger Booster Rocket Seal Failure 挑戰(zhàn)者號(hào)火箭發(fā)射失敗 Mars Landing Module Crash 火星升空失敗墜毀 Hubbell Telescope Reflector Error Hubbell望遠(yuǎn)鏡反射誤差 Exxon Valdez Oil Spill Exxon Valdez 石油泄露 Chernobyl Nuclear Power Plant Meltdown Chernobyl Nuclear Power 設(shè)備報(bào)廢 Release of Methyl Isocyanate (MIC) From Union Carbide Pl

23、ant in Bhopal, India 甲基異丙酮從Bhopal, India ,MIC碳化物廠房泄露 Three Mile Island Nuclear Plant 三英里小島的核廠房 Firestone Tires on Ford Explorer 福特車上的耐火石探測(cè)器 Error Proofing and Lean防錯(cuò)及精益生 產(chǎn) Lean Insists on One Piece Flow 精益生產(chǎn)強(qiáng)調(diào)單件流 If That One Piece Is Defective, Flow Is Disrupte 如果單件流有缺陷,流向就會(huì)被打斷 Lean Insists on Limit

24、ed Inventory 精益生產(chǎn)強(qiáng)調(diào)有限庫(kù)存 If That Inventory Is Defective, the Lines Can Sto 如果庫(kù)存有缺陷,線路就會(huì)停止 Lean Means Eliminating Waste 精益是指消除浪費(fèi) Defects and Corrective Actions Are Wast 缺陷以及糾正措施是針對(duì)浪費(fèi) Lean Requires That Equipment Is Ready When Needed and Functions Well As Long As Necessary 精益生產(chǎn)要求當(dāng)需要設(shè)備時(shí),設(shè)備馬上可以用,且功能完好 Er

25、ror Proofing the Tools, Fixtures, Setups, Methods and Documents Ensures Equipment Effectiveness 刀具,卡具,啟動(dòng),方法以及文件等防錯(cuò)以確保設(shè)備的有效性 Error Proofing Examples in Everyday Life 在每天生活中防錯(cuò)的一些例子 Home家里 Automatic Shutoff Irons 全自動(dòng)熨斗 Ground Fault Circuit Breakers for Bathroom or Outdoor Electric Circuits 浴室或室外電氣線路的接地

26、保護(hù) Pilotless Gas Ranges and Hot Water Heaters 油量表以及熱水器 Child-Proof Caps on Medicine Bottles 藥瓶上保護(hù)小孩安全的瓶蓋 Retail零售 Tamper-Proof Packaging 錐型防錯(cuò)包裝 Bar Coding at Checkou 檢驗(yàn)時(shí)的條碼 Office辦公室 Spell Check in Word Processing Software在 Word word處理軟件中進(jìn)行拼寫檢查 Verifying “Do you want to delete?” When Press the “Dele

27、te” Buttonon Your Computer 當(dāng)按刪除按鈕時(shí)電腦會(huì)詢問你“要 刪除嗎”? Factory工廠 Dual Palm Buttons and Other Guards on Machinery 設(shè)備上使用兩個(gè)按扭及其他保護(hù)裝 置 Bar Coding 條碼 Lock-Out / Tag-Out 鎖緊/打開標(biāo)簽 Error Proofing Exercise No. 1 防錯(cuò)練習(xí)的第一部分 Form Teams of Two 兩個(gè)一組 List As Many Examples of Error Proofing As You Can, From Everyday Life

28、從你每天的生活中,列出你能作到的關(guān)于防 錯(cuò)的許多例子 10 Minutes 10分鐘 Application of Error Proofing 防錯(cuò)的應(yīng)用 Essential Steps for Error Proofing 防錯(cuò)的基本步驟 Identify Opportunities for Errors (Critical Factors) 識(shí)別防錯(cuò)的時(shí)機(jī)(關(guān)鍵因素) Prioritize Potential Errors for Error Proofing 對(duì)潛在的錯(cuò)誤加以，區(qū)分進(jìn)行防錯(cuò) Absolutely Must Prevent the Defects 必須完全的防止錯(cuò)誤 Pr

29、ovide Containment and Study Further 預(yù)防錯(cuò)誤和深入研究 May Be Tolerated, Within Predefined Limits 在計(jì)劃的范圍內(nèi)進(jìn)行防錯(cuò) Identify Root Causes of the Errors 識(shí)別錯(cuò)誤根源 Develop and Evaluate Error Proofing Options 開發(fā)和評(píng)估防錯(cuò)方案 Select and “Design” the Error Proofing System 選擇和設(shè)計(jì)防錯(cuò)系統(tǒng) Implement - Plan, Install, Document, Train, Mon

30、itor 實(shí)施防錯(cuò)設(shè)計(jì)反錯(cuò)，安裝防錯(cuò),編制防錯(cuò)文件,培訓(xùn),監(jiān)控 Periodically Assess the Performance and Improve 對(duì)防錯(cuò)情況進(jìn)行定期評(píng)審及改進(jìn) Manufacturing Processes 制造過程制造過程 Product Quality 產(chǎn)品質(zhì)量產(chǎn)品質(zhì)量 Process Design 過程設(shè)計(jì)過程設(shè)計(jì) Product Design 產(chǎn)品設(shè)計(jì)產(chǎn)品設(shè)計(jì) What is the Right Time to Error Proof? 正確的防錯(cuò)時(shí)間是什么時(shí)間? 100:1 10:1 1:1 As Early As Possible 及早發(fā)現(xiàn)及早發(fā)現(xiàn) W

31、hy Error Proof Early During New Product Development 為什么在新產(chǎn)品開發(fā)期間防錯(cuò) Cost of “Fixing” the Defects “修理修理”缺陷的成本缺陷的成本 Concept Development 觀念開發(fā)觀念開發(fā) Preliminary Design 初步設(shè)計(jì)初步設(shè)計(jì) Detailed Product Design 詳細(xì)的產(chǎn)品詳細(xì)的產(chǎn)品 設(shè)計(jì)設(shè)計(jì) Customer Support 客戶支持客戶支持 Industrialization 產(chǎn)業(yè)化產(chǎn)業(yè)化 Production 生產(chǎn)生產(chǎn) Process Design 過程設(shè)計(jì)過程設(shè)計(jì)

32、Cost of “Fixing” 設(shè)備的花費(fèi)設(shè)備的花費(fèi) Multiplies With Life Cycle Stages 整個(gè)過程當(dāng)中的多項(xiàng)防錯(cuò)整個(gè)過程當(dāng)中的多項(xiàng)防錯(cuò) Stages of Product Life Cycle 產(chǎn)品生命周期中各個(gè)階段產(chǎn)品生命周期中各個(gè)階段 Why Error Proof Early During Processing 在處理期間為什么要盡早防錯(cuò) Cost of “Fixing” the Defects設(shè)備成本失效設(shè)備成本失效 Incoming Parts 外協(xié)件外協(xié)件 After Completing the Process 過程完成之后過程完成之后 At t

33、he End of the Line 產(chǎn)品最終離產(chǎn)品最終離 開生產(chǎn)線開生產(chǎn)線 After Delivery to Customer 交付給客戶之交付給客戶之 后后 Final Test 最后檢驗(yàn)最后檢驗(yàn) Cost of “Fixing” Increases With Process Steps 隨著程序步驟增長(zhǎng)修復(fù)錯(cuò)誤成隨著程序步驟增長(zhǎng)修復(fù)錯(cuò)誤成 本增長(zhǎng)本增長(zhǎng) Steps of Product Processing 產(chǎn)品處理的步驟產(chǎn)品處理的步驟 Reject & Return 廢棄件廢棄件 No Delay 沒有拖延沒有拖延 Reject & Scrap 廢棄件廢棄件&廢品廢品 Minor D

34、elay 稍微拖延稍微拖延 Reject & Scrap / Rework 廢棄件廢棄件&廢品廢品/返工返工 Reschedule Some Delay進(jìn)度稍有進(jìn)度稍有 拖延拖延 Significant Rework / Scrap Add to the Production Schedule Delayed Deliveries 重要的返工重要的返工/廢品影響生產(chǎn)進(jìn)度廢品影響生產(chǎn)進(jìn)度 及產(chǎn)品交付及產(chǎn)品交付 Warranty Costs Administrative Costs Liabilities Reputation Market Share Loss擔(dān)保擔(dān)保 成本及管理成本增加成本及管

35、理成本增加,導(dǎo)導(dǎo) 致市場(chǎng)份額損失致市場(chǎng)份額損失 Error Proofing Exercise No. 2 防錯(cuò)訓(xùn)練的第二部分 Form Teams of Two 兩個(gè)一組 Discuss and Agree on One Example of Product Design or Manufacturing Process to Analyze 討論一個(gè)產(chǎn)品設(shè)計(jì)或制造工藝的例子,并進(jìn)行分析 Identify 鑒別 Error Proofing Implemented防錯(cuò)實(shí)施 Estimate Cost / Quality Impact消除成本/質(zhì)量影響 OR或者 Error Proofing

36、Opportunities Missed喪失防錯(cuò)良機(jī) Estimate the Cost / Quality Impact消除成本/質(zhì)量影響 List Lessons Learned學(xué)到的教訓(xùn)清單 Prepare to Present to the Class準(zhǔn)備到課堂上展示 20 Minutes 20分鐘 Identify Opportunities for Errors 識(shí)別防錯(cuò)的時(shí)機(jī) Methods for Identifying Potential Errors 識(shí)別潛在的防錯(cuò)方法 Customer Demanded - Good Start 消費(fèi)者的需求-良好的開始 Internal

37、 Quality Results Reactive 內(nèi)部質(zhì)量成效-反應(yīng) Past Experience - Not Completely Reliable 以往經(jīng)驗(yàn)-不完全可靠 Customer 反饋 - Too Late 消費(fèi)者的反饋-太遲 Systematic Analyses to Identify Potential Errors 識(shí)別潛在的錯(cuò)誤需進(jìn)行系統(tǒng)分析 Potential Failure Mode and Effects Analysis (FMEA) 潛在的失效模式及效果分析(FMEA) Product FMEA 產(chǎn)品FMEA Process FMEA 過程FMEA Pote

38、ntial Failure Mode and Effects Analyses PFMEA 潛在的失效模式和 效果分析 Overview 總攬 Key Points of FMEA FMEA的關(guān)鍵部分 FMEA Analyses Potential Failures FMEA分析潛在失效 Fleas Have to Be Done by Multi-functional Teams Fleas應(yīng)由多功能組執(zhí)行 Design FMEA Should Be Initiated Before or at the Concept Stage 設(shè)計(jì)設(shè)計(jì)FMEA是在開始之前或者概念形成階段 Process

39、 FMEA Should Be Initiated Before or at the Feasibility Stage, Prior to Tooling or Equipment Finalization 過程過程FMEA是在工裝及設(shè)備調(diào)整好開始生產(chǎn)之前或者可研階段 FMEAs Should Be Continuously Updated, As Changes in Product & Process Designs Take Place 應(yīng)該不斷更新,比如FMEAs中的產(chǎn)品&過程設(shè)計(jì) FMEAs Are Living Documents FMEAs 是活的文件 FMEAs Are Ne

40、ver Ending Processes FMEAs 是永遠(yuǎn)都不會(huì)結(jié)束的工藝 FMEA Type and Levels FMEA的類型和水平 Design FMEA 設(shè)計(jì)設(shè)計(jì)FMEA Process FMEA 過程過程FMEA Subsystem 子系統(tǒng)子系統(tǒng) Critical Features 關(guān)鍵特性關(guān)鍵特性 Components / Parts零件零件 Subassemblies 分裝分裝 Workstations 工作臺(tái)工作臺(tái) Operations 加工操作加工操作 FMEA No. Item / ProcessProcess responsibilityPage Part No. /

41、 Drg. No.Key DatePrepared By Core Team: FMEA Date (Orig) Item or Process Function Requirement Potential Failure Mode Potential Effect(s) of Failure Se ver ity Cla ss Potential Cause(s)/ Mechanism(s) of Failure Occ ur Current Process Controls Det ect R. P. N. Recommended Action Responsibility & Targe

42、t Completion Date Potential Failure Mode and Effects Analysis (FMEA) General Information (1)總說(shuō)明總說(shuō)明 2 3 4 5 6 7 810 11 9 12 FMEA Steps FMEA 的步驟 Design FMEA 設(shè)計(jì)設(shè)計(jì)FMEA General Information - Details of the Product & FMEA 信息總說(shuō)明-產(chǎn)品及FMEA的詳情 Item Function / Requirement 項(xiàng)目的功能/要求 Enter All Functions of a Produ

43、ct Item 鍵入所有產(chǎn)品的功能 Potential Failure Mode 潛在的故障模式 Describe How a Product Item Could Fail 描述產(chǎn)品怎樣失效 Use Physical Terms, Not Symptoms 使用專用描述詞語(yǔ),不是癥狀 Process FMEA 過程過程FMEA General Information - Details of the Product & FMEA 信息總說(shuō)明- -產(chǎn)品的詳細(xì)資料和FMEA Process Function 過程功能 Enter Description & Purpose of the Proc

44、ess 鍵入過程描述和過程功能 Potential Failure Mode 潛在失效模式 Describe How Process Could Fail to Meet Requirements of Subsequent Operations 描述工藝為什么不能滿足分序要求 Describe Non-conformance 描述不一致性 FMEA Steps FMEA的步驟 Design FMEA 設(shè)計(jì)設(shè)計(jì)FMEA Potential Effect(s) of Failure 潛在失效效果 Perceived by Customer 客戶需要 Severity (Chart) 嚴(yán)肅性（圖表

45、） Seriousness of the Effect of Potential Failure 潛在失效效果的嚴(yán)肅性 Severity Ranking Reduced Only by Design Change 只有設(shè)計(jì)更改時(shí)嚴(yán)肅性級(jí)別降低 Classification分類 Safety / Regulation or Function / Appearance Based 安全/規(guī)定或功能/基本表象 Employ Customers Criteria 采用客戶標(biāo)準(zhǔn) Process FMEA 過程過程FMEA Potential Effect(s) of Failure 潛在失效效果 Per

46、ceived by Customer, Including Subsequent Operations 客戶需要,包括下述操作 Severity (Chart) 嚴(yán)肅性(圖表) Seriousness of the Effect of Potential Failure 潛在失效效果的嚴(yán)肅性 Classification分類 Safety / Regulation or Function / Appearance Based 安全/規(guī)定或功能/基本表象 Employ Customers Criteria 采用客戶標(biāo)準(zhǔn) Severity Rating Chart 嚴(yán)肅性級(jí)別表格 Descript

47、ion 描述描述 Definition定義定義 Rating 等級(jí)等級(jí) Dangerously High最高Failure could injure the customer or an employee.失效可以傷害客戶或員工 10 Extremely High 極高 Failure would create noncompliance with federal regulations.可以通過失效創(chuàng) 建不一致的規(guī)定 9 Very High 非常高 Failure renders the unit inoperable or unfit for use.失效是由于非正常操作或非 正常使用所導(dǎo)

48、致的 8 High高 Failure causes a high degree of customer dissatisfaction.失效導(dǎo)致客戶高度 不滿 7 Moderate一般 Failure results in a subsystem or partial malfunction of the product.失效導(dǎo)致分 系統(tǒng)或產(chǎn)品部分功能失效. 6 Low低 Failure creates enough of a performance loss to cause the customer to complain.失效導(dǎo)致績(jī)效損失,造成客戶抱怨 5 Very Low非常 低 Fa

49、ilure can be overcome with modifications to the customers process or product, but there is minor performance loss.可以通過對(duì)客戶工藝或產(chǎn)品進(jìn)行 修改來(lái)克服失效,但會(huì)有少量績(jī)效損失. 4 Minor次要的 Failure would create a minor nuisance to the customer, but the customer can overcome it in the process or product without performance loss.失效

50、可能會(huì)導(dǎo) 致對(duì)客戶有少量影響,但是客戶可以在產(chǎn)品或工藝中進(jìn)行克服,且沒有績(jī)效損失 3 Very Minor極次 要的 Failure may not be readily apparent to the customer, but would have minor effects on the customers process or product.失效不會(huì)很容易轉(zhuǎn)移到客戶,對(duì) 客戶的產(chǎn)品或工藝會(huì)有稍微影響. 2 None無(wú) Failure would not be noticeable to the customer and would not affect the customers p

51、rocess or product.客戶不會(huì)發(fā)現(xiàn)失效,也不會(huì)影響客戶的工藝及 產(chǎn)品. 1 FMEA Steps FMEA步驟 Design FMEA 設(shè)計(jì)設(shè)計(jì)FMEA Potential Cause(s) 潛在原因 List All the Causes (Design Weaknesses)列出 所有原因(設(shè)計(jì)弱點(diǎn)) Occurrence (Chart) 頻率(圖表) Likelihood of the Failure to Occur by the Specific Cause 特殊原因?qū)е率У目赡苄?Occurrence Ranking Reduced Only by Design C

52、hange 僅當(dāng)設(shè)計(jì)更改時(shí)才考慮降低發(fā)生頻率. Design Control 設(shè)計(jì)控制 Validation / Verification Activities Which Will Assure Adequacy of Design 驗(yàn)證/確認(rèn)活動(dòng)應(yīng)確保設(shè)計(jì)的準(zhǔn)確性 Process FMEA 過程過程FMEA Potential Cause(s) 潛在原因 Identify Root Cause, and Identify What Can Be Corrected 確定原因,確定可以采取什么糾正措施 Occurrence (Chart) 頻率(圖表) Expected Frequency

53、of Failure to Occur by Specific Cause 具體原因?qū)е率Оl(fā)生的頻率 Classification (Chart)類別 Process Controls That Prevent or Detect the Failure 預(yù)防或探測(cè)缺陷的過程控制 Occurrence Rating Chart 頻率等級(jí)表格 Description描述描述Potential Failure Rate 潛在的失效等級(jí)潛在的失效等級(jí)Rating等級(jí)等級(jí) More than one occurrence per day or a probability of more than t

54、hree occurrences in 10 events (Cpk 2.00).每5年或5年以上發(fā)生一次或每10萬(wàn)個(gè)事件 (Cpk 2.00)中發(fā)生的 頻率低于2次1 Very High: Failure is almost inevitable非常 高：失效是不可避免 的 High: Repeated Failures 高：重復(fù)故障 Low: Relatively Few Failures低：相對(duì)少的 故障 Moderate: Occasional Failures 中等：偶發(fā)故障 FMEA Steps FMEA 的步驟 Design FMEA 設(shè)計(jì)設(shè)計(jì)FMEA Detection (Ch

55、art) 檢測(cè)（圖表） Ability of a Current Design Control to Identify a Potential Cause 現(xiàn)行控制設(shè)計(jì)能力,以識(shí)別潛在的原因 當(dāng)前設(shè)計(jì)的能力 Process FMEA 過程過程FMEA Detection (Chart) 檢測(cè)（圖表） Assuming Failure Has Occurred, Assess Detection Capability of All the Process Controls 假設(shè)發(fā)生失效,應(yīng)檢測(cè)所有工藝控制的能力 4 RPN (Risk Priority No.) 4 RPN(風(fēng)險(xiǎn)優(yōu)先號(hào)) 4Pr

56、oduct of S (Severity), O (Occurrence) & D (Detection) 4產(chǎn)品的S(嚴(yán)重性),O(發(fā)生頻率)&D(檢測(cè)) 4Used As a Guide to Help Rank Design / Process Concerns 4為進(jìn)行設(shè)計(jì)及過程等級(jí)等提供向?qū)?4No Threshold Value 4無(wú)界限值 4Pay Special Attention If Severity Is High 4如果嚴(yán)重級(jí)別高的話,應(yīng)提高警惕 4 Corrective Action, Responsibility, and Monitoring Results 4

57、實(shí)施糾正措施,確定責(zé)任人,監(jiān)控結(jié)果 11 12 Detection Rating Chart 檢測(cè)等級(jí)表 Description描描 述述 Definition定義定義 Rating 等級(jí)等級(jí) Absolute Uncertainty 完全 不確定 The product is not inspected or the defect caused by failure is not detectable. 產(chǎn) 品沒有檢驗(yàn)或失效導(dǎo)致的缺陷不可以檢測(cè) 10 Very Remote 比 較不確定 Product is sampled, inspected, and released based on

58、 Acceptable Quality Level (AQL) sampling plans. 根據(jù)接收質(zhì)量水平樣件計(jì)劃產(chǎn)品已經(jīng)進(jìn)行了樣件選擇，檢測(cè) 以及發(fā)放 9 Remote不確定 Product is accepted based on no defectives in a sample.根據(jù)樣件沒有缺陷，據(jù)此 接收了產(chǎn)品 8 Very Low 比較 確定 Product is 100% manually inspected in the process.在工藝上100對(duì)件進(jìn)行了手 動(dòng)檢驗(yàn) 7 Low一般確定 Product is 100% manually inspected using

59、 go/no-go or other error-proofing gauges.通過通/止規(guī)或其他防錯(cuò)量具對(duì)產(chǎn)品進(jìn)行了手動(dòng)檢驗(yàn) 6 Moderate確定 Some Statistical Process Control (SPC) is used in process and product is final inspected off-line. 工藝上使用了一些統(tǒng)計(jì)過程控制，產(chǎn)品最終下線時(shí)進(jìn)行了最終檢 驗(yàn) 5 Moderately High 很確定 SPC is used and there is immediate reaction to out-of-control conditio

60、ns.使用了統(tǒng) 計(jì)技術(shù)控制，對(duì)于不符合條件的件進(jìn)行了立即處理 4 High非常確定 An effective SPC program is in place with process capabilities (Cpk) greater than 1.33.實(shí)施了有效的統(tǒng)計(jì)技術(shù)控制項(xiàng)目，工藝能力(Cpk) 大于1.33. 3 Very High 極為 確定All product is 100% automatically inspected. 所有的產(chǎn)品進(jìn)行100自動(dòng)檢驗(yàn) 2 Summarized Rating Chart 總結(jié)等級(jí)表 Rating 等級(jí)等級(jí) Severity of Effec