FMEA失效模式與效應 3

FMEAFailureModeandEffectsAnalysis失效模式與效應分析1of33陳啟政中原大學品質(zhì)研究中心中原大學工業(yè)工程系TheQualityResearchCenterIndustrialEngineeringDepartmentChungYuanChristianUniversityFMEA意義說明FMEA是不良預防的工具,是一種有條理程序可藉由一張包含所有的失效模式的表,並以數(shù)據(jù)來表示風險的大小和預先採取預防改善措施。

2of33導入FMEA的優(yōu)點Teamwork方式提高部門或Function間連繫溝通,共同預防改善問題

腦力激盪方式,讓每一成員在同一議題上發(fā)揮想像力,經(jīng)由有系統(tǒng)整合提出有效之預防改善對策徹底了解產(chǎn)品功能架構(gòu)圖或產(chǎn)品製造組合流程圖以魚骨圖分析方式列出失效模式每一種可能因子以失效樹分析(FTA)方法了解產(chǎn)品失效模式各種組合型式

把失效模式量化針對TopFailureMode優(yōu)先採取對策預防確保所有想像得到失效模式和影響,在正常操作情況之下均被考慮到藉由過去的資料給未來參考,協(xié)助分析失效的範圍和影響性提供設計產(chǎn)品或製程管制預防採取對策時使用3of33

Coreteam:列出與FMEAteam相關(guān)人員名字,部門與職責

Failuremode:失效模式種類

Effect:失效後對產(chǎn)品產(chǎn)生影響

Cause:造成失效模式之原因

Severity:失效模式發(fā)生之嚴重程度等級(1～10)

Occurrence:失效模式之發(fā)生頻度等級(1～10)

Detection:失效模式發(fā)生可被偵測程度等級(1～10)

RPN:RiskPriorityNumber指評估風險及優(yōu)先處理指數(shù)是Severity*Occurrence*Detection之乘積

FTA:Faulttreeanalysis是失效樹分析是導果為因由頂端事件利用邏輯(OR或AND)持續(xù)分析第1.2…層直至真正Rootcause將這些原因謀求徹底改善FMEA相關(guān)名詞解說4of33

QFD:QualityFunctionDeployment

DOE:DesignofExperiments

VOC:VoiceofCustomer

VOE:VoiceofEngineering

SOP:StandardOperationProcedure

SIP:StandardInspectionProcedure

FRACAS:FailureReportAnalysisandCorrectiveActionSystem

SPC:StatisticProcessControl

TQM:TotalQualityManagement

DVT:DesignValuationTest

MTBF:MeanTimeBetweenFailureFMEA書籍相關(guān)名詞解說5of33FMEA型式SYSTEM

SFMEADesign

DFMEA*Component*Unit*ModuleProcess

PFMEAMachine

MFMEAEquipment

EFMEAService

SFMEA6of33組成FMEA團隊設計FMEA流程(DFMEA)蒐集資料完成FMEA執(zhí)行方案系統(tǒng)特性系統(tǒng)功能硬品架構(gòu)分析失效模式分析設計管制方法分析失效原因分析失效效應分析嚴重度計算關(guān)鍵指數(shù)分析發(fā)生率分析難檢度建議改正行動決定關(guān)鍵性失效模式設計審查評估資料設計改善參考資料可靠度分析參考資料標準檢驗程序資料教育訓練參考資料失效報告。分析與改正作業(yè)系統(tǒng)(FRACAS)設計改善撰寫報告維護度分析參考資料7of33組成FMEA團隊製程FMEA流程(PFMEA)蒐集資料完成FMEA執(zhí)行方案定義製造流程分析產(chǎn)品特性分析製程特性分析失效模式分析現(xiàn)行管制方法分析失效原因分析失效效應分析嚴重度計算關(guān)鍵指數(shù)分析發(fā)生率分析難檢度建議改正行動決定關(guān)鍵性失效模式設計審查評估資料設計改善參考資料新製程設計參考資料標準檢驗程序資料教育訓練參考資料失效報告。分析與改正作業(yè)系統(tǒng)(FRACAS)製程改善檢驗程序改善撰寫報告8of33FMEA實施步驟1.決定FMEA對象2.成立&組成FMEAteammembers3.收集&準備相似產(chǎn)品之歷史資料4.列出產(chǎn)品方塊圖或製程流程圖5.列出Failuremode各種可能情況6.列出Failuremode對產(chǎn)品/機器之影響(Effect)7.魚骨圖分析造成此Failuremode之可能原因(Cause)8.根據(jù)相關(guān)產(chǎn)品之歷史資料定義出Severity/OccurrenceDetection之等級9.根據(jù)S/O/D的定義定出每個Failuremode之S/O/D值10.列出相似Model目前採行之Action11.計算出RPN=S*O*D值12.取RPN值≧100(值大小需定義)orTop20%優(yōu)先採取對策13.針對RPN值超出上述定之項目提出Action再改善14.定出Actionitem之owner及完成日期15.Action切入後檢視其效果及切入時間點16.重新計算Action後之RPN值17.若RPN值未達定義要求RPN≧100orTop20%回覆到item13重提Action18.若RPN達到要求完成FMEA表格9of33FMEATeamMembers

DFMEA(Design)

Chairperson*ProgramManager(PM)*ElectronicEngineer(EE)*MechanicalEngineer(ME)*QualityEngineer(QE)*QualityEngineer(QA)

*Manufacturing(MES)SupportTeam*Purchasing(Buyer)ifNeed

PFMEA(Process)

Chairperson*ProgramManager(PM)*QualityEngineer(QA)*IndustryEngineer(IE)*MechanicalEngineer(MFGME)*TestEngineer(TE)*ManufactureSupervisor(MFG)*ElectronicEngineer(EE)ifNeed*MechanicalEngineer(ME)ifNeed

10of33FailureModeFishboneAnalysisHi-Pot不不良良FailureMode(Defect)錫面組立加工不不良第一層層分析析Workmanship第二層層分析析第三層層分析析第四層層分析析正面裝裝插零件插插歪斜斜零件面面有異異物無線尾尾零件變變形零件碰碰case零件相相碰第一層層分析析Material變壓器器不良良PCB不良良Y電容容不良良PowerCable破EMI不良良Case不不良第二層層分析析第三層層分析析絕緣tape破破引腳超超出base焊點過過大造造成tape破破儀器設設備儀器設設定Layout安安規(guī)規(guī)距離離不夠夠Arcing規(guī)規(guī)定定過嚴嚴零件間間安規(guī)規(guī)距離離不足足第一層層分析析Design第一層層分析析Test第二層層分析析第三層層分析析第二層層分析析第三層層分析析鎖螺絲絲過長長套管短短零件本本體大大Layout面面積小小測試條條件設設錯O/I寫錯錯測試線線接錯錯11of33Hi-PotFailureAnalysisFaultTreeAnalysisForHi-PotFailure5.板邊零件傾斜踫Case,造成安規(guī)距離不夠b.Socket上Y電容線腳靠近馬口鐵a.SocketFG線漏焊Process4.錫面3.正面裝插2.組立1.加工不良d.錫面短路︵錫珠,錫渣︶c.線腳過長b.漏焊︵Y電容︶a.異物c.零件插歪斜零件變形碰Case碰T1碰H/S相互碰撞b.零件面有異物a.無線尾h.鎖絲未鎖緊或漏鎖g.掉金屬物進產(chǎn)品f.絕緣片放置不當或漏裝d.PCB沒有卡到位c.組立時,B+B-線壓傷壓破b.絕緣片膠布破a.FG線有無Touch任何零件c.膠布沒貼到位Design2.元件之間安規(guī)距離不夠3.Arcing規(guī)格過嚴c.鎖螺絲過長b.套管短a.原件本體大Layout面積小4.板邊零件與Case安規(guī)距離不夠1.Layout安規(guī)距離不夠Material9.變壓器PFC︵電感︶8.膠雜質(zhì)過多7.Y電容不良6.線材PowerCable破5.PCB4.EMISocket3.Case2.接地小黃豆電容耐壓不夠c.有毛刺b.耳掛有凸起a.碎屑b.本身耐壓不夠a.FG線氧化不吃錫b.Trace近似短路或開路a.PCB受潮e.絕緣Tape破d.零件本體歪斜c.焊點過大,造成錫間賜破絕緣層b.引線腳超出basea.絕緣膠布位置不恰當1.光藕合器不良e.O/I寫錯誤Test2.儀器設定1.儀器c.測試條件設置錯誤b.O/I寫錯誤a.測試線接錯b.儀器本身電壓頻率誤差大a.接觸不良f.本身繞線造成Arcing過大其他2.接地銅箔被燒斷3.接地跳線斷4.未依O/I作業(yè)1.SocketY電容線腳斷5.油墨,黑色Mark筆,在初級側(cè)導電12of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement Cannot CustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNThiscolumnisusedtolistthepartnameandfunction.ListallthefunctionsforthefunctionalblockFMEA格格式逐項項解說..3.13of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement Cannot CustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPN2.Inthefailuremodecolumn,listeachofthefailuremodesforthefunction.FMEA格式式逐項解解說..4of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement CannotCustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceDetectionDetectionRPNRPNOccurrence3.Listtheeffectsoffailureforeachofthefailuremodes.FMEA格式式逐項解解說..5of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement CannotCustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNForeachoneoftheeffects,listtheseverity(scalefrom1to10)4.FMEA格式式逐項解解說..6of33符合需求,17of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannot CustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannot CustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNTheClasscolumnisoptional.Itistypicallyusediftheseverityis9or10.5.FMEA格格式逐項解說說..8of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannot CustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannot CustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNIntheCausecolumn,listthecausesforeachfailuremode6.FMEA格格式逐項解說說..9of33FMEAModelLinkingFailureModetoCauseandEffectCauseFailureMode(Defect)Effect20of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannot CustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannot CustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNEstimatethelikelihoodofthe“causes”happeningona“1to10”scale.Thehigherthenumberthemorelikelythe“causes”willoccur.7.FMEA格格式逐項解說說..1of3322of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannot CustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannot CustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNListtheprevention,designvalidation/verification,orotheractivitieswhichwillassurethedesignadequacyforthefailuremodeand/orcause/mechanismunderconsideration.TestsDesignreviews,Mathematicalstudies,Fail/safe(Example:redundantpowersupplies)8.FMEA格格式逐項項解說..3of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement Cannot CustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNEstimatethelikelihoodofthedetectionona“1to10”scale.Thelowerthenumberthemorelikelythecausewillbedetected.9.FMEA格格式逐項項解說..4of3325of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement Cannot CustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNRPN(RiskPriorityNumber)istheproductofSeverity,Occurrence,andDetection.Thehigherthenumber,thehighertherisk.10.FMEA格格式逐項項解說..6of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNWhatactionsneedtobetakentopreventtheFailureMode?Ifnoactionistaken,record““none””11.FMEA格格式式逐逐項項解解說說..7of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement CannotCustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNAssignappropriateindividual,area,functionorteam.SetarealistictargetforcompletionTargetdatecouldbeestablishedbydevelopmentprogram12.FMEA格式式逐項解解說..8of33PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagement CannotCustomerSoftwareMonitor dissatisfactionFailureMonitor BatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaultsSeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNListtheresultsoftheactionstaken.Alwaysenterareferencesuchasdataortestreports.13.FMEA格式式逐項解解說.5.6.8