DFMEA-失效模式與后果分析課件

DFMEA------失效模式與后果分析

(DesignFailureMode&EffectAnalysis)Marian(Shenzhen)Co.,Ltd編制：曹喜元FormationBy：JackCao

日期：

Date：1-Feb-2013DFMEA------失效模式與后果分析

(DesignF1主要內(nèi)容

Maincontent1.DFMEA介紹4.DFMEA關(guān)鍵參數(shù)DFMEAPresentationDFMEAKeyParameter2.DFMEA職責(zé)5.DFMEA表單填寫說明DFMEAResponsibilityDFMEAFormFillingExplanation3.DFMEA制作流程6.DFMEA案例DFMEAMakeProcessDFMEAExample主要內(nèi)容

Maincontent2一、DFMEA的介紹

DFMEAPresentationDFMEA是FMEA中的一種，F(xiàn)MEA分為：DFMEA和PFMEADFMEAisintheFMEAonetype,FMEAContain:DFMEA&PFMEADFMEA是由負(fù)責(zé)設(shè)計(jì)的工程師或小組，在產(chǎn)品設(shè)計(jì)階段盡可能的范圍內(nèi)預(yù)估產(chǎn)品在設(shè)計(jì)上可能發(fā)生的缺點(diǎn).DFMEAisEngineerorgrouptoresponsiblescheme,Asfaraspossiblewithinthescopeoftheestimatedproductdesignonthepossiblefaultsintheproductdesignstage.PFMEA是由負(fù)責(zé)制造裝配的工程師或小組，預(yù)估產(chǎn)品在生產(chǎn)過程階段或之前可能會(huì)發(fā)生的缺點(diǎn).PFMEAisPEorgrouptoresponsiblescheme,Asfaraspossibletheestimatedproductpossiblefaultsintheproductiveprocessorbefore.本章節(jié)重點(diǎn)講述DFMEAThischapterfocuseson

DFMEA.一、DFMEA的介紹

DFMEAPresentatio3DFMEA的形成

DFMEAFormationDFMEA是由負(fù)責(zé)設(shè)計(jì)的工程師或小組，在盡可能的范圍內(nèi)預(yù)估產(chǎn)品在設(shè)計(jì)上可能發(fā)生的缺點(diǎn)，衡量該項(xiàng)缺點(diǎn)或可能造成的影響，并擬定為防止或檢測(cè)該缺點(diǎn)應(yīng)改善的設(shè)計(jì)控制，并推動(dòng)其標(biāo)準(zhǔn)化作業(yè)，且必須配合設(shè)計(jì)發(fā)展之程序反復(fù)執(zhí)行.DFMEAisEngineerorgrouptoresponsiblescheme,Asfaraspossiblewithinthescopeoftheestimatedproductdesignonthepossiblefaultsintheproductdesignstage,Measurethefaultsorcancauseinfluence,andplantopreventortestingthedefectshouldbeimproveddesigncontrol,andpromotethestandardizedoperation,andmustfitinwiththedevelopmentofdesignprogramandimplementation.最終成品及其所有相關(guān)的系統(tǒng)、子系統(tǒng)都應(yīng)納入評(píng)估.DFMEA是設(shè)計(jì)小組，即公司工程，運(yùn)用設(shè)計(jì)，工程經(jīng)驗(yàn)或分析方法等而形成的.Thefinalandallrelatedsystem,subsystemshouldbeincludedinassessment.DFMEAisthedesignteam,namelythecompanyproject,theuseofdesign,engineeringexperienceoranalysismethodsandform.DFMEA的形成

DFMEAFormationDFMEA4DFMEA必備條件

DFMEAEssentialCondition

確認(rèn)已知及潛在的失效模式；Confirmtheknownandthepotentialfailuremode.

確認(rèn)每一個(gè)失效模式的效應(yīng)和原因；

Confirmeachfailuremodeeffectandreasons.

風(fēng)險(xiǎn)優(yōu)先評(píng)估（嚴(yán)重性、發(fā)生頻率、難檢度）；Riskpriorityevaluation(severity,occurrencefrequency

anddifficulttocheckdegree)

提供問題的數(shù)據(jù)及改善行動(dòng)；Provideproblemofdataandimprovementaction.

DFMEA必備條件

DFMEAEssentialCon5DFMEA的動(dòng)態(tài)鏈

DFMEATrendsCatenationDFMEA是個(gè)循環(huán)過程，在設(shè)計(jì)方案最終形成之時(shí)或之前開始.DFMEAisacyclicprocess,thedesignschemeoffinalformorbeforethestart.在產(chǎn)品開發(fā)各階段中，當(dāng)設(shè)計(jì)有變化或得到其他信息時(shí)，應(yīng)及時(shí)，不斷地修改，最終在產(chǎn)品加工圖樣完成之前全部結(jié)束。Ineverystageofproductdevelopment,whenthedesignchangeorgetotherinformation,shouldbeprompt,constantlymodified,finally,inproductprocessingpatternuntilallover.DFMEA的動(dòng)態(tài)鏈

DFMEATrendsCatena6二、DFEMA職責(zé)

DFMEAResponsibility

工程經(jīng)理：DFMEA總體負(fù)責(zé)人，負(fù)責(zé)組建DFMEA團(tuán)體，提出DFMEA實(shí)施計(jì)劃，并組織召開DFMEA會(huì)議，分配團(tuán)隊(duì)人員任務(wù)

組織DFMEA評(píng)審，DFMEA審核.Projectmanager:generalmanager,responsibleforDFMEA,this

paperputsforwardaDFMEAgroupDFMEAimplementationplan,

andorganizeaDFMEAmeeting,distributionteampersonneltask

OrganizationDFMEAreview,DFMEAaudit.

工程師：負(fù)責(zé)主導(dǎo)DFMEA文件編寫、修改和升級(jí).Engineer:responsibleforleadingDFMEAdocumentpreparation,

modificationandupgrade.二、DFEMA職責(zé)

DFMEAResponsibilit7二、DFEMA職責(zé)

DFMEAResponsibility

工程助理：負(fù)責(zé)客戶投訴問題，研發(fā)、試產(chǎn)、量產(chǎn)中問題的收集，及

時(shí)反饋到DFMEA團(tuán)體負(fù)責(zé)人處，并參與O,S,D參數(shù)評(píng)估，提供量

產(chǎn)CPK數(shù)據(jù).Projectassistant:responsibleforcustomercomplaintproblem,research

andtrialproduction,thequantityofcollection,andrenderWhenthe

feedbacktoDFMEAgroupplace,andparticipateinO,S,Dparameter

evaluation,SupplyvolumeproductionCPKdata.

試樣工程師：負(fù)責(zé)研發(fā)產(chǎn)品測(cè)試過程中所出現(xiàn)問題點(diǎn)的收集并及時(shí)

反饋到DFMEA負(fù)責(zé)人處，參與O,S,D參數(shù)評(píng)估.Sampleengineer:responsibleforresearchanddevelopmentinthe

processofproducttestingproblemspointcollectionandtimelyfeedback

totheDFMEAchiefplace,participateinO,S,Dparameterevaluation.二、DFEMA職責(zé)

DFMEAResponsibilit8二、DFEMA職責(zé)

DFMEAResponsibilityCQE：負(fù)責(zé)客戶需求信息歸納整理，DFMEA建議措施監(jiān)督實(shí)施、追

蹤，實(shí)施效果反饋，根據(jù)DFMEA和客戶需求等信息制定控制計(jì)劃，

并參與

O,S,D參數(shù)評(píng)估.CQE:Beresponsibleforthecustomerdemandinformationsummary,

DFMEAsuggestedmeasuressupervisionandimplementation,

trackingandeffectfeedback,accordingtotheDFMEAandrequirementsforinformationsuchascontrolplan,andparticipatein

O,S,Dparameterevaluation.二、DFEMA職責(zé)

DFMEAResponsibilit9三、DFMEA制作流程

DFMEAMakeprocess

注：團(tuán)隊(duì)制定目標(biāo)，使團(tuán)隊(duì)清楚新產(chǎn)品或以改善為

目標(biāo)，并需要了解客戶需求。

Note:Theteamsetgoals,maketheteamclear

newproductsortoimproveasthegoal,and

needtounderstandcustomerneeds.

使用方法；Methodofapplication.

客戶要求的設(shè)計(jì)/工程SPEC；Customer

requestedproject&EngineeringSPEC.

產(chǎn)品信賴；ProductTrust.

制程、生產(chǎn)、裝配要求；Process,Production

AssembleofRequirement.

品質(zhì)目標(biāo).QualityDestination.組成DFMEA團(tuán)隊(duì)ConstituteDFMEATeam確定目標(biāo)ConfirmDestination三、DFMEA制作流程

DFMEAMakeproces10三、DFMEA制作流程

DFMEAMakeprocess

產(chǎn)品設(shè)計(jì)及類似產(chǎn)品設(shè)計(jì)的問題及原因；

Productdesignandsimilarproductdesignproblemsandreasons

制造工藝及類似產(chǎn)品制程中常及的不良原因；

Manufacturingprocessandsimilarproductsinprocessandbadreason.

類似產(chǎn)品的制程能力及原因；

Similarproductsofprocesscapabilityandthereason.

類似產(chǎn)品的客訴及原因；

Similarproductsofcustomercomplaintandthereason.

類似產(chǎn)品的依賴性失效及原因；

Similarproductsthedependenceofthefailureandthereason.

類似產(chǎn)品的管理性問題；

Similarproductsofmanagerialproblems.資料收集DataCollection三、DFMEA制作流程

DFMEAMakeproces11三、DFMEA制作流程

DFMEAMakeprocess

使用維修；

UseMaintain.

環(huán)境.

Environment.

表格格式TableFormat.

分層層次DelaminationAdministrativelevels.

失效定義FailureDefinition.

成果整合AchievementIntegration.

時(shí)機(jī)Opportunity.資料收集DataCollection制訂執(zhí)行方案FormulateimplementPlan三、DFMEA制作流程

DFMEAMakeproces12三、DFMEA制作流程

DFMEAMakeprocess分析制程特性AnalysisProcessCharacter定義制造流程DefinitionproductionProcess分析產(chǎn)品特性AnalysisProductCharacter分析失效原因AnalysisFailureCause分析現(xiàn)行控制方法AnalysisControlMethod分析失效效應(yīng)AnalysisFailureEffect分析發(fā)生率AnalysisOccurrenceRate分析難檢度AnalysisDetection分析嚴(yán)重度AnalysisSeverity計(jì)算風(fēng)險(xiǎn)優(yōu)先數(shù)CalculatedRiskPriorityNumber分析制程特性AnalysisProcessCharacter三、DFMEA制作流程

DFMEAMakeproces13三、DFMEA制作流程

DFMEAMakeprocess決定優(yōu)先改善的失效模式DecideAmeliorativeFailureMode建議改善措施RecommendationImprovementMeasures改善實(shí)施ImprovementImplement結(jié)果確認(rèn)有效ResultNotarizeEffective三、DFMEA制作流程

DFMEAMakeproces14四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度、發(fā)生率、難檢度、風(fēng)險(xiǎn)優(yōu)生數(shù)Severity,Occurrence,Detection,RPN嚴(yán)重度Severity-----------------------------S發(fā)生率Occurrence------------------------O難檢度Detection---------------------------D風(fēng)險(xiǎn)優(yōu)生數(shù)RiskPriorityNumber-------RPNRPN=S*O*D四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet15四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度Severity衡量失效的影響程度.Assessmentfailureincidence失效影響產(chǎn)品或制程，某一失效會(huì)對(duì)產(chǎn)品外觀、結(jié)構(gòu)、功能、性能穩(wěn)定性、可靠性的影響；或?qū)ο乱粋€(gè)制程，使用者和設(shè)備的影響；或?qū)ψ罱K客戶，政府法規(guī)、安全、環(huán)保等的違及.Failureaffectproductorprocess,afailuretoproductappearance,structure,function,performancestabilityandreliabilityoftheinfluence;Ortothenextprocess,theuserandtheinfluenceoftheequipment;Ortoendcustomers,governmentregulations,safety,andenvironmentalprotection,andadefault.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet16四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度Severity嚴(yán)重度的劃分標(biāo)準(zhǔn)---------------------------------------主觀判定SeverityClassificationStandard-------------------SubjectivityDecide其大小由失效模式的影響程度而定，以1至10表示等級(jí).It’ssizeofthefailuremodeoftheinfluencedegreetodecide,be1to10showlevel.1級(jí)最輕微，10級(jí)最嚴(yán)重.1Levelbestslight,10Levelbestgrave.1級(jí)-------------------------------幾乎不會(huì)有什么影響.1Level--------------------------Almosthasnoinfluence.10級(jí)-----------------------------違反安全和法規(guī).10Level-------------------------Violationofsafetyandregulations.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet17四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度分類SeverityClassify

耐火性、自然性、UL、RHoS&HF

FireResistance,Naturalness,UL,RHoS&HF一、危險(xiǎn)特性Catastrophic工業(yè)標(biāo)準(zhǔn)(無法滿足而不能銷售）IndustryStandardIncapableConnotMarket.客戶要求

CustomerRequest

內(nèi)部工程需要由Critical測(cè)量項(xiàng)目

InternalENGneedforcriticalmeasureproject四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet18四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度分類SeverityClassify

客戶及供應(yīng)商共同制定特性；

CustomerandSuppliertogetherformulatefeatures.二、重大特性Significant或客戶指定特性，如導(dǎo)電或絕緣；(滿足而不能銷售給指定客戶)Orcustomerappointfeatures,ForinstanceEC&Insulation.ContentConnotMarket設(shè)計(jì)工程指定的特性；

DesignationCustomerDEappointfeatures.

行業(yè)標(biāo)準(zhǔn).

Industrialstandard.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet19四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度分類SeverityClassify

可靠性測(cè)試，如拉拔力測(cè)試；

.ReliabilityTesting,Forexampledrawingforcetest.三、主要特性Major產(chǎn)品制程不良率及分析

Productprocessrejectratioandanalysis.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet20四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度等級(jí)標(biāo)準(zhǔn)SeverityRankStandard等級(jí)/評(píng)分Rank劃分標(biāo)準(zhǔn)DivideStandard1幾乎無影響Almostnoinfluence2產(chǎn)品在客戶使用組裝過程中，組裝性差，客戶一般難已發(fā)現(xiàn)，關(guān)注的問題.Productsinthecustomerstouseassemblyprocess,assemblysexdifference,thecustomergeneraldifficulthasfound,payattentiontotheproblem.3產(chǎn)品之中主要應(yīng)用的功能稍有瑕疵，如絕緣等，非專業(yè)人員無法識(shí)別，EMCII級(jí)要求.Theproductismainlyusedinthefunctionoftheslightlydefects,suchasinsulation,laypeoplecan'tidentify,EMClevelIIrequirements.4在高于產(chǎn)品承諾的環(huán)境中使用失效，但此環(huán)境低于公司內(nèi)部控制標(biāo)準(zhǔn)或者已達(dá)到行業(yè)協(xié)會(huì)標(biāo)準(zhǔn)要求，EMCI級(jí)要求.不符合標(biāo)準(zhǔn)化的定義.Intheaboveproductpromisedenvironmentwithfailure,buttheenvironmentislowerthantheinternalcontrolstandardsorhasreachedindustryassociationstandardrequirements,EMCIlevelrequirement.Donotconformtothestandarddefinition.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet21四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度等級(jí)標(biāo)準(zhǔn)SeverityRankStandard等級(jí)/評(píng)分Rank劃分標(biāo)準(zhǔn)DivideStandard5存在的問題使產(chǎn)品長(zhǎng)期運(yùn)行的可靠性能降低，如產(chǎn)品粘力、導(dǎo)電產(chǎn)品的導(dǎo)電性能等，產(chǎn)品結(jié)構(gòu)復(fù)雜，甚至需要培訓(xùn)才能完成或當(dāng)前的技術(shù)無法解決的功能性問題.Problemsmaketheproductlong-termoperationofthelowerreliability,suchasproductviscousforce,conductiveproductsofconductiveperformanceandsoon,theproductstructureiscomplex,evenneedtrainingtocompleteorcurrenttechnologycannotsolvetheproblemoffunctional.6產(chǎn)品維護(hù)復(fù)雜，裝配、生產(chǎn)非常困難；設(shè)計(jì)的產(chǎn)品公司工藝無法完成；客戶獨(dú)特配件的兼容性問題；不能95以%以上機(jī)率復(fù)現(xiàn)的問題；計(jì)算機(jī)監(jiān)測(cè)功能失效或誤差大.Productmaintenance,assembly,productionisverydifficult;Designproductscompanyprocesswasunabletocomplete;Customeruniqueaccessoriescompatibilityproblem;Can't95to%aboveprobabilityreproduction;Computermonitoringfunctionfailureorbigerror.7客戶關(guān)注的重點(diǎn)功能性問題或者是產(chǎn)品主推場(chǎng)所應(yīng)用的兼容性問題；產(chǎn)品量化參數(shù)不達(dá)標(biāo).Customerfocusofconcernfunctionalproblemsoristheproductofthemainplacetheapplicationcompatibilityproblem;Productquantitativeparametersnotstandard.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet22四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter嚴(yán)重度等級(jí)標(biāo)準(zhǔn)SeverityRankStandard等級(jí)/評(píng)分Rank劃分標(biāo)準(zhǔn)DivideStandard8基本功能失效，失效影響計(jì)算機(jī)數(shù)據(jù)處理功能.Thebasicfunctionfailureandinfluencethecomputerdataprocessingfunction.9影響產(chǎn)品安全運(yùn)行或者包含不符合法律、法規(guī)；產(chǎn)品執(zhí)行標(biāo)準(zhǔn)影響人身安全；產(chǎn)品失效時(shí)有警告.Influencethesafeoperationoftheproductorcontaindoesnotcomplywiththelaws,rulesandregulations.Productstandardsaffectpersonalsafety;Productfailureiswarning.10影響產(chǎn)品安全運(yùn)行或者包含不符合法律、法規(guī)；產(chǎn)品執(zhí)行標(biāo)準(zhǔn)影響人身安全；產(chǎn)品失效時(shí)無警告.Influencethesafeoperationoftheproductorcontaindoesnotcomplywiththelaws,rulesandregulations.Productstandardsaffectpersonalsafety;Productfailureisn’twarning.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet23四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter發(fā)生率Occurrence某一原因而導(dǎo)致失效發(fā)生的幾率.Areasontotheoddsoffailure.劃分標(biāo)準(zhǔn)：依據(jù)不良品出現(xiàn)的機(jī)率來定，以1至10表示等級(jí).Thedivisionstandard:accordingtotheprobabilityofbadproductappearedtodecide,be1to10showlevel.1級(jí)最輕微，10級(jí)最嚴(yán)重.1Levelbestslight,10Levelbestgrave.1級(jí)-------------------------------幾乎不會(huì)發(fā)生.1Level--------------------------Almostwon'thappen.10級(jí)-----------------------------肯定會(huì)發(fā)生.10Level-------------------------Willhappen四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet24四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter發(fā)生率Occurrence劃分標(biāo)準(zhǔn)--------------------------------------CPK、主觀判定、統(tǒng)計(jì)資料DivideStandard--------------CPK,Subjectivejudge,statisticalinformation劃分標(biāo)準(zhǔn)DivideStandard等級(jí)/評(píng)分Rank描述Describe發(fā)生率OccurrenceCPK1(Remote)幾乎不可能發(fā)生Almostwon'thappen.1/1500K≥1.672(VeryLow)有輕度發(fā)生的可能Withmildpossible1/150K≥1.503(Low)有可能發(fā)生possible1/15K≥1.334(Moderate)偶爾發(fā)生，但不占有大的比例Occasionallyoccur,butdon'thavegreatproportion1/2K≥1.175(Moderate)1/400PCS≥1.006(Moderate)1/80PCS≥0.83四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet25四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter發(fā)生率Occurrence劃分標(biāo)準(zhǔn)--------------------------------------CPK、主觀判定、統(tǒng)計(jì)資料DivideStandard--------------CPK,Subjectivejudge,statisticalinformation劃分標(biāo)準(zhǔn)DivideStandard等級(jí)/評(píng)分Rank描述Describe發(fā)生率OccurrenceCPK7(High)經(jīng)常發(fā)生Oftenoccur1/20PCS≥0.678(High)1/8PCS≥0.519(Veryhigh)幾乎不可避勉Almostdonotavoidlayer1/3PCS≥0.3310(Veryhigh)1/2PCS<0.33四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet26四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter難檢度Detection在現(xiàn)行的控制措施下，偵測(cè)失效發(fā)生的能力.Inthecurrentcontrolmeasures,theabilitytodetectfailurehappened.劃分標(biāo)準(zhǔn)：依據(jù)失效模式檢驗(yàn)的難易程度來定，以1至10表示等級(jí).Thedivisionstandard:Accordingtothefailuremodeofthetestdifficulty

toset,be1to10showlevel.1級(jí)最容易，10級(jí)為幾乎不可能發(fā)現(xiàn).1Levelbesteasy,10LevelforAlmostimpossibilityfind.1級(jí)-----------------------用有效的手段完全可以檢測(cè)出來1Level-------------------Witheffectivemeanscompletelycanbedetected.10級(jí)----------------------無任何手段可以檢測(cè)出來.10Level------------------Nomeanscanbedetected.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet27四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter難檢度Detection劃分標(biāo)準(zhǔn)--------------------------------------主觀判定、統(tǒng)計(jì)資料DivideStandard--------------Subjectivejudge,statisticalinformation劃分標(biāo)準(zhǔn)DivideStandard等級(jí)/評(píng)分Rank描述Describe可偵度Detection1~2幾乎可以肯定地檢測(cè)出來Almostcertainlydetected≥99.99%3~5有良好的手段可以檢測(cè)出來Havegoodmeanscanbedetected≥99.80%6~8可能能檢測(cè)出來Mightbeabletotestout≥98.00%9有可能檢測(cè)不出Maycannotbedetected≥90.00%10很有可能檢測(cè)不出來Verylikelytestdoesnotcomeout≤90.00%四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet28四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParameter風(fēng)險(xiǎn)系數(shù)RiskPriorityNumberRPN=S*O*D風(fēng)險(xiǎn)系數(shù)RPN排出次序后，RPN越大越優(yōu)先解決.RPN在100以上必須解決；50<RPN<100應(yīng)盡可能解決，不能解決必須加嚴(yán)控制；RPN<50可不加控制.當(dāng)嚴(yán)重度(S)很高或發(fā)生率(O)很高時(shí)，不管RPN大小如何，都必制定相應(yīng)改善或控制措施，并指定責(zé)任人和改善完成日期.RiskcoefficientRPNdischargeorder,thebiggertheRPNpriority.RPNinmorethan100mustbesolved;50<RPN<100shouldasfaraspossibletosolve,can'tsolvemustbetightenedcontrol;RPN<50don'taddcontrol.Whentheseverity(S)orhighincidence(O)isveryhigh,nomatterhowRPNsizewillbeformulatethecorrespondingimprovementorcontrolmeasures,andappointresponsiblepersonsandimprovethecompletiondate.四、DFMEA關(guān)鍵參數(shù)

DFMEAKeyParamet29如何制定改善措施

Howtomaketheimprovementmeasures針對(duì)預(yù)防/糾正措施，以降低評(píng)價(jià)等級(jí)的內(nèi)容順序?yàn)椋簢?yán)重度、發(fā)生率及偵測(cè)度；Aimingatpreventing/correctivemeasures,inordertoreducethecontentoftheevaluationgradeorder:(S),(O),(D).通過設(shè)計(jì)變更來消除或控制一個(gè)或多個(gè)失效模式的起因機(jī)理，能降低嚴(yán)重度等級(jí)；Throughthedesignchangetoeliminateorcontroloneormoreofthecauseofthefailuremodemechanism,canreducetheseveritylevel;透過設(shè)計(jì)變更，去除或管制某一或多個(gè)影響失效模式的原因或設(shè)備，只能降低發(fā)生率的等級(jí).Throughthechangeofthedesign,removeorcontroloneormoreofthecauseofthefailuremodeeffectorequipment,canreducetheincidenceofgrade.增加設(shè)計(jì)驗(yàn)證，修改測(cè)試計(jì)劃，修改原物料規(guī)格，只可降低難檢度.Toincreasethedesignverification,modifyingthetestplan,modifytheoriginalmaterialspecifications,canonlyreducethedifficultdegreeoftest.如何制定改善措施

Howtomaketheimpro30五、DFMEA表單填寫說明1

DFMEANotesoncompletingtheform(1)

DFMEA編號(hào)：填入DFMEA文件的編號(hào)，以便要詢；DFMEANumbers:fillintheDFMEAfileNumbers,sothattoinformation;

項(xiàng)目：填入所分析的系統(tǒng)、子系統(tǒng)或零件的過程名稱，編號(hào)；Project:fillintheanalysisofthesystem,subsystemorpartsoftheprocessname,Numbers;

設(shè)計(jì)責(zé)任：部門、小組還應(yīng)包括供方的名稱；Designresponsibility:department,theteamalsoshouldincludethenameofthesupplier;

填入負(fù)責(zé)DFMEA工作的工程師姓名、電話及所在公司名稱；FillintheresponsibleoftheengineersDFMEAname,phonenumberandthenameofthecompany;

填入將使用或正被分析的設(shè)計(jì)過程影響的預(yù)期的機(jī)型和料號(hào)；Fillinwilluseorarebeinganalyzedtheinfluenceofthedesignprocessoftheexpectedtypeand

materialnumber;

關(guān)鍵日期：填入DFMEA初次預(yù)定完成日期，該日期不應(yīng)超過計(jì)劃開始設(shè)計(jì)生產(chǎn)發(fā)布日期.Thekeydate:fillintheDFMEAfirsttargetcompletiondate,thisdateshallnotexceedthedesign

plantobeginproductionreleasedate.五、DFMEA表單填寫說明1

DFMEANoteson31五、DFMEA表單填寫說明2

DFMEANotesoncompletingtheform(2)

DFMEA日期：填入編制DFMEA原始稿的日期及最新修訂日期；

DFMEAdate:fillinthedrawupDFMEAdateandlatestrevisiondate.

核心小組：列出有權(quán)確定和執(zhí)行任務(wù)的責(zé)任部門和個(gè)人姓名，如果對(duì)某一特定原因無建議措施，那么

就在該欄中寫“N/A”.Thecoreteam:listshallhavetherighttodetermineandimplementtheresponsibilityofthe

departmentandindividualtaskname,ifforAparticularreasonnosuggestedmeasures,thenwritein

thecolumnof"N/A".

項(xiàng)目/功能：填入被分析項(xiàng)目的名稱和編號(hào)，若該項(xiàng)目有多種功能，且有不同的失效模式，應(yīng)把所有功

都單獨(dú)列出.

Project/function:fillinthenameoftheprojectareanalyzedandNumbers,iftheprojecthasavariety

offunctions,andhavedifferentfailuremode,weshouldputallfunctionsarelistedseparately.

潛在失效模式：對(duì)一個(gè)特定項(xiàng)目及其功能，應(yīng)用規(guī)范化，專業(yè)性的術(shù)語來列出每一個(gè)潛在的失效模式

前提是這種失效可能發(fā)生，但不一定發(fā)生.Potentialfailuremode:foraspecificprojectanditsfunction,theapplicationofstandardized,

professionaltermstolisteachpotentialfailuremodeprovidedthatfailuremayoccur,butdoesnot

necessarilyoccur.五、DFMEA表單填寫說明2

DFMEANoteson32五、DFMEA表單填寫說明3

DFMEANotesoncompletingtheform(3)

潛在失效后果，就是失效模式對(duì)系統(tǒng)功能的影響，一般是客戶在使用時(shí)看到的狀況；

Potentialfailureconsequences,isthefailuremodeoftheinfluenceofthesystemfunction,itistosee

thecustomersintheuseofthesituation.嚴(yán)重度(S)

Severity

分級(jí)（重要程序）用于對(duì)零件、系統(tǒng)、子系統(tǒng)的產(chǎn)品特性分級(jí)：關(guān)鍵、主要、重要、輕微等.Classification(importantprogram)forparts,system,subsystemproductcharacteristicsclassification

:thekey,major,major,minor,etc.

潛在失效的起因/機(jī)理：潛在失效模式的起因是指一個(gè)設(shè)計(jì)或工藝薄弱部分的跡象；機(jī)理是什么導(dǎo)致失

效.Thecauseofthepotentialfailure/mechanism:thecauseofthepotentialfailuremodesistopointtoa

designorprocessunderbellysigns;Mechanismofwhatcausesthefailure.五、DFMEA表單填寫說明3

DFMEANoteson33五、DFMEA表單填寫說明4

DFMEANotesoncompletingtheform(4)

頻度是指某一特定失效起因或機(jī)理（已列于前欄中）出現(xiàn)的可能性；Occurrenceistopointtoaspecificfailurecauseormechanism(alreadylistedinfrontbar)eventualities;現(xiàn)行的設(shè)計(jì)，工藝控制，控制的方法指的是那些已經(jīng)用于或正在用于相同或相似設(shè)計(jì)中的那些方法.Thecurrentdesign,processcontrol,thecontrolmethodreferstothosewhohaveusedorareusedin

thesameorsimilardesignofthosemethods.

探測(cè)度Detection

風(fēng)險(xiǎn)順序數(shù)

RPN

建議措施：例如：設(shè)計(jì)變更、過程變更、特殊管控等；如果對(duì)某種特定原因無建議措施那么就在該欄

中填寫“N/A”.

Suggestionsandmeasures,suchas:thechangeofthedesign,processchange,specialcontrol,

etc.;IfforAspecificreasonnosuggestedmeasurestheninthebartofillin"N/A".五、DFMEA表單填寫說明4

DFMEANoteson34五、DFMEA表單填寫說明5

DFMEANotesoncompletingtheform(5)

責(zé)任：把負(fù)責(zé)建議措施執(zhí)行的組織和個(gè)人及預(yù)計(jì)完成的日期填寫在此欄中；Responsibilities:responsiblefortheimplementationoftheadviceoftheorganizationsand

individualsandthedateisexpectedtofillinthiscolumn;采取的措施：跟蹤評(píng)審，確認(rèn)和控制計(jì)劃等，記錄具體的措施和生效日期；

Takemeasures:trackingreview,identifyandcontrolplan,recordthespecificmeasuresand

effectivedate;

糾正后的RPN

CorrectedRPN

跟蹤小組成員應(yīng)保證所有建議措施或妥善落實(shí)；Trackingteammembersshallensurethatallsuggestmeasuresorproperlyimplement.

RPN的再改進(jìn)，一般行業(yè)要求RPN≤50.ToimprovetheRPN,generalindustryrequirementsRPN≤50五、DFMEA表單填寫說明5

DFMEANoteson35DFMEA------失效模式與后果分析

(DesignFailureMode&EffectAnalysis)案例：CaseDFMEA------失效模式與后果分析

(DesignF36DFMEA------失效模式與后果分析

(DesignFailureMode&EffectAnalysis)謝謝大家！Thankyou!DFMEA------失效模式與后果分析

(DesignF37DFMEA------失效模式與后果分析

(DesignFailureMode&EffectAnalysis)Marian(Shenzhen)Co.,Ltd編制：曹喜元FormationBy：JackCao

日期：

Date：1-Feb-2013DFMEA------失效模式與后果分析

(DesignF38主要內(nèi)容

Maincontent1.DFMEA介紹4.DFMEA關(guān)鍵參數(shù)DFMEAPresentationDFMEAKeyParameter2.DFMEA職責(zé)5.DFMEA表單填寫說明DFMEAResponsibilityDFMEAFormFillingExplanation3.DFMEA制作流程6.DFMEA案例DFMEAMakeProcessDFMEAExample主要內(nèi)容

Maincontent39一、DFMEA的介紹

DFMEAPresentationDFMEA是FMEA中的一種，F(xiàn)MEA分為：DFMEA和PFMEADFMEAisintheFMEAonetype,FMEAContain:DFMEA&PFMEADFMEA是由負(fù)責(zé)設(shè)計(jì)的工程師或小組，在產(chǎn)品設(shè)計(jì)階段盡可能的范圍內(nèi)預(yù)估產(chǎn)品在設(shè)計(jì)上可能發(fā)生的缺點(diǎn).DFMEAisEngineerorgrouptoresponsiblescheme,Asfaraspossiblewithinthescopeoftheestimatedproductdesignonthepossiblefaultsintheproductdesignstage.PFMEA是由負(fù)責(zé)制造裝配的工程師或小組，預(yù)估產(chǎn)品在生產(chǎn)過程階段或之前可能會(huì)發(fā)生的缺點(diǎn).PFMEAisPEorgrouptoresponsiblescheme,Asfaraspossibletheestimatedproductpossiblefaultsintheproductiveprocessorbefore.本章節(jié)重點(diǎn)講述DFMEAThischapterfocuseson

DFMEA.一、DFMEA的介紹

DFMEAPresentatio40DFMEA的形成

DFMEAFormationDFMEA是由負(fù)責(zé)設(shè)計(jì)的工程師或小組，在盡可能的范圍內(nèi)預(yù)估產(chǎn)品在設(shè)計(jì)上可能發(fā)生的缺點(diǎn)，衡量該項(xiàng)缺點(diǎn)或可能造成的影響，并擬定為防止或檢測(cè)該缺點(diǎn)應(yīng)改善的設(shè)計(jì)控制，并推動(dòng)其標(biāo)準(zhǔn)化作業(yè)，且必須配合設(shè)計(jì)發(fā)展之程序反復(fù)執(zhí)行.DFMEAisEngineerorgrouptoresponsiblescheme,Asfaraspossiblewithinthescopeoftheestimatedproductdesignonthepossiblefaultsintheproductdesignstage,Measurethefaultsorcancauseinfluence,andplantopreventortestingthedefectshouldbeimproveddesigncontrol,andpromotethestandardizedoperation,andmustfitinwiththedevelopmentofdesignprogramandimplementation.最終成品及其所有相關(guān)的系統(tǒng)、子系統(tǒng)都應(yīng)納入評(píng)估.DFMEA是設(shè)計(jì)小組，即公司工程，運(yùn)用設(shè)計(jì)，工程經(jīng)驗(yàn)或分析方法等而形成的.Thefinalandallrelatedsystem,subsystemshouldbeincludedinassessment.DFMEAisthedesignteam,namelythecompanyproject,theuseofdesign,engineeringexperienceoranalysismethodsandform.DFMEA的形成

DFMEAFormationDFMEA41DFMEA必備條件

DFMEAEssentialCondition

確認(rèn)已知及潛在的失效模式；Confirmtheknownandthepotentialfailuremode.

確認(rèn)每一個(gè)失效模式的效應(yīng)和原因；

Confirmeachfailuremodeeffectandreasons.

風(fēng)險(xiǎn)優(yōu)先評(píng)估（嚴(yán)重性、發(fā)生頻率、難檢度）；Riskpriorityevaluation(severity,occurrencefrequency

anddifficulttocheckdegree)

提供問題的數(shù)據(jù)及改善行動(dòng)；Provideproblemofdataandimprovementaction.

DFMEA必備條件

DFMEAEssentialCon42DFMEA的動(dòng)態(tài)鏈

DFMEATrendsCatenationDFMEA是個(gè)循環(huán)過程，在設(shè)計(jì)方案最終形成之時(shí)或之前開始.DFMEAisacyclicprocess,thedesignschemeoffinalformorbeforethestart.在產(chǎn)品開發(fā)各階段中，當(dāng)設(shè)計(jì)有變化或得到其他信息時(shí)，應(yīng)及時(shí)，不斷地修改，最終在產(chǎn)品加工圖樣完成之前全部結(jié)束。Ineverystageofproductdevelopment,whenthedesignchangeorgetotherinformation,shouldbeprompt,constantlymodified,finally,inproductprocessingpatternuntilallover.DFMEA的動(dòng)態(tài)鏈

DFMEATrendsCatena43二、DFEMA職責(zé)

DFMEAResponsibility

工程經(jīng)理：DFMEA總體負(fù)責(zé)人，負(fù)責(zé)組建DFMEA團(tuán)體，提出DFMEA實(shí)施計(jì)劃，并組織召開DFMEA會(huì)議，分配團(tuán)隊(duì)人員任務(wù)

組織DFMEA評(píng)審，DFMEA審核.Projectmanager:generalmanager,responsibleforDFMEA,this

paperputsforwardaDFMEAgroupDFMEAimplementationplan,

andorganizeaDFMEAmeeting,distributionteampersonneltask

OrganizationDFMEAreview,DFMEAaudit.

工程師：負(fù)責(zé)主導(dǎo)DFMEA文件編寫、修改和升級(jí).Engineer:responsibleforleadingDFMEAdocumentpreparation,

modificationandupgrade.二、DFEMA職責(zé)

DFMEAResponsibilit44二、DFEMA職責(zé)

DFMEAResponsibility

工程助理：負(fù)責(zé)客戶投訴問題，研發(fā)、試產(chǎn)、量產(chǎn)中問題的收集，及

時(shí)反饋到DFMEA團(tuán)體負(fù)責(zé)人處，并參與O,S,D參數(shù)評(píng)估，提供量

產(chǎn)CPK數(shù)據(jù).Projectassistant:responsibleforcustomercomplaintproblem,research

andtrialproduction,thequantityofcollection,andrenderWhenthe

feedbacktoDFMEAgroupplace,andparticipateinO,S,Dparameter

evaluation,SupplyvolumeproductionCPKdata.

試樣工程師：負(fù)責(zé)研發(fā)產(chǎn)品測(cè)試過程中所出現(xiàn)問題點(diǎn)的收集并及時(shí)

反饋到DFMEA負(fù)責(zé)人處，參與O,S,D參數(shù)評(píng)估.Sampleengineer:responsiblefor