6Sigma六西格玛精益生产持续改善分析管理常用工具资料 05_Fmea(失效模式及后果分析).ppt

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1、CauseFailure Mode(Defect)EffectFailure Modes and Effects AnalysisChampion Training1Six Sigma Champion Training A FMEA is a disciplined procedure that allows the engineer to anticipate failures and prevent their occurrence in manufacturing.Identify ways the product or process can fail.Then plan to pr

2、event those failures.ConceptWhat is a FMEA?2Six Sigma Champion Training System FMEA:Used to analyze systems and subsystems in the early concept and design stages.Focuses on potential failure modes associated with the functions of a system caused by design.Design FMEA:Used to analyze products before

3、they are released to production.Process FMEA:Used to analyze manufacturing and assembly processes.Types of FMEAs3Six Sigma Champion Training Cause 1Cause 2Effect 1Effect 2Cause 1Cause 2Effect 1Cause 1Effect 1Effect 2C&Es may be related in different ways.Important to Understand the Cause&Effect Relat

4、ionship4Six Sigma Champion Training Linking Failure Mode to Cause and EffectCauseFailure Mode(Defect)EffectTIMEAQuA FMEA Model5Six Sigma Champion Training Linking Failure Mode to Cause and EffectManEffectMeasurementMaterialsEnvironmentMachinesMethodsFailureMode(Defect)Brainstorming Unstructured prob

5、lem solingFishbone Model(5Ms&E)6Six Sigma Champion Training ManEffectMeasurementMaterialsEnvironmentMachinesMethodsPrevent or detectGoal of FMEA is to understand your process well enough to anticipate and prevent or detect the Failure Mode.Prevent or DetectFailure Mode Fishbone Model 7Six Sigma Cham

6、pion Training Rates the Severity of the Effect to the Customer on a 1 to 10 ScaleLists Failure Modes for each Process Step List of Process Steps or Product PartsLists the Effects of each Failure ModeFile:Fmeaform.xlsFMEA Form-Assessing Current Situation8Six Sigma Champion Training Lists the Causes f

7、or each Failure Mode:Each Cause is Associated with a process input out-of-SpecRates how often a particular Cause or Failure Mode Occurs:Documents how the Cause is Currently being controlled in the ProcessRates how well the Cause or Failure Mode can be detected.Risk Priority Number(RPN)is:Sev*Occ*Det

8、FMEA Form-Assessing Current Situation9Six Sigma Champion Training Documents actions recommended based on RPN ParetoDesignates who is responsible for Action and projected completion dataRPN number is recalculated when action is completedFMEA Form-Improvement Plan10Six Sigma Champion Training Severity

9、(SEV):How significant is the impact of the Effect to the customer(internal or external)?Occurrence(OCC):How likely is the Cause of the Failure Mode to occur?Detection(DET):How Likely will the current system detect the Cause or Failure Mode if it occurs?Ratings to Determine overall RiskEach is Scored

10、 on a 1(Best)to 10(Worst)ScaleA numerical calculation of the relative risk of a particular Failure Mode.Risk Priority Number(RPN)=SEV x OCC x DETThis number is then used to place priority on which items need additional quality planning.Risk Priority NumberRPN Directs the Improvement Effort11Six Sigm

11、a Champion Training Standard Ratings12Six Sigma Champion Training Steps in the FMEA Process1.Select the Process FMEA team2.Develop a Process Map and identify all process steps3.List all the Key Process Outputs(deliverables)to satisfy internal and external customer requirements 4.For each Process Ste

12、p,list Key Process Inputs 5.Develop C&E matrix relating Product Outputs to Process Inputs6.Rank the inputs according to importance13Six Sigma Champion Training Note:When doing a Process FMEA,first assume the material is good,but the process is bad.Then assume the process is good,but the material is

13、bad.Last,assume the process is unsafe.Steps in the FMEA Process7.Start the process FMEA by listing ways that each process step can fail(Failure Modes)8.For each Failure Mode,identify the Effects and Causes9.Assign Severity,Occurrence and Detection rating to each Cause10.Calculate the risk priority n

14、umber for each potential failure mode 11.Determine recommended actions to reduce all RPNs12.Take appropriate actions13.Re-calculate all RPNs14Six Sigma Champion Training Cause and Effect Matrix Relating Customer Requirements to Process Inputs15Six Sigma Champion Training Cause&Effect MatrixThis matr

15、ix provides the initial input to the FMEA.When each of the Key Output Variables(Customer Requirements)are not correct,that represents potential”Effects.When each Process Step/Key Input Variable is not correct,that represents a”Failure Mode.1.List the Key Process Output Variables2.Rate each Key Proce

16、ss Output Variable on a 1-to-10 scale to importance to the customer3.List Process Steps/Key Input Variables4.Rate each Process Step/Key Input Variable relationship to each Output Variable on a 1-to-10 scale 5.Select the top Process Steps or Key Input Variables based upon C&E Matrix Importance column

17、 to start the FMEA process16Six Sigma Champion Training 2.Rate each Output according to importance to customer3.List Process Steps&Key Input Variables 4.Rate each Process Step/Input on the strength association with the Outputs5.Spreadsheet multiplies the importance x association and adds across inputs6.A Pareto for inputs assists in a FMEA risk analysis1.List the Key Process Output Variables(Customer Requirements)Review the file C&ematrx.xls 17Six Sigma Champion Training