偉創(chuàng)力FMEA培訓教材Train-PFMEA-Chinese課件

FailureModesandEffectsAnalysis(FMEA)潛在失效模式及影響分析FailureModesandEffectsAnalIntroduction介紹

AprocesspotentialFMEAisananalyticaltechniqueutilizedbyamanufacturingresponsibleengineer/teamasameanstoassurethat,totheextentpossible,potentialfailuremodesandtheirassociatedcauses/mechanismshavebeenconsideredandtheengineer’s/team’sthoughts(includingananalysisofitemsthatcouldgowrongbasedonexperienceandpastconcerns)asaprocessisdeveloped.Thissystematicapproachparallelsandformalizesthementaldisciplinethatanengineernormallygoesthroughinanymanufacturingplanningprocess.過程的FMEA是負責制造生產的工程師/隊伍使用的分析技法，用來在一定程度上確保潛在的失效模式和相關的原因/機制都已考慮到，以及工程師/隊伍的想法（包括基于經驗和過去的想法得出的可能失效項目分析）。這種系統(tǒng)性的方法將工程師在任何生產計劃過程中通常會碰到的問題標準化了。2Introduction介紹 AprocesspotTheProcesspotentialFMEAIdentifiespotentialproductrelatedprocessfailuremodes.確認與產品有關的過程失效模式Assessesthepotentialcustomereffectsofthefailures.評估失效對客戶潛在的影響Identifiesthepotentialmanufacturingofassemblyprocesscausesandidentifiesprocessvariablesonwhichtofocuscontrolsforoccurrencereductionordetectionofthefailureconditions.確定潛在的制造原因和過程變數(shù)，以便加以控制，減少發(fā)生可能性，增加發(fā)現(xiàn)到的可能性Developsarankedlistofpotentialfailuremodes,thusestablishingaprioritysystemforcorrectiveactionconsiderations.列出潛在失效模式的排行表，建立一個優(yōu)先系統(tǒng)以做出改善行動Modifymanufacturingorassemblyprocess.

改變生產或生產線過程3TheProcesspotentialFMEAIdeFMEAStep步驟:

1.DefinethescopefortheFMEA定義FMEA的范圍2.Identifyteammembers,customer,andknowledgeexperts確認隊伍成員、客戶，和專家3.Developrolesandresponsibilitiesforteammembers制定每個成員的任務和職責4.Studytheproduct/process/service研究產品/制程/服務5.Brainstormfailuremodes,knownandpotential集體討論已知的和潛在的失效模式6.Listtheeffects,causes,andcurrentcontrolsforeachfailuremode列出影響、原因和失效模式當前控制情況7.AssignratingsforSeverity,Occurrence,andDetection給嚴重性、發(fā)生率、發(fā)現(xiàn)度的評分8.CalculateRPN計算RPN9.DecideonathresholdRPN制定采取行動的RPN界限值10.PrioritizebasedonRPNandseverity,orasrequiredbythecustomer優(yōu)先性要根據(jù)RPN，嚴重性，或客戶的要求11.Identifycorrectiveactions確認改善行動12.Implementandverifyeffectivenessofcorrectiveaction執(zhí)行并確認改善行動的有效性13.Completethedocumentation完成文件記錄4FMEAStep步驟: 4DefinethescopefortheFMEA

定義FMEA的范圍Definetheboundarieswithinwhichtheproduct,process,orservicewillbestudied,identifyingtheoperatingassumptions,currentconditionsandconstraints.定義產品、制程或服務的研究范圍，確認運作前提，當前條件和約束。5DefinethescopefortheFMEA

2.Identifyteammembers,customer,andknowledgeexperts

確認隊伍成員、客戶和專家

Gettheteamtogether,identifythecustomerandinvolvethemintheprocess.Somepreliminaryworkmustbedonetounderstandtheproduct/process/service,sotherightteamcanbeassembled.將成員集合，確認客戶并使他們參與進來。為了很好地理解產品/制程/服務，一些先前工作要做，已使小組集合起來。62.Identifyteammembers,cust

3.Developrolesandresponsibilitiesforteammembers

制定每個成員的任務和職責Whodoeswhatontheteam.Clearlydefinetherolesandresponsibilitiesforeachoftheteammembers.Atthistime,itisimportanttoconsiderthestrengthsofeachindividualandleveragethesame.誰做什么，清楚地定義每個成員的職責。這時，考慮每個人的長處很重要。Example:TeamLeader:*Coordinatetheactivitiesoftheteam,andkeepontrack

例：隊長協(xié)調隊伍的活動，時時追蹤*Actascheerleader,andinterfacewithmanagement

充當鼓舞者與管理相結合

*Ensurethedecisionsaremadewithconsensus

確保和大家一起做決定

Customer:*Definerequirements定義需求

客戶*Participateindevelopingratingscales,especiallyforSeverityKnowledge參與等級制定，尤其是嚴重性Expert:*Asconsultantprovideinfoondetailsofproduct/

專家

processorservice作為顧問提供產品等信息73.Developrolesandresponsi4.Studytheproduct/process/service

研究產品/制程/服務

Theobjectiveofthisstepistoacquireasmuchknowledgeaspossible.Itishighlyrecommendedthatallteammembersdelveintothis,sincethereisnootherwaytofamiliarizeyourselfwiththeproduct/process/service.此步驟的目的是為了盡可能多的獲取知識。高度建議所有成員都參與，因為沒有其他的方式使你去熟悉產品/制程/服務。84.Studytheproduct/process5.Brainstormfailuremodes,knownandpotential

集體討論已知的和潛在的失效模式*Failuremodesshouldbedescribedin“physical”ortechnicalterms,notasasymptomnoticeablebythecustomer.

失效模式應描述為物理量或技術術語，而不是簡單的表面現(xiàn)象 *Theideaistoidentifyasmanyfailuremodesaspossible.Thiswillinvolvegettingallteammembersandstakeholdersinvolved,however,theproperapproachtobrainstormingmustbeused.Deferalljudgment,maybeeventoasubsequentmeeting.確認盡可能多的失效模式，使所有的成員都參與。使用適當?shù)哪X力震蕩方法。所有的調節(jié)整理留給以后的會議。*Thebiggestriskinthisstepisthatparticipantswillstartmixingupfailuremodeswithcauses,andeffects.Topreventthis,itishighlyrecommendedthatmeetingleaderdoadryruntofamiliarizethegroupwiththedifferencesbetweenfailuremodes,effects,andcauses.Alistingoftheproduct/process/services’specifications,oroutputsandrequirementswillbenefithere.

最大的風險是參與者會混淆失效模式、原因和影響。建議會議領導者做個排練，使大家熟悉失效模式、原因和影響的差別。產品/制程/服務的規(guī)格，產出或需求會對此有所幫助。*Postitpadsareaconvenientwayofcollectingthisinformation,andgroupingitintologicalgroups.小紙貼是收集此種信息的有效途徑，然后按邏輯分組。*Ifyouwritetheseonaworksheet,makesureyouleaveenoughspaceforeffectsandcauses

如果你將此寫在工作紙上，要確保留出足夠的空間填寫影響和原因。95.Brainstormfailuremodes,kn5.Brainstormfailuremodes,knownandpotential

集體討論已知的和潛在的失效模式SeparatingFailureModes,EffectsandCauses分開失效模式，影響和原因Multiplicitywillexistforcauses,failuremodes,andeffects失效模式，影響和原因是多種多樣的FailureModes:Willsharecauses,andeffects失效模式：有共同的原因和影響Causes:Thereasonsforfailure,canbeoneormanyforagivenfailuremode原因：不良的原因可以是一個或多個已有的失效模式的原因Effects:Theresultsofthefailure,canbeoneormanyforagivenfailuremode影響：不良的結果可以是一個或多個已有的失效模式的結果Cause1Cause2FailureMode1Effect1FailureMode2Effect2105.Brainstormfailuremodes,kn6.Listtheeffects,causes,andcurrentcontrolsforeachfailuremode

列出影響、原因和失效模式的當前控制情況

*Tocapturetheeffects,causes,andexistingcontrolsifanyforthefailuremodeinquestion.Inputfromcustomer,knowledgeexpertswillbeespeciallyhelpfulatthisstep.專家及客戶在失效模式的影響、原因，和當前控制上尤其能提供幫助。*Caution:Manyteamscommiterrorsofwishfulthinkinghere,especiallywithregardtocurrentcontrols.Youshouldfocusonthecurrentstate,andnotonwhatcouldbedone,orwhatoughttobedone.

注意：許多成員由于打如意算盤而犯錯誤，尤其對當前的控制。我們應該關注當前的狀況，而不是關注應該做的或可以做的。*Nowstartdocumentingontheworksheet,knowingthateachfailuremodecanhavemultipleeffects,andmultiplecauses.現(xiàn)在開始做文件整理，要意識到失效模式有很多的影響和原因。116.Listtheeffects,causes,a6.Listtheeffects,causes,andcurrentcontrolsforeachfailuremode

列出影響、原因和不良型號的當前控制情況

Example舉例:Loadcapacitylisted列出載重能力Overloaded超載TempGageCoolingSystem制冷系統(tǒng)StrandedonRoad在路上擱淺Oveheats過熱Car汽車RPNDCurrentControls當前控制OCause原因SEffect影響FailureMode失效模式ProductProcessorService產品制程或服務126.Listtheeffects,causes,7.AssignratingsforSeverity,Occurrence,andDetection

給嚴重性、發(fā)生率、發(fā)現(xiàn)度評分

Hereweaccomplishtheconversionofeachofthesefactorsintoanumericalvalue.Dependingonthequalityoftheratingscalesthisstepcanbeveryeasyorsomewhatfrustrating.

這里我們將每個因素都轉換成相對應的數(shù)值。根據(jù)質量等級標準，這個步驟可以很簡單或有點煩人。

Therewillbetimeswhentheteamwilldisagreeonthevaluesassignedtoaparticularcause,effect,orfailuremode.Ratherthanvoting,itisrecommendedthattheteamtrytoreachconsensus.Incaseofdisagreements,aknowledgeexpert’sopinioncanbeusedtoincreaseunderstanding,ormoredatacanbesought.Inanycasetheteam’sdecisionshouldprevail.對于任何一個原因、影響或失效模式的等級劃分，小組成員之間很多時候會意見相左，建議多收集數(shù)據(jù)，專家的意見也可以用以提高理解，達成共識。137.AssignratingsforSeverity7.AssignratingsforSeverity,Occurrence,andDetection

給嚴重性、發(fā)生率、發(fā)現(xiàn)度評分

Example舉例:ProductProcessorService產品制程或服務FailureMode失效模式Effect影響SCause原因OCurrentControls當前控制DRPNCar汽車Oveheats過熱StrandedonRoad在路上擱淺7CoolingSystem制冷系統(tǒng)3TempGage4Overloaded超載8Loadcapacitylisted列出栽重能力8147.AssignratingsforSeverity8.CalculateRPN計算RPNSimplyassigningratingsforSeverity,Occurrence,andDetectiondoesn’thelpquantifytheriskintoasinglemeasurablevalue.Multiplyingtheratingscoresthusfillsthisgap.NotethatinthisapproachwehavemaintainedequalweightforeachofthethreeS,O,D給嚴重性、發(fā)生率、發(fā)現(xiàn)度評分并不能將風險變?yōu)橐粋€單一測量的數(shù)值，把三個分數(shù)乘起來填進RPN欄，注意三個單值的權重是一樣的。ProductProcessorService產品制程或服務FailureMode失效模式Effect影響SCause原因OCurrentControls當前控制DRPNCar汽車Oveheats過熱StrandedonRoad在路上擱淺7CoolingSystem制冷系統(tǒng)3TempGage484Overloaded超載8Loadcapacitylisted列出栽重能力8448158.CalculateRPN計算RPNSimply

9.DecideonathresholdRPN制定采取行動的RPN界限值

Identifythefailuremodesyouwillchoosetoworkon.Itmaynotbepracticaltoaddressallofthem.Thiscriticalstepmustbeconductedwithcustomerinvolvement,andconsensusbuilding.

確認你選擇需要采取行動的失效模式。對所有的模式整改是不實際的，這個關鍵步驟需客戶參與

Manyteamsrunintodifficultieshere,especiallywhenthecustomerinsistsallitemsneedtobeaddressed.Itneedstobeunderstoodthatsomeelementofriskwillalwaysbepresent.Thequestionthereforeis“Whatlevelofriskisacceptable”?

許多小組都會在這碰到困難，尤其當客戶要求所有的項目都要被討論。風險總是會存在的。問題是：“什么程度的風險可以接受？”

Someofthedifferentapproachesthathavebeenusedtodefinethethresholdare;ParetoAnalysis,Topcauseforeachfailuremode,etc.

一些不同的方法都已被用來定義界限：泊拉圖分析，最高分等等DocumentonFMEAstartupformtoindicatethiswasdiscussed,andagreementreachedonthethresholdvalue.

關于FMEA的討論要寫成文件，要在界限值上達成一致。169.DecideonathresholdRPN

9.DecideonathresholdRPN

制定采取行動的RPN界限值

*DecideonathresholdRPN,withoutignoringhighseverityfailuremodes決定RPN的臨界點，不要忽略失效模式的高嚴重性ExampleusingParetoChart用Pareto圖表舉例:80%ofCumulativeRPNCumulativeRPNCurveL累積RPN曲線Cause原因CumulativeRPN累積RPN179.DecideonathresholdRPN

10.PrioritizebasedonRPNandseverity,orasrequiredbythecustomer

優(yōu)先性要根據(jù)RPN，嚴重性，或客戶的要求

*Arriveattheorderinwhichyouwillstartaddressingthefailuremodesandcauseforcorrectiveaction.AlthoughRPNandseveritybasedprioritizationseemsthemostlogical,yourdecisiontoproceedmustbemadewithcustomerinput.

訂出你對于失效模式和原因整改的順序。雖然RPN和按先后次序的嚴重性很有邏輯性，你仍然要根據(jù)客戶的信息來決定。*Thisstepiseasilyaccomplishedbysortingthedata,indescendingorder.Youcandothiswithineachfailuremodetomaintaindataintegrity.這個步驟根據(jù)數(shù)據(jù)分類可以很容易按降序完成，。每一個失效模式都可以這樣做以保證數(shù)據(jù)的完整。*Documentationonworksheetisimportanttoensurethewholeteamisinsync.相關的文件很重要，可以確保整個隊伍工作的同步性。1810.PrioritizebasedonRPNanExampleofsortedworksheetbyRPNwithineachfailuremode失效模式用RPN排序的例子：10.PrioritizebasedonRPNandseverity,orasrequiredbythecustomer

優(yōu)先性要根據(jù)RPN，嚴重性，或客戶的要求

844TempGage3CoolingSystem制冷系統(tǒng)4488Loadcapacitlistedonsideofdoor在門邊列出載重能力8Overloaded超載7StrandedonRoad在路上擱淺Oveheats過熱Car汽車RPNDCurrentControls當前控制OCause原因SEffect影響FailureMode失效模式ProductProcessorService產品制程或服務19Exampleofsortedworksheetby11.Identifycorrectiveactions確認改善措施

*Inthisstepyouidentifythecorrectiveactionsneededtoeliminate/controlthecauses,andreducetheriskleveltoorbelowtheagreeduponthreshold.這個步驟你要確認消除/控制起因的整改方法，去減低風險等級或使之低于規(guī)定的界限。

*Therewillbetimeswhenyoucannotworkontherootcause;insuchcasethebestcourseofactionwillbeviaadditionofcontrols/adequatewarningdevices/mechanismsofimpendingfailure.Re-evaluatetheratingsforS,OandD,followedbyRPNcalculation.很多時候你不能找出根本原因；這時最好的方法就是對未解決的不良進行額外的控制/足夠的提醒裝置。根據(jù)RPN計算結果，重新衡量S，O，D的等級劃分。*Discussionwiththecustomerisimportantagainsincethecorrectiveactionswillimpactthem.Knowledgeexpertsmayalsoprovidevaluableinputastowhatkindsofcorrectiveactionwillbebestsuitedforthegivencause/failuremode.整改會影響到客戶，因此和他們討論很重要。專家也應提供有用的信息，提議什么樣的整改最適合現(xiàn)存的問題。*Finally,fromallpossiblecorrectiveactions,theteammaychooseonebasedoncost/benefitanalysis,speedofimplementation,andthenewlevelofrisk.最后，對所有可能的改善行動，小組可以成本/效益分析，執(zhí)行快慢，及新的風險等級選擇其中一個行動計劃2011.Identifycorrectiveaction11.Identifycorrectiveactions確認整改Example舉例:10FebAllTraininadvanceddrivingtechniques提高駕駛技巧3505ABSandtractioncontrolABS和牽引控制7Drivinghabit駕駛習慣30MarRobertTakeupmatterwithcity與城市聯(lián)系3505Listentoforecasts聽預報7Slickroads潮濕的路10Accident-injury事故受傷Skids剎車None無844Tempgage3CoolingSystem制冷系統(tǒng)22JanJohnInstallloadcapacitysignseasilyvisibletodriver在司機容易看到的地方粘貼載重能力4488LoadCapacitylistedonsideofdoor在門邊列出載重能力8Overloaded超載7Strandedonroad在路上擱淺Overheats過熱Car汽車RPNDOSCompDate日期AssignedTo負責人CorrectiveAction整改RPNDCurrentControls當前控制OCause原因SEffect影響FailureMode失效模式Product/Process/Service產品/制程/服務2111.Identifycorrectiveaction12.Implementandverifytheeffectivenessofcorrectiveaction

執(zhí)行并確認整改的有效性

*Correctiveactionsidentifiedoughttobeimplementedlikeprojects-withadefinitestartandend.Inmanycasesaprojectteamsmaybeformedtocarryouttheimplementation.TheseprojectteamsmayhavemembersfromoutsidetheFMEAteam,howeveratleastonemembershouldbedrawnfromtheFMEAteam.確認整改方案應該象完成一個項目-有明確的開頭和結尾。很多時候一個項目組都已形成以完成方案。這些項目組可以擁有FMEA小組外的成員，至少需有一個屬于FMEA的成員。*Acheckontheeffectivenessofthecorrectiveactionisimportant,intheabsenceofwhichyouwillnothaveacloseloopfeedbackonwhatreallytranspired.ThischeckshouldbeconductedbytheFMEAteamafterthecorrectiveactionshavebeeninplaceforsometime.Thisisbecausethecorrectiveaction,likeachange,maynotlast.Ittakesdiligentefforttoensurethechangewillhavepermanence.檢查整改是否有效很重要，否則你不能得知實際情況。檢查須在整改進行了一段時間后由FMEA成員執(zhí)行。因為整改并不是最終結果。需要努力才能確認這個改變是否永久。*Ifthecorrectiveactionisnoteffectiveenough,youmayneedtoimplementsomemorecontrols/takemoreaction.如果整改沒有效，需要進行更多的控制/行動。2212.ImplementandverifytheeExample舉例:12.Implementandverifytheeffectivenessofcorrectiveaction

執(zhí)行并確認整改的有效性Product/Process/Service產品/制程/服務FailureMode失效模式Effect影響SCause原因OCurrentControls當前控制DRPNCorrectiveAction整改AssignedTo負責人CompDate日期SODRPNCar汽車Overheats過熱Strandedonroad在路上擱淺7Overloaded超載8LoadCapacitylistedonsideofdoor在門邊列出載重能力8448Installloadcapacitysignseasilyvisibletodriver在司機容易看到的地方粘貼載重能力John22Jan744112CoolingSystem制冷系統(tǒng)3Tempgage484None無N/ASkids剎車Accident-injury事故受傷10Slickroads潮濕的路7Listentoforecasts聽預報5350Takeupmatterwithcity與城市聯(lián)系Robert30MarTBDDrivinghabit駕駛習慣7ABSandtractioncontrolABS和牽引控制5350Traininadvanceddrivingtechniques提高駕駛技巧All10Feb104520023Example舉例:12.Implementandve13.Completethedocumentationandsaveinarchives/database

完成文件記錄并存入數(shù)據(jù)庫

*ThislaststepisoverlookedbymanyoftheFMEAteams.Whileitisunderstandablethatthenextprojectneedstobeworkedon,itisalsoimportantnottolosetheknowledgegainedbytheteam.最后一步經常被忽略。之后還有下一個項目，因此很重要的是不要丟掉在這個項目里得到的知識。*Thebestwaytodocumentistousearchivingsystemsinthecompanyiftheyexist,electronicstorageisnowacceptedbymostregulatoryagenciesnow.如果公司有文件歸檔系統(tǒng)，文件最好都如此處理?，F(xiàn)在大部分的管理機構都接受電子資料。*Itemthatshouldbesavedinclude需要收藏的資料:-FMEAstartupformFMEA開始執(zhí)行時的表格-FMEAworksheetsFMEA工作表-Meetingminutes會議記錄-Processflow流程表-Designspecs,andvoiceofcustomer設計說明書，客戶反饋-Detailsofprojectscreatedandimplementedaspartofactionitems作為其中某部分的項目的產生及執(zhí)行細節(jié)

2413.CompletethedocumentationFailureModesandEffectsAnalysis(FMEA)潛在失效模式及影響分析FailureModesandEffectsAnalIntroduction介紹

AprocesspotentialFMEAisananalyticaltechniqueutilizedbyamanufacturingresponsibleengineer/teamasameanstoassurethat,totheextentpossible,potentialfailuremodesandtheirassociatedcauses/mechanismshavebeenconsideredandtheengineer’s/team’sthoughts(includingananalysisofitemsthatcouldgowrongbasedonexperienceandpastconcerns)asaprocessisdeveloped.Thissystematicapproachparallelsandformalizesthementaldisciplinethatanengineernormallygoesthroughinanymanufacturingplanningprocess.過程的FMEA是負責制造生產的工程師/隊伍使用的分析技法，用來在一定程度上確保潛在的失效模式和相關的原因/機制都已考慮到，以及工程師/隊伍的想法（包括基于經驗和過去的想法得出的可能失效項目分析）。這種系統(tǒng)性的方法將工程師在任何生產計劃過程中通常會碰到的問題標準化了。26Introduction介紹 AprocesspotTheProcesspotentialFMEAIdentifiespotentialproductrelatedprocessfailuremodes.確認與產品有關的過程失效模式Assessesthepotentialcustomereffectsofthefailures.評估失效對客戶潛在的影響Identifiesthepotentialmanufacturingofassemblyprocesscausesandidentifiesprocessvariablesonwhichtofocuscontrolsforoccurrencereductionordetectionofthefailureconditions.確定潛在的制造原因和過程變數(shù)，以便加以控制，減少發(fā)生可能性，增加發(fā)現(xiàn)到的可能性Developsarankedlistofpotentialfailuremodes,thusestablishingaprioritysystemforcorrectiveactionconsiderations.列出潛在失效模式的排行表，建立一個優(yōu)先系統(tǒng)以做出改善行動Modifymanufacturingorassemblyprocess.

改變生產或生產線過程27TheProcesspotentialFMEAIdeFMEAStep步驟:

1.DefinethescopefortheFMEA定義FMEA的范圍2.Identifyteammembers,customer,andknowledgeexperts確認隊伍成員、客戶，和專家3.Developrolesandresponsibilitiesforteammembers制定每個成員的任務和職責4.Studytheproduct/process/service研究產品/制程/服務5.Brainstormfailuremodes,knownandpotential集體討論已知的和潛在的失效模式6.Listtheeffects,causes,andcurrentcontrolsforeachfailuremode列出影響、原因和失效模式當前控制情況7.AssignratingsforSeverity,Occurrence,andDetection給嚴重性、發(fā)生率、發(fā)現(xiàn)度的評分8.CalculateRPN計算RPN9.DecideonathresholdRPN制定采取行動的RPN界限值10.PrioritizebasedonRPNandseverity,orasrequiredbythecustomer優(yōu)先性要根據(jù)RPN，嚴重性，或客戶的要求11.Identifycorrectiveactions確認改善行動12.Implementandverifyeffectivenessofcorrectiveaction執(zhí)行并確認改善行動的有效性13.Completethedocumentation完成文件記錄28FMEAStep步驟: 4DefinethescopefortheFMEA

定義FMEA的范圍Definetheboundarieswithinwhichtheproduct,process,orservicewillbestudied,identifyingtheoperatingassumptions,currentconditionsandconstraints.定義產品、制程或服務的研究范圍，確認運作前提，當前條件和約束。29DefinethescopefortheFMEA

2.Identifyteammembers,customer,andknowledgeexperts

確認隊伍成員、客戶和專家

Gettheteamtogether,identifythecustomerandinvolvethemintheprocess.Somepreliminaryworkmustbedonetounderstandtheproduct/process/service,sotherightteamcanbeassembled.將成員集合，確認客戶并使他們參與進來。為了很好地理解產品/制程/服務，一些先前工作要做，已使小組集合起來。302.Identifyteammembers,cust

3.Developrolesandresponsibilitiesforteammembers

制定每個成員的任務和職責Whodoeswhatontheteam.Clearlydefinetherolesandresponsibilitiesforeachoftheteammembers.Atthistime,itisimportanttoconsiderthestrengthsofeachindividualandleveragethesame.誰做什么，清楚地定義每個成員的職責。這時，考慮每個人的長處很重要。Example:TeamLeader:*Coordinatetheactivitiesoftheteam,andkeepontrack

例：隊長協(xié)調隊伍的活動，時時追蹤*Actascheerleader,andinterfacewithmanagement

充當鼓舞者與管理相結合

*Ensurethedecisionsaremadewithconsensus

確保和大家一起做決定

Customer:*Definerequirements定義需求

客戶*Participateindevelopingratingscales,especiallyforSeverityKnowledge參與等級制定，尤其是嚴重性Expert:*Asconsultantprovideinfoondetailsofproduct/

專家

processorservice作為顧問提供產品等信息313.Developrolesandresponsi4.Studytheproduct/process/service

研究產品/制程/服務

Theobjectiveofthisstepistoacquireasmuchknowledgeaspossible.Itishighlyrecommendedthatallteammembersdelveintothis,sincethereisnootherwaytofamiliarizeyourselfwiththeproduct/process/service.此步驟的目的是為了盡可能多的獲取知識。高度建議所有成員都參與，因為沒有其他的方式使你去熟悉產品/制程/服務。324.Studytheproduct/process5.Brainstormfailuremodes,knownandpotential

集體討論已知的和潛在的失效模式*Failuremodesshouldbedescribedin“physical”ortechnicalterms,notasasymptomnoticeablebythecustomer.

失效模式應描述為物理量或技術術語，而不是簡單的表面現(xiàn)象 *Theideaistoidentifyasmanyfailuremodesaspossible.Thiswillinvolvegettingallteammembersandstakeholdersinvolved,however,theproperapproachtobrainstormingmustbeused.Deferalljudgment,maybeeventoasubsequentmeeting.確認盡可能多的失效模式，使所有的成員都參與。使用適當?shù)哪X力震蕩方法。所有的調節(jié)整理留給以后的會議。*Thebiggestriskinthisstepisthatparticipantswillstartmixingupfailuremodeswithcauses,andeffects.Topreventthis,itishighlyrecommendedthatmeetingleaderdoadryruntofamiliarizethegroupwiththedifferencesbetweenfailuremodes,effects,andcauses.Alistingoftheproduct/process/services’specifications,oroutputsandrequirementswillbenefithere.

最大的風險是參與者會混淆失效模式、原因和影響。建議會議領導者做個排練，使大家熟悉失效模式、原因和影響的差別。產品/制程/服務的規(guī)格，產出或需求會對此有所幫助。*Postitpadsareaconvenientwayofcollectingthisinformation,andgroupingitintologicalgroups.小紙貼是收集此種信息的有效途徑，然后按邏輯分組。*Ifyouwritetheseonaworksheet,makesureyouleaveenoughspaceforeffectsandcauses

如果你將此寫在工作紙上，要確保留出足夠的空間填寫影響和原因。335.Brainstormfailuremodes,kn5.Brainstormfailuremodes,knownandpotential

集體討論已知的和潛在的失效模式SeparatingFailureModes,EffectsandCauses分開失效模式，影響和原因Multiplicitywillexistforcauses,failuremodes,andeffects失效模式，影響和原因是多種多樣的FailureModes:Willsharecauses,andeffects失效模式：有共同的原因和影響Causes:Thereasonsforfailure,canbeoneormanyforagivenfailuremode原因：不良的原因可以是一個或多個已有的失效模式的原因Effects:Theresultsofthefailure,canbeoneormanyforagivenfailuremode影響：不良的結果可以是一個或多個已有的失效模式的結果Cause1Cause2FailureMode1Effect1FailureMode2Effect2345.Brainstormfailuremodes,kn6.Listtheeffects,causes,andcurrentcontrolsforeachfailuremode

列出影響、原因和失效模式的當前控制情況

*Tocapturetheeffects,causes,andexistingcontrolsifanyforthefailuremodeinquestion.Inputfromcustomer,knowledgeexpertswillbeespeciallyhelpfulatthisstep.專家及客戶在失效模式的影響、原因，和當前控制上尤其能提供幫助。*Caution:Manyteamscommiterrorsofwishfulthinkinghere,especiallywithregardtocurrentcontrols.Youshouldfocusonthecurrentstate,andnotonwhatcouldbedone,orwhatoughttobedone.

注意：許多成員由于打如意算盤而犯錯誤，尤其對當前的控制。我們應該關注當前的狀況，而不是關注應該做的或可以做的。*Nowstartdocumentingontheworksheet,knowingthateachfailuremodecanhavemultipleeffects,andmultiplecauses.現(xiàn)在開始做文件整理，要意識到失效模式有很多的影響和原因。356.Listtheeffects,causes,a6.Listtheeffects,causes,andcurrentcontrolsforeachfailuremode

列出影響、原因和不良型號的當前控制情況

Example舉例:Loadcapacitylisted列出載重能力Overloaded超載TempGageCoolingSystem制冷系統(tǒng)StrandedonRoad在路上擱淺Oveheats過熱Car汽車RPNDCurrentControls當前控制OCause原因SEffect影響FailureMode失效模式ProductProcessorService產品制程或服務366.Listtheeffects,causes,7.AssignratingsforSeverity,Occurrence,andDetection

給嚴重性、發(fā)生率、發(fā)現(xiàn)度評分

Hereweaccomplishtheconversionofeachofthesefactorsintoanumericalvalue.Dependingonthequalityoftheratingscalesthisstepcanbeveryeasyorsomewhatfrustrating.

這里我們將每個因素都轉換成相對應的數(shù)值。根據(jù)質量等級標準，這個步驟可以很簡單或有點煩人。

Therewillbetimeswhentheteamwilldisagreeonthevaluesassignedtoaparticularcause,effect,orfailuremode.Ratherthanvoting,itisrecommendedthattheteamtrytoreachconsensus.Incaseofdisagreements,aknowledgeexpert’sopinioncanbeusedtoincreaseunderstanding,ormoredatacanbesought.Inanycasetheteam’sdecisionshouldprevail.對于任何一個原因、影響或失效模式的等級劃分，小組成員之間很多時候會意見相左，建議多收集數(shù)據(jù)，專家的意見也可以用以提高理解，達成共識。377.AssignratingsforSeverity7.AssignratingsforSeverity,Occurrence,andDetection

給嚴重性、發(fā)生率、發(fā)現(xiàn)度評分

Example舉例:ProductProcessorService產品制程或服務FailureMode失效模式Effect影響SCause原因OCurrentControls當前控制DRPNCar汽車Oveheats過熱StrandedonRoad在路上擱淺7CoolingSystem制冷系統(tǒng)3TempGage4Overloaded超載8Loadcapacitylisted列出栽重能力8387.AssignratingsforSeverity8.CalculateRPN計算RPNSimplyassigningratingsforSeverity,Occurrence,andDetectiondoesn’thelpquantifytheriskintoasinglemeasurablevalue.Multiplyingtheratingscoresthusfillsthisgap.NotethatinthisapproachwehavemaintainedequalweightforeachofthethreeS,O,D給嚴重性、發(fā)生率、發(fā)現(xiàn)度評分并不能將風險變?yōu)橐粋€單一測量的數(shù)值，把三個分數(shù)乘起來填進RPN欄，注意三個單值的權重是一樣的。ProductProcessorService產品制程或服務FailureMode失效模式Effect影響SCause原因OCurrentControls當前控制DRPNCar汽車Oveheats過熱StrandedonRoad在路上擱淺7CoolingSystem制冷系統(tǒng)3TempGage484Overloaded超載8Loadcapacitylisted列出栽重能力8448398.CalculateRPN計算RPNSimply

9.DecideonathresholdRPN制定采取行動的RPN界限值

Identifythefailuremodesyouwillchoosetoworkon.Itmaynotbepracticaltoaddressallofthem.Thiscriticalstepmustbeconductedwithcustomerinvolvement,andconsensusbuilding.

確認你選擇需要采取行動的失效模式。對所有的模式整改是不實際的，這個關鍵步驟需客戶參與

Manyteamsrunintodifficultieshere,especiallywhenthecustomerinsistsallitemsneedtobeaddressed.Itneedstobeunderstoodthatsomeelementofriskwillalwaysbepresent.Thequestionthereforeis“Whatlevelofriskisacceptable”?

許多小組都會在這碰到困難，尤其當客戶要求所有的項目都要被討論。風險總是會存在的。問題是：“什么程度的風險可以接受？”

Someofthedifferentapproachesthathavebeenusedtodefinethethresholdare;ParetoAnalysis,Topcauseforeachfailuremode,etc.

一