流程圖,失效模式分析,控制計(jì)劃

ProcessPlanning,Analysis&ControlPFDPFMEAPCPCTIS#305132PFD-PFMEA-PCPTraining

-AgendaAgenda(8am-5pm)

Day1WelcomeandIntroductions 15minWhyWeareHere(includingpre-test) 30minPFDClassLecture(includingbreak) 60min1stClassPFDActivity(includingbreak)

45minPFD–gettingthedetailsClassLecture 10minPFMEAClassLecture(includinglunchbreak) 90min1stClassPFMEAActivity

(includingbreak)

30minPFMEA-Functions>FailureModes>EffectsClassLecture 60min2ndClassPFMEAActivity(includingbreak)

45minPFMEA-Causes>Controls3Agenda(8am-5pm)Day2PFMEA(cont.)ClassLecture(includingre-capofAct#2) 60min3rdClassPFMEAActivity(includingbreak)

45minPFMEA–RiskAssessment>ActionPlans> Timing>ResponsibilityClassLecture 15minProcessControlPlan(PCP)ClassLecture(includingbreak) 60min1stClassPCPActivity(includingbreak) 60minPCP–definingtheactionsClassLectureandSummary

10minProcessDocuments(StdCell&EOP)ClassLecture 15min1stClassSTDCellDocsActivity(includingbreak) 40minWrap-up(includingpost-test&eval) 40minNextStepsfor“On-Site”Workshop 15minPFD-PFMEA-PCPTraining

-Agenda4Establish“TheDay”forFollow-upPlantFocusedWorkshopEstablishdateforworkshop(preferablydayafterthetrainingsession)DetermineareaoffocusfortheworkshopMultipleprocesses&groupsmaybeselectedCollectprocessdocumentationforthefocusareaIfPlantFocusedWorkshopisthedayfollowingthe2-daytraining,thisstepneedstobecompletedbeforetheworkshopbeginsPlantFocusedWorkshopAgendaWhyWeareHerePFD,PFMEA,PCP,ProcessMonitoring,WorkInstructions,etc.Howgoodistheplanning&execution(inthedocuments&results)PFD-PFMEA-PCPTraining

PlantFocusedWorkshop5PlantFocusedWorkshopAgenda(Cont’d)PFDWalktheprocessandobserveactualvs..documentedprocessstepsandflow.Lookfor‘hiddenfactory’processesthatmaynotbedocumentedPFMEAHaveallpotentialFailureModesbeenidentified?Areratingsappropriate?PCPAreallcontrolsidentifiedinthePFMEAincludedonthePCP?Arereactionplansadequatelydefined?WrapUp&NextStepsComparePFDandPFMEAandPCPtoensureappropriatelinkageDevelopaplanforupdatingthedocumentsbasedonreviewfindingsPFD-PFMEA-PCPTraining

PlantFocusedWorkshop6TheDelphiAbsolutesofExcellenceFocus:YourcustomerPerformanceGoal:DoItRightTheFirstTime,EveryTimeMethod:InnovationandContinuousImprovementTHEDELPHIABSOLUTESofEXCELLENCEControl:CustomerFeedbackPeople:CaringStyle:TeamworkReward:RecognitionandSecurity7ObjectivesThisTrainingwillallowyouto:knowthecorrectuseofProcessFlowDiagrams(PFD)inprocessplanningunderstandtheneedforincluding“hiddenfactories”andmaterialhandlinginPFDsknowthedefinition&purposeofProcessFailureModeandEffectsAnalysis(PFMEA)beabletoperformallstepsinthePFMEAprocessusethePFMEAasatoolinProcessDevelopmentknowhowtotakeinformationfromPFD&PFMEAinthecreationofProcessControlPlans(PCP)knowtherelationshipsbetweenPFD,PFMEA,&PCPbeabletofollowthroughtoProcessDocuments(StdCell,EOP,Monitoringforms,etc.)Introduction8QualitySystemsStandardsandGuidelinesWorkInstructionsOtherDocumentationINDIVIDUALSUPPLIERSQualityManualProceduresINTERNATIONALSTANDARDSISO9000CustomerRequirementsQS-9000orISO/TS16949ProductionPartsApprovalProcessCompanySpecificRequirementsCustomerReferenceManualsAPQP&ControlPlanFMEAMSASPCReference:PFDs,FMEAs,PCPs9PPAPRequiredDocumentationStandardsandGuidelines1.DesignRecordsofSaleableProduct2.Engineeringchangedocuments(ifany)3.CustomerEngineeringApproval(ifrequired)4.DesignFMEA5.ProcessFlowDiagrams6.ProcessFMEA7.DimensionalResults8.Material,PerformanceTestResults9.InitialProcessStudy10.MeasurementSystemAnalysisStudies11.QualifiedLaboratoryDocumentation12.ProcessControlPlan13.PartSubmissionWarrant(PSW)14.AppearanceApprovalReport(AAR)(ifapplicable)15.BulkMaterialRequirementsChecklist(forbulkmaterialPPAPonly)16.SampleProduct17.MasterSample18.CheckingAids19.RecordsofCompliancewithCustomer-SpecificRequirements10DelphiCommonProcedure

RequirementsDelphiBusinessSystemStandardsandGuidelinesRegion,Unit/LocationandStaffProceduresandWorkInstructionsDivisionalProceduresDelphiCommonProcedureRequirementsCorporate,Divisional/StaffandRegionalPolicySupplementsDelphiBusinessSystemManual(togetherwithcustomer-specificrequirements)AddressPFD,FMEA&PCPwithintheDivision/Location11ProductCharacteristicsReferenceDP272&KCDSReferenceManualStandardsandGuidelinesSpecialCareAdditionalCareDefinedCareStandardCare(usualandcustomarycare)Safety/ComplianceS/CKPCFit/FunctionF/FKPCVariationReductionnotRequiredifCapable,

MeanCenteringmaybeRequiredMeanCenteringandVariationReductionRequiredQuality/CustomerInterfaceQCIStandardProductCharacteristicsNodesignationorsymbolSpecialorKeyProductCharacteristicsImportantProductCharacteristics12ExecutionofPFMEA’s*FailuremodenotidentifiedinPFMEA52%

48%GMNAOsummary(allsuppliers)ExecutionofPFMEA’s*FailuremodenotidentifiedinPFMEA66%34%WearegoingtobefocusingonwhatwecanaddressNOW–executionofPFMEA’s, including:SpillsEmergingIssues*PredictPhase(ProcessPlanning)ofDrillDeep&WidePFMEAnotupdatedNotidentifiedinAPQPplanPFMEAteamlackstrainingLow(incorrect)RPNvalueinPFMEAplanPFMEAplannotupdated&reviewedPFMEAplanningbypassedWhatOurLargestCustomerisTellingUs13FailureModes,Effects,andCausesmustbemorespecificTypicalfailuremodesandcontrolsforspecificprocesstechnologiesmustbedocumentedandusedasPFMEAinputAcommonformatforallPFMEAsmustbeutilizedFormattingandAIAGguidelineinterpretationdifferencesresultedina“red”status.PrimaryfocusondetectionversuspreventionProductsandProcessesmustbetterfacilitatepreventingversusdetectingfailuresRiskreductionmustbeanon-goingactivityLargenumberoflineitemswiththedetectionrankingtoolow.PastproblemsthatimpactedcustomernotcomprehendedMaterialCertificationsmustappearascontrolinthereceivingdockPFMEAEffectsofthefailurenotfocusedonthecustomer(includingseverity)In-depthPFD-PFMEA-PCPtrainingforallfunctions(ME,PE,PC&L,Quality)isrequiredGMReviewPFMEAs

LessonsLearned14InvesteffortEarly

(HaveanImpact)DrivetoDetail

(DefinecorrectControls)Consistent/CommonUsageofRankings

(SetPriorities)NeedtoFocusonHighValueAspectsofPFD-PFMEA-PCP$$$$$$$$$$$$$$$$Approach15ApproachThemindsetrequiredtowhencreatingPFD,PFMEA,ControlPlan,andOperatorInstructionsistobeabletoanswerthequestion…Howdoyouknoweverypartshippedtoourcustomermeetsallrequirements?16

ProcessDocumentationPFDPFMEAEquipmentOperatingProcedureStandardCellControlPlanProcessMonitorFormsDataRecordingHowToInstructionsInformationflowsfromthePFDtothePFMEAtotheControlPlan.Thesedocumentsdefinewhattheprocessis,theanalysisoftheprocess,andthecontroloftheprocess.ProcessFlowDiagram(PFD)

Energy&ChassisSystemsPFDTraining18ProductDefinition:Characteristics:KPC's,QCI's,DFMEAProcessDefinition:ProcessFlowDiagram(PFD),FailureModeAnalysis:PFMEA,LinesideReviewProcessControlStrategy:ControlPlan,ErrorproofingCustomerRequirements:CharacteristicVerificationMatrix(CVM)Manufacturing:ProcessMonitoring,StandardCell,LayeredAuditInformationFlowSOR,VehicleTechSpecs,SystemTechnicalSpecsKCC's,QCCs19SomeTheoryInputsandOutputsAllprocesseshaveinputsandoutputsInputscontroloutputsINPUTSOUTPUTSPROCESSFACT:Ifyoudon’tcontroltheinputs, youcan’tcontroltheoutputs.20WhatisaPFD?Definition:AProcessFlowDiagramisaflowchartlinkingindividualprocessstepstoformamanufacturingsystem.Scope:Identifyeverypossiblepathapartcantakethroughtheanticipatedmanufacturingprocess

DP268Encompassesthe“HiddenFactory”QualityAuditsReworkProcessesAlternativeProcessesScrapToolChangesPartBuffersChangeoversPartIdent./LabelingTeardownGaugingStationsRejectHandlingPartmovement21Background“HiddenFactory”issuescontinuallyaffectDelphi’squalityperformanceandremainsessentiallyundocumentedReworkpartsbypassprocesscontrolsMixedpartsatchangeoversQualityauditandscrappartsfindingtheirwaybackintotheprocessNeedforcommonsystemsPartoftheoverallDelphiBusinessStrategyInclusionintotheDelphiEngineeringSystemcommoncontent,commonformat,commonapproachExtendtheapproachtooursuppliersconsideredanextensionoftheDelphiprocesses22ProcessFlowDiagramProcessFlowDiagramisthefoundationTheprocessmustbedefinedstepbystepTheinputsandoutputsarealsodefinedThePFDprovidesthestructuretostartthinkingaboutwhatproductcharacteristics(OUTPUTS)areaffectedbyagivenoperationandhowthesecharacteristicsarecontrolled(INPUTS)

IfaprocessstepismissingfromthePFD,thereisnoreasontobelieveitwillgetevaluatedforriskoradequateprocesscontrolThePFDisthetriggerforPFMEAandcontrolmethoddiscussions.23WhyaPFD?AcomprehensiveanddetailedPFDisthestartingpointfordocumentingthemanufacturingprocess.GraphicalrepresentationofthemanufacturingprocessEssentialfoundationforaPFMEA-“Roadmap”Springboardforprocessdocumentation-PFMEA,PCP,OperatorInstructions,etc.Helpsindevelopingequipmentspecifications.Howshouldtheprocesscontrolnon-conformingmaterial?Howwillinspectionsbeperformed,whatisrequired?Howwillpartsbere-introducedintotheprocess?24WhyaPFD?HowdoesanenhancedPFDhelpdevelopthePFMEA?Organizedtohelpseetheentireprocesschangeover,fab,inspect,rework,scrap,move,store,auditIdentifiesSignificantProductandProcessCharacteristicsProductCharacteristics=Outputs=PotentialFailureModesalsoProcessRequirements=Outputs=PotentialFailureModesProcessCharacteristics=Inputs=PotentialCausesNote:SignificantProductand/orProcessCharacteristics may(ormaynot)beKPC's/KCC's8025DocktoDockPFD/PFMEAA“DocktoDock”PFD/PFMEAisacollectionofPFD/PFMEA’sforthematerialmovementprocessesandmanufacturingprocessesassociatedwithaparticularpartorpartfamily.TheMaterialMovementProcessesinclude:ReceivingdockactivitiesMovementofmaterialto/fromMfg.ProcessMovementbetweenMfg.ProcessesShippingdockactivitiesMaterialStoragePFD/PFMEAsmustbedevelopedforeachMaterialMovementprocessaswellaseachMfg.ProcessMaterialmovementprocessesPFD/PFMEAsarelinkedtotheMfgProcessesviaanindexsheet26PreliminaryPFDApreliminaryPFDistypicallyasimpleblockdiagramthatshowsthemainoperations.GeneratedduringManufacturingSystemsDesignworkshops27PFDExcelWorksheetInstructionsandreferenceinformationcanbefoundbyviewingthecommentedcells(thosewiththesmallredtriangleinthecorner).TheExcelworkbookalsocontainsaHelpworksheetforinstructionsondrawingsymbols,connectors,etc.8028Operation-Sequence#“Operation”O(jiān)p-seqmajorprocesssteps(bytens):10-,20-,30-,40-...establishedbyapreliminaryPFD(processblockdiagram)“Sequence”op-Seqindividualdetailedstepswithinagivenoperation.Sequencedbyone:##-5,##-10,##-15,...Note:ThePFDestablishestheOp-Seqnumbersandtheymust

matchthePFMEA,ControlPlan,andotherprocessdocumentation.OperationDescription:describewhatishappeningtothepart.notamachine’ssequenceofoperationoranoperator’sstandardizedwork.29PathsDashedpathsshowthe“HiddenFactory”rework,scrapauditserrorproofingverificationpartflowalternative(backup)processesRedpaths:RejectpartflowReworkpartflowPathsbetweensymbolsaredrawnusingExcelAutoShapeConnectors-notlines30Fab“Fab”value-addedactivitiesthatchangethestateofthepartmachining,chemical,assembly,welding,paint,etc.labeling,partidentification,etc.SignificantCharacteristicsWhatproductcharacteristic(s)arearesult(output)ofthefabstep?AretheyKPC’sorQCI’s?Whatprocesscharacteristic(s)createand/orcontroltheassociatedproductcharacteristic?AretheyKCC’sorQCC's?QCC-1QCCQCC-3QCC-231PFMEALink(Fab)ProcessCharacteristics(Inputs)translateintoPotentialCausesProductCharacteristics(Outputs)translateintoPotentialFailureModes82QCIQCIQCI32Store/GetandMove“Move”partsaremovedwithintheprocesspartsinastoragedevicearerelocated(docktosupermarket)“Get”startingpoint-partsareintroducedtotheprocessfromastorageorpresentationdevice“Store”endingpoint-partsarereturnedtoastoragedevicepartsarelocatedinabuffer33InspectionsRed,Yellow,GreenshadingcanbeusedtoshowtestresultsandtheirrespectivepathsNoticetheflowofMasterpartsintoandoutofautomaticinspectionsShowwherepartsgoiftheyareremovedfromanesttoperformtheerrorproofingverification.LetterinsidetheboxindicatestypeofinspectionV=operatorvisualM=operatormanualgagingQ=qualityauditA=automatic34Rework“Rework”replace,repair,reload,tear-down,retest,etc.reworkcantakeplaceonlineorofflineconsideredpartoftheprocessReminders:takeintoaccountthemovestoofflineoperationsshowinspectionsthattakeplaceduringreworkshowre-entrypointtothemainprocessflow35Scrap/Contain“Scrap”rejectedmaterialispermanentlyremovedfromtheprocessandcontainedinadesignatedscrapcontainerNotes:considerpartsin/onarack,chute,conveyor,bench,neststillalive.includemovesrequiredtogettheparttotherejectcontainer(i.e.operatorwalk)“Contain”suspectmaterialisremovedfromtheprocessandcontaineduntilitisclassifiedasscraporreworkScrap/ContainpointsonthePFDshouldcorrespondtoFTQdatacollectionpoints8036PFMEALink(Scrap) Howdoyouknowthedefectivepartmadeittothescrapcontainer?

wasok)37ChangeoverFlageachstepthatrequiresa“Changeover”P=ProductT=ToolChangeS=SoftwareD=DunnageL=LabelsImproperchangeoverstranslatetothePFMEAcausesCaution:

considerprocesses(adjacentcells)thatmayhavesimilarcomponents,tooling,ordunnagetherebyprovidinganopportunityforerror(mixedparts).38PFMEALinks(Changeover)IncorrectChangeoverisaPotentialCause78439 ThePFDisnottheend,butaveryimportantsteptowardhavingarobustcontrolplaninmanufacturingProductDefinition:Characteristics:KPC's,QCI's,DFMEAProcessDefinition:ProcessFlowDiagram(PFD),FailureModeAnalysis:PFMEA,LinesideReviewProcessControlStrategy:ControlPlan,ErrorproofingCustomerRequirements:CharacteristicVerificationMatrix(CVM)Manufacturing:ProcessMonitoring,StandardCell,LayeredAuditSOR,VehicleTechSpecs,SystemTechnicalSpecsKCC's,QCCsInformationFlow40ZeroPPM,CustomerComplaints,Disruptions:

It’sintheDetails!!!

Summarizing41 AbicycleproductandmanufacturingprocesswillbeusedasanexampletoillustratetheProcessFMEAmethod Requirementswillbedescribed,andthecurrentprocesswillbeillustrated Aproposedchangetothedesign/processwillbepresentedandusedfortheexampleinthePFD,FMEAandPCP.ProcessExamplePFDExample42AssumeanimaginaryDelphiBicycleDivisionProductisamen’sbicycleCustomerisalsotheuserRequirementsaredefinedbycustomersandgovernmentregulationsProductEngineeringisresponsiblefordesignandvalidationofallproductrequirementsManufacturingEngineeringisresponsibleforprocessdevelopmentandvalidationManufacturingisresponsibleforproductconformancetoalldesignspecificationsTheDelphiBicycleDivisionPFDExample43GeneralorganizationofDelphiBicycleOperationsHandleBarassemblyFrontWheelassemblyRearWheelassemblySprocketassemblySeatassemblyChainassemblyCleanandprepareforpaintingPaintCureOvenProcessLevelsFrameassemblyMovetoFinalAssemblyManuallyloadtubesintoassemblyfixtureInitiateweldsequenceRemoveframeassemblyMovetoClean

andPaintBicycleAssemblyFrame

SubassemblyFrame

WeldingFrameWeldingPaintandTrimPFDExample44DelphiBicycleOperationsAwidenumberofbicycletypesareproducedinthemanufacturingoperationsThespecificproductconsideredfortheexampleisatrailbikeDuetothehighinvestmentcostsinroboticwelders,avarietyofmodelsareproducedineachweldingcellThisnecessitatesdifferentsetups,changeoversandpartsmanagementschemesOperationshastriedtooptimizeflowandminimizeWIPManycellsareatornearone-pieceflow45PFDExampleMen’sRoadandTrailbicycleObjectivesforMY2006Modifydesigntoaccommodate95thpercentileProvideforincreaseinriderleglengthMaintainsafetyanddurabilitywith225poundriderPerformreliablyduringoff-roadtrailridingProcessPlanningApproachIdentifychangestoproductrequirementsDetermineprocessstepsaffectedbychangesPerformPFMEAtoidentifyandpreventproblemsUsePFMEAtodevelopprocessControlPlanProcessObjectivesandApproach46ProcessControlsOurexamplewillincludeanalysisoftheexistingweldoperationMorestringentproductspecificationswillrequireimprovementoftheprocesscapabilityDifferentModelswillberuninthissameoperationrequiringtoolingandpartchangeoverThePFDwillbeusedtoidentifypotentialproblemsrelatedtomissinginformationTheobjectivewillbetoimprovethecurrentprocessanddeliverzerodefectsPFDExample47CriticalBicycleProcessRequirements

Frameweldsmustfailintheparentmaterialwhenpulltested.Weldsmustbevisuallyconfirmedtobedistributed/locatedequallyonpartswelded.ProcessParameters/RequirementsWeldvoltage¤tWeldwirefeedrateInertgasflowrate andgascompositionWeldelectrodeangleTorchcleanlinessElectrodeholderto

workdistanceGoodgroundconnections toweldfixtureProcessControlsPFDExampleWeld2Seatstay

WeldsWeldWeldWeldWeld2Chainstay

WeldsSeatstayTubes(2)ChainstayTubes(2)SeatTubeUpperTubeLowerTubeForkTubeSprocketHub48TeamsusetheProcessFlowDiagramtoidentifyallelementsoftheprocessplusinputsandoutputsPFDsaretoolsthatidentifyallprocessstepsandhelpsetthePFMEAscopeStep1–ProcessFlowDiagram80ProcessFlowdiagramshelpensureallstepsandfunctionsareconsideredintheFMEAandPCPTubeExtrusion

Op.120InjectionMolding

Op.110FinalAssembly

Op.300Stamping/Forming

Op.

140CleanandPaint

Op.

220IncomingMaterialSubassembly

Op.200AssembleSeatTop

Op.

250FrameTubesandHandlebar

TubeBrakeand

ShiftCables

Op.

370RearWheel&GearAsm.toFrameOp.

320SeatAsm.toFrame

Op.

330SprocketAsm.

toFrame

Op.

340HandlebartoFrame

Op.

360PedalCrank

toSprocket

Op.

350InspectandPack

Op.

380FrontWheeltoFrame

Op.

310AttachSeatPosttoTop

Op.

260PaintCureOven

Op.

230FrameTubeButting

Op.130Rims/HandlebarSeatTopandHandlebarGripsPlating

Op.150Fabrication

Op.100FrameWelding

Op.

210AssembleSeatFrame

Op.

240PFDExample49ProcessFlowDiagramforBicycleManufacturingPFDfortheDelphiBicycleProcessFlowDiagramSeatTopandHandlebarGripsFrameWelding

Op.

210Fabrication

Dept.100TubeExtrusion

Op.120Rims/HandlebarInjectionMolding

Op.110FinalAssembly

Dept.300Stamping/Forming

Op.

140Plating

Op.150CleanandPaint

Op.

220AssembleSeatFrame

Op.

240IncomingMaterialSubassembly

Dept.200AssembleSeatTop

Op.

250FrameTubesandHandlebarTubeBrakeand

ShiftCables

Op.

370RearWheel&GearAsm.toFrameOp.

320SeatAsm.toFrame

Op.

330SprocketAsm.

toFrame

Op.

340HandlebartoFrame

Op.

360PedalCrank

toSprocket

Op.

350InspectandPack

Op.

380FrontWheeltoFrame

Op.

310AttachSeatPosttoTop

Op.

260PaintCureOven

Op.

230FrameTubeButting

Op.13050SeatTopandHandlebarGripsFrameWelding

Op.

210Fabrication

Dept.100TubeExtrusion

Op.120Rims/HandlebarInjectionMolding

Op.110FinalAssembly

Dept.300Stamping/Forming

Op.

140Plating

Op.150CleanandPaint

Op.

220AssembleSeatFrame

Op.

240IncomingMaterialSubassembly

Dept.200AssembleSeatTop

Op.

250FrameTubesandHandlebarTubeBrakeand

ShiftCables

Op.

370RearWheel&GearAsm.toFrameOp.

320SeatAsm.toFrame

Op.

330SprocketAsm.

toFrame

Op.

340HandlebartoFrame

Op.

360PedalCrank

toSprocket

Op.

350InspectandPack

Op.

380FrontWheeltoFrame

Op.

310AttachSeatPosttoTop

Op.

260PaintCureOven

Op.

230FrameTubeButting

Op.130ProcessFlowDiagramforFrameTubeWeldingPFDfortheDelphiBicyclePosition&securetubesintoassemblyfixture

Op.211Initiateweldsequence

Op.212Removeframeassembly

Op.213MovetoCleanandPaint

Op.214FrameWelding

Op.21080ProcessFlowDiagram51ProcessStepsforInitiateWeldSequencePFDfortheDelphiBicycleFrameWelding

Op.210Position&securetubesintoassemblyfixture

Op.211Initiateweldsequence

Op.212Removeframeassembly

Op.213MovetoCleanandPaint

Op.214Initiateweldsequence

Op.212Pressbothpalmbuttonstostartrobotwelders.

Op.212.3Confirmweldcompleted.Opencurtain.

Op.212.4Confirmsettings:voltage,current,gasflow,andweldwirefeed.

Checktorchcleanliness.

Op.212.2Closeandlatchcurtain.

Op.212.181ProcessFlowDiagram52PFDTrainingActivity#1Breakintomanageablegroupsof4-6anddevelopacompletePFDfortheweldingoperation.IdentifythesignificantproductandprocesscharacteristicsineachstepDocumentrejecthandlingandreworkoperationsFlagchangeoverelementsTracetheflowofqualityauditpartsConsideranyother“HiddenFactories”53ProcessDocumentationAllProcessDocumentationislinkedviatheOperationandSequenceNumberThisincludes:PFDPFMEAControlPlanProcessMonitoringSheetsStandardCellDocumentationPlantLayoutForExampleOp30-1shouldmeanthesamethingonalldocuments54ProcessDocumentationPFDPFMEAControlPlanMonitoringFormEntertheOPERATIONnumber(s),correspondingtoProcessFlowDiagram.StdCellDocs55ProcessDocumentationPFDPFMEAControlPlanStdCellDocsTheoperationdescriptionsshouldalsomatch56ProcessDocumentationNounnamesonproductdrawings,CVM,PFD,PFMEA,Controlplans,etcmustmatchAllprocessdocumentationmustbeconsistentAllProcessDocumentsareunderDP295changecontroloncetheyhavebeenreleasedtoproductionRevisionstoonedocumentcannotbereleaseduntilallotherimpacteddocumentsareupdatedandreleasedperDP295DocumentdistributionwithinasitemustcomefromacentraldocumentdistributioncenterProcess

FailureMode

and

EffectsAnalysis

58InformationFlowProductDefinition:Characteristics:KPC's,QCI's,DFMEAProcessDefinition:ProcessFlowDiagram(PFD),FailureModeAnalysis:PFMEA,LinesideReviewProcessControlStrategy:ControlPlan,ErrorproofingCustomerRequirements:CharacteristicVerificationMatrix(CVM)Manufacturing:ProcessMonitoring,StandardCell,LayeredAuditSOR,VehicleTechSpecs,SystemTechnicalSpecsKCC's,QCCs59FMEADefinitionStandardsandGuidelinesDocumentManagementFMEAApplicationsResponsibilityMulti-disciplinaryApproachRelationshipsBackgroundInformationHowtoGetStartedProcessFMEAMethodSummaryAgendaIntroduction60ProcessFMEADefinition1.RecognizeandEvaluate“Whatcouldgowrong?”“Whatwouldbetheeffect?”2.TakeAction“Whatcanwedotopreventthefailure?”“Whatcanwedotomaketheconsequenceslesssevere?”3.Document“Doweneedtokeeptrackofthis?”AnFMEAcanbedescribedasasystematicgroupofactivities61ProcessFMEA

DefinitionTheFMEAfirstanalyzestheprocessto:identifytheprocessstepfunctions/requirementsdeterminehowtheprocessmightfailtofunction

correctlyassesstheeffectsofanypotentialfailuredeterminepossiblecausesofthefailure62ProcessFMEADefinitionTheFMEAthendevelopsactionsto:improvetheprocessbyeliminatingthefailurecausesreducetheprobabilitythatafailurewillhappenexposeweaknessesintheprocessbeforeproductionimprovetheabilitytodetectfailuremodesand/or

causesduringprocessdevelopmentandmanufacturing63PFMEAandRiskThePFMEAisaprimarytoolforriskmanagement

duringthedevelopmentofaprocessFourelementsofprocessriskareevaluated:Severity

howseriousapotentialfailuremightbeOccurrencetheprobabilitythatthepotentialfailurewilloccurDetectionwhetherourmanufacturingcontrolswilldiscoverapotentialproblemintheprocessRiskPriorityanoverallassessmentoftheriskofapotential

processproblemDefinition64IndustryGuidelinesand

CustomerRequirementsQualitySystemRequirementsQS-9000

and/or

ISOTS16949AutomotiveIndustriesActionGroupAIAGFMEAManualSocietyof

AutomotiveEngineersSAEJ1739-PotentialFMEAPFMEAfortheNorthAmericanautomobileindustryisdefinedinthe

SocietyofAutomotiveEngineers(SAE)RecommendedPracticeJ1739.TheAutomotiveIndustryActionGroup(AIAG)3rdEditionFMEAreferencemanualisbasedontheSAEpractice.StandardsandGuidelines65ControlandStorageofFMEAsDocumentManagement81 FMEAdocumentssubmitted withPPAPMUSTbesaved (includingALLupdates) Eachdivisionshouldhave anofficialstoragelocation.FMEACentralFiles FMEAs:MusthaveaRevisionDateMusthaveanOwnerHardCopycabinetsWeb-sitecabinets66ControlandStorageofFMEAsDocumentManagementFMEAfilesmustbesavedforaminimumof10yearsafterthepart/systemgoesoutofproductionfortheOEMcustomer.(ReferenceDelphiCorporateRetentionSchedule)THEVAULT80Thisincludesservicepartproductionaswell!!67DesignFMEA FMEAsarealsousedforproductdesignsSystem –

MachineryandEquipment

Subsystem