質(zhì)量改善防錯(cuò)培訓(xùn)教材

1、14/11/03Error Proofing防錯(cuò)防錯(cuò)24/11/03Topics - Error Proofing TrainingDuration時(shí)間區(qū)間時(shí)間區(qū)間Start開(kāi)始時(shí)間開(kāi)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 AMWhat 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 AMCoffee Break中間休息中間休息0:159:15

2、 AMApplication 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 AMIdentify 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 AMError Proofing Options0:3011:30 AM 防錯(cuò)方案1:0010:30 AMLunch Break 午休午休0:4512:00 PMError Proofing Options (continue)

3、 Exercise 41:0012:45 PM防錯(cuò)方案(續(xù))練習(xí)41:0012:45 PMActivities 措施措施34/11/03Topics主題主題4 Objectives of the Training4 培訓(xùn)的目的4 What and Why of Error Proofing4 什么是防錯(cuò)，怎樣進(jìn)行防錯(cuò)4 Application of Error Proofing4 防錯(cuò)應(yīng)用4Identify Opportunities for Errors4防錯(cuò)時(shí)機(jī)的確定8Overview of Failure Mode and Effects Analysis (FMEA)8失效模式和效果分

4、析總括4Error Proofing Options4防錯(cuò)的選擇4Prevention & Detection Through Poka Yoke Devices4通過(guò)Poka Yoke進(jìn)行預(yù)防與探測(cè)4 Move to The Next Level4 轉(zhuǎn)入下一級(jí)4A Benchmark Within Eaton4伊頓內(nèi)部標(biāo)準(zhǔn)4 Summary4 概要44/11/03Objectives of the Training培訓(xùn)的目的培訓(xùn)的目的4Understand What Is Error Proofing and What It Can Do4了解什么是防錯(cuò)和防錯(cuò)能做什么4Underst

5、and the Principles of Error Proofing4了解防錯(cuò)的原理4Learn How to Apply Error Proofing to Products and Processes4了解怎樣對(duì)產(chǎn)品及工藝過(guò)程應(yīng)用防錯(cuò)4Learn About the Poka Yoke Devices and Systems4了解Poka Yoke裝置和系統(tǒng)4Learn the Process of Implementation and Continuous Improvements4了解實(shí)施防錯(cuò)的過(guò)程和持續(xù)改進(jìn)的過(guò)程54/11/03What Are Your Expectations

6、?你們的期望是什么？你們的期望是什么？64/11/03What and Why of Error Proofing什么是防錯(cuò)以及為什么要防錯(cuò)什么是防錯(cuò)以及為什么要防錯(cuò)74/11/03Definition定義定義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

7、錯(cuò))84/11/03Error Proofing by Other Names以其他名稱(chēng)進(jìn)行防錯(cuò)以其他名稱(chēng)進(jìn)行防錯(cuò)4Fool Proofing防止愚蠢行為4Idiot Proofing防止白癡行為4Mistake Proofing防止錯(cuò)誤行為4Fail Safing安全失效4Poka Yoke4Zero Quality Control (Zero Defects)4零質(zhì)量控制（零缺陷）4Design for Manufacture and Assembly4制造和裝配的設(shè)計(jì)Let Us Not Argue the Merits of These NamesLet Us Decide What

8、We Want to Achieve我們不要爭(zhēng)論這些名稱(chēng),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)94/11/03Characteristics of Error Proofing防錯(cuò)的特點(diǎn)防錯(cuò)的特點(diǎn)4 Proactive Identification and Prevention前期識(shí)別及預(yù)防4Prevent First首先進(jìn)行防錯(cuò)4Do Not Allow Defect From Going Further4其次不準(zhǔn)許缺陷進(jìn)一步發(fā)展4 Intentionally Designed, Not Happenstance4 設(shè)計(jì)錯(cuò)誤,非偶然錯(cuò)誤.4 At th

9、e Source - Close to the Origination 4 錯(cuò)誤的來(lái)源_接近發(fā)源地.4 Inexpensive First 首先成本不高4 Transparent to the Operator 操作者很容易發(fā)現(xiàn)4 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104/11/034 Defects in Products Are the Imperfections (or Faults, or Flaws, or Blemishes, or Shortcomings

10、, or Failings, or Deficiencies) 4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(guò)失4 ，或者不足)4 Resulting From Errors4 錯(cuò)誤產(chǎn)生的結(jié)果4 Errors Are Human Oversights (or Faults, or Blunders, or Boo-boos, or Slip-ups, or Inaccuracies or Miscalculations) That Cause Defects in Products4錯(cuò)誤錯(cuò)誤是人為疏忽(或者過(guò)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

11、計(jì)算4 失誤)，這些引起產(chǎn)品的缺陷。Defects and Errors 缺陷和錯(cuò)誤缺陷和錯(cuò)誤SO, Errors Cause Defective Products!所以,錯(cuò)誤導(dǎo)致有缺陷的產(chǎn)品產(chǎn)生!114/11/03Why Are Errors Made為什么會(huì)導(dǎo)致錯(cuò)誤為什么會(huì)導(dǎo)致錯(cuò)誤4 Any Product Is a Result of Numerous Decisions Made and Actions Taken by Human Beings, During:4 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：4Product Design4產(chǎn)品設(shè)計(jì)4Process Design4過(guò)

12、程設(shè)計(jì)4Equipment Design4設(shè)備設(shè)計(jì)4Component Fabrication Processes4零件加工過(guò)程4Product Assembly Processes4產(chǎn)品裝配過(guò)程4Inspection Processes4檢驗(yàn)過(guò)程4Paperwork Generation4程序行程過(guò)程4Etc.等等And Human Beings are Fallible or Imperfect人是容易犯錯(cuò)或不完美的124/11/03SOME Examples of Defects屬于缺陷的一些例子屬于缺陷的一些例子4 Wrong or Inappropriate Material4 錯(cuò)誤

13、或不適合的材料4 Wrong or Non-functioning Components4 錯(cuò)誤或者沒(méi)有功能的零件4 Wrong Dimensions or Tolerances4 尺寸或公差錯(cuò)誤4 Missing Components4 零件漏裝4 Foreign Matters, Contamination4 雜質(zhì)物質(zhì),污穢物4 Damaged Product or Components4 受損產(chǎn)品或零件4 Wrong Paperwork, or Wrong Product Shipped4 程序錯(cuò)誤或者運(yùn)輸了錯(cuò)誤的產(chǎn)品4 Non-functioning or Malfunctioning

14、 Product4 沒(méi)有功能的產(chǎn)品或者是故障產(chǎn)品4 Wrong Shipping, or Wrong Billing4 運(yùn)輸錯(cuò)誤或者是填單錯(cuò)誤134/11/03SOME Examples of Causes of Defects導(dǎo)致缺陷的一些例子導(dǎo)致缺陷的一些例子4 Poor Design Decisions4 設(shè)計(jì)比較乏味4 Omitted or Wrong Processing4 過(guò)程疏忽或過(guò)程錯(cuò)誤4 Missing / Extra Parts or Wrong Parts4 漏裝/多裝了錯(cuò)誤的零件4 Omitted or Wrong Adjustment / Testing 4 遺漏調(diào)整

15、/測(cè)試或調(diào)整/測(cè)試過(guò)程錯(cuò)誤4 Wrong Equipment Setup or Loss of Setup4 設(shè)備設(shè)置錯(cuò)誤或沒(méi)有進(jìn)行設(shè)備設(shè)置4 Wrong Material, Components or Assemblies4 材料，零件或者裝配錯(cuò)誤4 Wrong Communication, Instructions, Procedures, or Methods4 錯(cuò)誤的信息，指令，程序，或者方法4 Inexperience, Lack of Training, Wrong Training, Lack of Retraining4 缺乏經(jīng)驗(yàn)，缺乏培訓(xùn)，培訓(xùn)錯(cuò)誤，缺少再培訓(xùn)144/11/0

16、3SOME Examples of Results of Defects缺陷導(dǎo)致的結(jié)果示例缺陷導(dǎo)致的結(jié)果示例4 Malfunction or Non-functioning Product4 有故障或者缺乏機(jī)能的產(chǎn)品4 Inconvenience, Discomfort, Injury, Death4 麻煩，不便，傷害，死亡4 Delays, Cancellations4 延期，取消4 Financial Losses4 財(cái)政損失4Loss of Use or Productivity4效用或者生產(chǎn)力的缺乏4Damage to Customers Property4損害客戶的利益4Liabil

17、ities and Law Suites4負(fù)債和法律問(wèn)題4 Loss of Reputation and Business4 名譽(yù)和業(yè)務(wù)受損154/11/03SOME Causes of Human Errors導(dǎo)致人們犯錯(cuò)誤的一些原因?qū)е氯藗兎稿e(cuò)誤的一些原因4 Forgetfulness, Loss of Concentration, Lack of Attention or Diverted Attention4 健忘，不集中，缺乏注意力或者轉(zhuǎn)移注意力4 Misunderstanding or Lack of Understanding4 誤會(huì)或者缺乏理解4 Lack of or Impr

18、oper Experience / Training4 缺乏經(jīng)驗(yàn)/培訓(xùn)或者不正確的經(jīng)驗(yàn)/培訓(xùn)4 Lack of Standardization4 缺乏標(biāo)準(zhǔn)4 Intentional or Willful Error4 有意圖的或者惡意的錯(cuò)誤4 Wrong or Delayed Decision4 決定錯(cuò)誤或拖延4 Limited or Lack of Sensory Capability (e.g., Smell, Color, Touch)4 有限的或者沒(méi)有感官能力（例如，嗅覺(jué)，色彩，觸覺(jué)）4 Lack of Application of Common Sense4 缺乏運(yùn)用常識(shí)判斷的能力1

19、64/11/03Error Proofing in a Few Words預(yù)防錯(cuò)誤的一些方法預(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 neglecting those err

20、ors. 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(guò)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 Shingo174/11/03Why Error Proof?為什么防錯(cuò)？為什么防錯(cuò)？4 99.9% Error Free Could Result in 4 99.9

21、%沒(méi)有錯(cuò)誤導(dǎo)致什么結(jié)果42,000,000 Documents Lost by IRS IRS缺少2，000，000檔案416,000 Pieces of Mail Lost Every Day 每天丟失16，000郵件422,000 Wrongly Debited / Credited Checks Per Hour4每個(gè)小時(shí)都會(huì)發(fā)生22，000寫(xiě)錯(cuò)借方和貸方的支票41,314 Wrongly Connected Phone Calls Per Minute4每個(gè)小時(shí)都會(huì)發(fā)生1，314起電話占線420,000 Incorrect Drug Prescriptions Per Year4每個(gè)小

22、時(shí)都會(huì)發(fā)生20，000起用錯(cuò)藥物的情況412 Newborn Babies Given to Wrong Parents412個(gè)小孩被父母抱錯(cuò)42 Unsafe Landings Every Day at OHare Airport4每天都會(huì)有2起飛機(jī)不安全著陸432,000 Missed Heartbeats Per Person Each Year4每年每個(gè)人都會(huì)有32，000Is 99.9% Good Enough? 99.9% 夠不夠好?184/11/03The Errors That Became Headlines錯(cuò)誤變成頭條錯(cuò)誤變成頭條4 Titanic Sinking4 泰坦尼

23、克號(hào)的沉沒(méi)4 Challenger Booster Rocket Seal Failure4 挑戰(zhàn)者號(hào)火箭發(fā)射失敗4 Mars Landing Module Crash4 火星升空失敗墜毀4 Hubbell Telescope Reflector Error4 Hubbell望遠(yuǎn)鏡反射誤差4 Exxon Valdez Oil Spill4 Exxon Valdez 石油泄露4 Chernobyl Nuclear Power Plant Meltdown4 Chernobyl Nuclear Power 設(shè)備報(bào)廢4 Release of Methyl Isocyanate (MIC) From

24、Union Carbide Plant in Bhopal, India4 甲基異丙酮從Bhopal, India ,MIC碳化物廠房泄露4 Three Mile Island Nuclear Plant 4 三英里小島的核廠房4 Firestone Tires on Ford Explorer4 福特車(chē)上的耐火石探測(cè)器194/11/03Error Proofing and Lean防錯(cuò)及精益生產(chǎn)防錯(cuò)及精益生產(chǎn)4 Lean Insists on One Piece Flow4 精益生產(chǎn)強(qiáng)調(diào)單件流4If That One Piece Is Defective, Flow Is Disrupte4

25、如果單件流有缺陷,流向就會(huì)被打斷4 Lean Insists on Limited Inventory4 精益生產(chǎn)強(qiáng)調(diào)有限庫(kù)存 If That Inventory Is Defective, the Lines Can Sto4如果庫(kù)存有缺陷,線路就會(huì)停止4 Lean Means Eliminating Waste4 精益是指消除浪費(fèi)4Defects and Corrective Actions Are Wast4缺陷以及糾正措施是針對(duì)浪費(fèi)4 Lean Requires That Equipment Is Ready When Needed and Functions Well As Long

26、 As Necessary4 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4Error Proofing the Tools, Fixtures, Setups, Methods and Documents Ensures Equipment Effectiveness 4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204/11/03Error Proofing Examples in Everyday Life在每天生活中防錯(cuò)的一些例子在每天生活中防錯(cuò)的一些例子4Home家里4Automatic Shutoff Irons4全自動(dòng)熨斗4Ground Fault Circui

27、t Breakers for Bathroom or Outdoor Electric Circuits4浴室或室外電氣線路的接地保護(hù)4Pilotless Gas Ranges and Hot Water Heaters4油量表以及熱水器4Child-Proof Caps on Medicine Bottles4藥瓶上保護(hù)小孩安全的瓶蓋4Retail零售4Tamper-Proof Packaging4錐型防錯(cuò)包裝4Bar Coding at Checkou4檢驗(yàn)時(shí)的條碼4Office辦公室4Spell Check in Word Processing Software在 Word 4word處

28、理軟件中進(jìn)行拼寫(xiě)檢查4Verifying “Do you want to delete?” When Press the “Delete” Buttonon Your Computer4當(dāng)按刪除按鈕時(shí)電腦會(huì)詢問(wèn)你“要?jiǎng)h除嗎”?4Factory工廠4Dual Palm Buttons and Other Guards on Machinery 4設(shè)備上使用兩個(gè)按扭及其他保護(hù)裝置4Bar Coding4條碼4Lock-Out / Tag-Out 4鎖緊/打開(kāi)標(biāo)簽214/11/03Error Proofing Exercise No. 1防錯(cuò)練習(xí)的第一部分防錯(cuò)練習(xí)的第一部分4Form Teams o

29、f Two4兩個(gè)一組4List As Many Examples of Error Proofing As You Can, From Everyday Life4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410 Minutes410分鐘224/11/03Application of Error Proofing防錯(cuò)的應(yīng)用防錯(cuò)的應(yīng)用234/11/03Essential Steps for Error Proofing防錯(cuò)的基本步驟防錯(cuò)的基本步驟4 Identify Opportunities for Errors (Critical Factors)4 識(shí)別防錯(cuò)的時(shí)機(jī)(關(guān)鍵因素)4 P

30、rioritize Potential Errors for Error Proofing4 對(duì)潛在的錯(cuò)誤加以，區(qū)分進(jìn)行防錯(cuò)4Absolutely Must Prevent the Defects4必須完全的防止錯(cuò)誤4Provide Containment and Study Further4預(yù)防錯(cuò)誤和深入研究4May Be Tolerated, Within Predefined Limits4在計(jì)劃的范圍內(nèi)進(jìn)行防錯(cuò)4 Identify Root Causes of the Errors4 識(shí)別錯(cuò)誤根源4 Develop and Evaluate Error Proofing Options

31、 4 開(kāi)發(fā)和評(píng)估防錯(cuò)方案4 Select and “Design” the Error Proofing System4 選擇和設(shè)計(jì)防錯(cuò)系統(tǒng)4 Implement - Plan, Install, Document, Train, Monitor4 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4 Periodically Assess the Performance and Improve4 對(duì)防錯(cuò)情況進(jìn)行定期評(píng)審及改進(jìn)244/11/03Manufacturing Processes制造過(guò)程制造過(guò)程Product Quality產(chǎn)品質(zhì)量產(chǎn)品質(zhì)量Process Design過(guò)程設(shè)計(jì)過(guò)程設(shè)

32、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)間正確的防錯(cuò)時(shí)間是什么時(shí)間?100:110:11:1As Early As Possible及早發(fā)現(xiàn)及早發(fā)現(xiàn)254/11/03Why Error Proof Early During New Product Development為什么在新產(chǎn)品開(kāi)發(fā)期間防錯(cuò)為什么在新產(chǎn)品開(kāi)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(kāi)發(fā)觀念開(kāi)發(fā)Preliminary Des

33、ign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(guò)程設(shè)計(jì)過(guò)程設(shè)計(jì)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(guò)程當(dāng)中的多項(xiàng)防錯(cuò)整個(gè)過(guò)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264/11/03Why Error Proof Early During

34、 Processing在處理期間為什么要盡早防錯(cuò)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(guò)程完成之后過(guò)程完成之后At the End of the Line產(chǎn)品最終離產(chǎn)品最終離開(kāi)生產(chǎn)線開(kāi)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

35、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(méi)有拖延沒(méi)有拖延Reject & Scrap廢棄件廢棄件&廢品廢品Minor Delay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RescheduleSome Delay進(jìn)度稍有進(jìn)度稍有拖延拖延Significant Rework / ScrapAdd to the Production ScheduleDelayed Deliverie

36、s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 CostsAdministrative CostsLiabilitiesReputationMarket Share Loss擔(dān)保擔(dān)保成本及管理成本增加成本及管理成本增加,導(dǎo)導(dǎo)致市場(chǎng)份額損失致市場(chǎng)份額損失274/11/03Error Proofing Exercise No. 2防錯(cuò)訓(xùn)練的第二部分防錯(cuò)訓(xùn)練的第二部分4 Form Teams of Two4 兩個(gè)一組4 Discuss and Agree on One Example of Product Design or Manufacturing

37、Process to Analyze4 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4 Identify 4 鑒別4Error Proofing Implemented防錯(cuò)實(shí)施4Estimate Cost / Quality Impact消除成本/質(zhì)量影響OR或者4Error Proofing Opportunities Missed喪失防錯(cuò)良機(jī)4Estimate the Cost / Quality Impact消除成本/質(zhì)量影響4 List Lessons Learned學(xué)到的教訓(xùn)清單4 Prepare to Present to the Class準(zhǔn)備到課堂上展示4 20 Minutes

38、4 20分鐘284/11/03Identify Opportunities for Errors識(shí)別防錯(cuò)的時(shí)機(jī)識(shí)別防錯(cuò)的時(shí)機(jī)294/11/03Methods for Identifying Potential Errors識(shí)別潛在的防錯(cuò)方法識(shí)別潛在的防錯(cuò)方法4 Customer Demanded - Good Start4 消費(fèi)者的需求-良好的開(kāi)始4 Internal Quality Results Reactive4 內(nèi)部質(zhì)量成效-反應(yīng)4 Past Experience - Not Completely Reliable4 以往經(jīng)驗(yàn)-不完全可靠4 Customer 反饋 - Too Late

39、4 消費(fèi)者的反饋-太遲4 Systematic Analyses to Identify Potential Errors4 識(shí)別潛在的錯(cuò)誤需進(jìn)行系統(tǒng)分析4Potential Failure Mode and Effects Analysis (FMEA)4潛在的失效模式及效果分析(FMEA)8Product FMEA 8產(chǎn)品FMEA8Process FMEA8過(guò)程FMEA304/11/03Potential Failure Mode and Effects AnalysesPFMEA潛在的失效模式和潛在的失效模式和 效果分析效果分析Overview總攬314/11/03Key Points

40、of FMEAFMEA的關(guān)鍵部分的關(guān)鍵部分4 FMEA Analyses Potential Failures4 FMEA分析潛在失效4 Fleas Have to Be Done by Multi-functional Teams4 Fleas應(yīng)由多功能組執(zhí)行4 Design FMEA Should Be Initiated Before or at the Concept Stage4 設(shè)計(jì)設(shè)計(jì)FMEA是在開(kāi)始之前或者概念形成階段4 Process FMEA Should Be Initiated Before or at the Feasibility Stage, Prior to T

41、ooling or Equipment Finalization4 過(guò)程過(guò)程FMEA是在工裝及設(shè)備調(diào)整好開(kāi)始生產(chǎn)之前或者可研階段4 FMEAs Should Be Continuously Updated, As Changes in Product & Process Designs Take Place 4 應(yīng)該不斷更新,比如FMEAs中的產(chǎn)品&過(guò)程設(shè)計(jì) 4FMEAs Are Living Documents 4FMEAs 是活的文件4FMEAs Are Never Ending Processes 4FMEAs 是永遠(yuǎn)都不會(huì)結(jié)束的工藝324/11/03FMEA Type

42、and LevelsFMEA的類(lèi)型和水平的類(lèi)型和水平Design FMEA設(shè)計(jì)設(shè)計(jì)FMEAProcess FMEA過(guò)程過(guò)程FMEASubsystem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334/11/03FMEA No.Item / ProcessProcess responsibilityPage Part No. / Drg. No.Key DatePrepared ByCore Team: FMEA Date (Or

43、ig)Item orProcessFunctionRequirementPotentialFailure ModePotential Effect(s) ofFailureSeverityClassPotential Cause(s)/Mechanism(s) ofFailureOccurCurrent ProcessControlsDetectR.P.N.RecommendedActionResponsibility &TargetCompletionDatePotential Failure Mode and Effects Analysis (FMEA)General Infor

44、mation (1)總說(shuō)明總說(shuō)明23456781011912344/11/03FMEA Steps FMEA 的步驟的步驟Design FMEA設(shè)計(jì)設(shè)計(jì)FMEAGeneral 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4 Enter All Functions of a Product Item4 鍵入所有產(chǎn)品的功能 Potential Failure Mode 潛在的故障模式4 Describe How a Product Item

45、Could Fail4 描述產(chǎn)品怎樣失效8 Use Physical Terms, Not Symptoms8 使用專(zhuān)用描述詞語(yǔ),不是癥狀Process FMEA過(guò)程過(guò)程FMEAGeneral 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(guò)程功能4 Enter Description & Purpose of the Process4 鍵入過(guò)程描述和過(guò)程功能 Potential Failure Mode 潛在失效模式4 Describe How Process

46、 Could Fail to Meet Requirements of Subsequent Operations4 描述工藝為什么不能滿足分序要求8Describe Non-conformance8描述不一致性354/11/03FMEA Steps FMEA的步驟的步驟Design FMEA設(shè)計(jì)設(shè)計(jì)FMEAPotential Effect(s) of Failure潛在失效效果4Perceived by Customer4客戶需要 Severity (Chart) 嚴(yán)肅性（圖表）4Seriousness of the Effect of Potential Failure4潛在失效效果的嚴(yán)肅

47、性4Severity Ranking Reduced Only by Design Change4只有設(shè)計(jì)更改時(shí)嚴(yán)肅性級(jí)別降低 Classification分類(lèi)4Safety / Regulation or Function / Appearance Based4 安全/規(guī)定或功能/基本表象8Employ Customers Criteria8 采用客戶標(biāo)準(zhǔn)Process FMEA過(guò)程過(guò)程FMEA Potential Effect(s) of Failure 潛在失效效果4Perceived by Customer, Including Subsequent Operations4客戶需要,包

48、括下述操作 Severity (Chart) 嚴(yán)肅性(圖表)4Seriousness of the Effect of Potential Failure4潛在失效效果的嚴(yán)肅性 Classification分類(lèi)4Safety / Regulation or Function / Appearance Based4安全/規(guī)定或功能/基本表象8 Employ Customers Criteria8 采用客戶標(biāo)準(zhǔn)364/11/03Severity Rating Chart嚴(yán)肅性級(jí)別表格嚴(yán)肅性級(jí)別表格Description描述描述Definition定義定義Rating等級(jí)等級(jí)DangerouslyH

49、igh最高Failure could injure the customer or an employee.失效可以傷害客戶或員工10Extremely High極高Failure would create noncompliance with federal regulations.可以通過(guò)失效創(chuàng)建不一致的規(guī)定9Very 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)致的8High高Failure causes a high degree of customer dissatisfa

50、ction.失效導(dǎo)致客戶高度不滿7Moderate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.6Low低Failure creates enough of a performance loss to cause the customer tocomplain.失效導(dǎo)致績(jī)效損失,造成客戶抱怨5Very Low非常低Failure can be overcome with modifications to the customers process orproduct

51、, but there is minor performance loss.可以通過(guò)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.4Minor次要的Failure would create a minor nuisance to the customer, but the customer canovercome it in the process or product without performance loss.失效可能會(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(méi)有績(jī)效損失3Very Minor極次要的Failure may not be readily

52、apparent to the customer, but would have minoreffects 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.2None無(wú)Failure would not be noticeable to the customer and would not affect thecustomers process 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.1374/11/03FMEA Steps FMEA步驟步驟Design FMEA 設(shè)計(jì)設(shè)計(jì)FMEA P

53、otential Cause(s) 潛在原因4 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)4 Likelihood of the Failure to Occur by the Specific Cause4 特殊原因?qū)е率У目赡苄? Occurrence Ranking Reduced Only by Design Change4 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4 Validation / Verification Activities Whi

54、ch Will Assure Adequacy of Design4 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(guò)程過(guò)程FMEA Potential Cause(s) 潛在原因4 Identify Root Cause, and Identify What Can Be Corrected4 確定原因,確定可以采取什么糾正措施Occurrence (Chart)頻率(圖表)4 Expected Frequency of Failure to Occur by Specific Cause 4 具體原因?qū)е率Оl(fā)生的頻率Classification (Chart)類(lèi)別4 Proc

55、ess Controls That Prevent or Detect the Failure4 預(yù)防或探測(cè)缺陷的過(guò)程控制384/11/03Occurrence Rating Chart 頻率等級(jí)表格頻率等級(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 three occurrences in10 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.

56、00)中發(fā)生的頻率低于2次1Very High: Failure isalmost inevitable非常高：失效是不可避免的High: RepeatedFailures高：重復(fù)故障Low: Relatively FewFailures低：相對(duì)少的故障Moderate: OccasionalFailures中等：偶發(fā)故障394/11/03FMEA Steps FMEA 的步驟的步驟Design FMEA設(shè)計(jì)設(shè)計(jì)FMEA Detection (Chart) 檢測(cè)（圖表）4Ability of a Current Design Control to Identify a Potential Ca

57、use4現(xiàn)行控制設(shè)計(jì)能力,以識(shí)別潛在的原因4當(dāng)前設(shè)計(jì)的能力Process FMEA過(guò)程過(guò)程FMEA Detection (Chart) 檢測(cè)（圖表）4Assuming Failure Has Occurred, Assess Detection Capability of All the Process Controls4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))4Product of S (Severity), O (Occurrence) & D (Detection)4產(chǎn)品的S(嚴(yán)重性),O(發(fā)生頻率)&am

58、p;D(檢測(cè))4Used As a Guide to Help Rank Design / Process Concerns4為進(jìn)行設(shè)計(jì)及過(guò)程等級(jí)等提供向?qū)?No Threshold Value4無(wú)界限值4Pay Special Attention If Severity Is High4如果嚴(yán)重級(jí)別高的話,應(yīng)提高警惕4 Corrective Action, Responsibility, and Monitoring Results4 實(shí)施糾正措施,確定責(zé)任人,監(jiān)控結(jié)果1112404/11/03Detection Rating Chart檢測(cè)等級(jí)表檢測(cè)等級(jí)表Description描描述述De

59、finition定義定義Rating等級(jí)等級(jí)AbsoluteUncertainty 完全不確定The product is not inspected or the defect caused by failure is not detectable. 產(chǎn)品沒(méi)有檢驗(yàn)或失效導(dǎo)致的缺陷不可以檢測(cè)10Very Remote 比較不確定Product is sampled, inspected, and released based on 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9Remot

60、e不確定Product is accepted based on no defectives in a sample.根據(jù)樣件沒(méi)有缺陷，據(jù)此接收了產(chǎn)品8Very 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)7Low一般確定Product is 100% manually inspected using go/no-go or other error-proofinggauges.通過(guò)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)6Moderate確定Some Statistical Process Control (SPC) is used in process and product is finalins