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失效模式分析nullnull FMEA Failure Mode and Effects Analysis 失效模式與效應分析1 of 33陳 啟 政 中原大學品質研究中心 中原大學工業工程系 The Quality Research Center Industrial Engineering Department Chung Yuan Christian UniversitynullFMEA 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...

失效模式分析
nullnull FMEA Failure Mode and Effects Analysis 失效模式與效應 分析 定性数据统计分析pdf销售业绩分析模板建筑结构震害分析销售进度分析表京东商城竞争战略分析 1 of 33陳 啟 政 中原大學品質研究中心 中原大學工業 工程 路基工程安全技术交底工程项目施工成本控制工程量增项单年度零星工程技术标正投影法基本原理 系 The Quality Research Center Industrial Engineering Department Chung Yuan Christian UniversitynullFMEA 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,並以數據來表 示風險的大小和預先採取預防改 善措施。 2 of 33null導入FMEA的優點 Team work 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揮想像力, 經由有系統整合 提出有效之預防改善對策 徹底了解產品功能架構圖或產品製造組合流程圖 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)方法了解產品失效模式各種組合型式 把失效模式量化針對Top Failure Mode 優先採取對策預防 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, 協助分析失效的範圍和影響性 提供設計產品或製程管制預防採取對策時使用 3 of 33null Core team :列出與FMEA team 相關人員名字,部門與職責 Failure mode :失效模式種類 Effect :失效後對產品產生影響 Cause :造成失效模式之原因 Severity :失效模式發生之嚴重程度等級(1~10) Occurrence :失效模式之發生頻度等級(1~10) Detection :失效模式發生可被偵測程度等級(1~10) RPN : Risk Priority Number 指評估風險及優先處理指數 是Severity * Occurrence * Detection 之乘積 FTA :Fault tree analysis 是失效樹分析是導果為因由頂端 事件利用邏輯(OR 或 AND) 持續分析第1.2…層直 至真正Root cause 將這些原因謀求徹底改善FMEA相關名詞解說4 of 33null QFD : Quality Function Deployment DOE : Design of Experiments VOC : Voice of Customer VOE : Voice of Engineering SOP : Standard Operation Procedure SIP : Standard Inspection Procedure FRACAS : Failure Report Analysis and Corrective Action System SPC : Statistic Process Control TQM : Total Quality Management DVT : Design Valuation Test MTBF : Mean Time Between FailureFMEA書籍相關名詞解說5 of 33nullFMEA 型式 SYSTEM SFMEA Design DFMEA * Component * Unit * Module Process PFMEA Machine MFMEA Equipment EFMEA Service SFMEA6 of 33null組成FMEA團隊設計 FMEA 流程(DFMEA)蒐集資料完成FMEA執行 方案 气瓶 现场处置方案 .pdf气瓶 现场处置方案 .doc见习基地管理方案.doc关于群访事件的化解方案建筑工地扬尘治理专项方案下载 系統特性系統功能硬品架構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鍵指數分析發生率分析難檢度建議改正行動決定關鍵性 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 與改正作業系統 (FRACAS)設計改善撰寫報告 維護度分析 參考資料7 of 33null組成FMEA團隊製程 FMEA 流程(PFMEA)蒐集資料完成FMEA執行方案定義製造流程分析產品特性分析製程特性分析失效模式分析現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鍵指數分析發生率分析難檢度建議改正行動決定關鍵性 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 與改正作業系統 (FRACAS)製程改善檢驗程序改善撰寫報告8 of 33nullFMEA 實施步驟1. 決定FMEA 對象 2. 成立&組成FMEA team members 3. 收集&準備相似產品之歷史資料 4. 列出產品方塊圖或製程流程圖 5. 列出Failure mode 各種可能情況 6. 列出Failure mode 對產品/機器之 影響 (Effect) 7. 魚骨圖分析造成此Failure mode 之可能原因 (Cause) 8. 根據相關產品之歷史資料定義出 Severity /Occurrence Detection 之等級 9. 根據 S/O/D 的定義定出每個 Failure mode 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) or Top 20% 優先採取對策 13. 針對 RPN 值超出上述定之項目提 出Action 再改善 14. 定出 Action item 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 ≧100 or Top 20% 回覆到 item 13 重提 Action 18. 若 RPN 達到要求完成 FMEA 表格9 of 33nullFMEA Team Members DFMEA (Design) Chairperson * Program Manager (PM) * Electronic Engineer (EE) * Mechanical Engineer (ME) * Quality Engineer (QE) * Quality Engineer (QA) * Manufacturing (MES) Support Team * Purchasing (Buyer) if Need PFMEA (Process) Chairperson * Program Manager (PM) * Quality Engineer (QA) * Industry Engineer (IE) * Mechanical Engineer (MFG ME) * Test Engineer (TE) * Manufacture Supervisor (MFG) * Electronic Engineer (EE) if Need * Mechanical Engineer (ME) if Need 10 of 33nullFailure Mode Fishbone AnalysisHi-Pot 不良 Failure Mode (Defect)錫面組立加工不良第一層分析 Workmanship第二層分析第三層分析第四層分析正面裝插 零件插歪斜零件面有異物無線尾零件變形零件碰case零件相碰第一層分析 Material變壓器不良PCB不良Y電容不良Power Cable破EMI不良Case不良第二層分析第三層分析絕緣tape破引腳超出base焊點過大造成tape破儀器設備儀器設定Layout 安規距離不夠Arcing 規定過嚴零件間安規距離不足第一層分析 Design第一層分析 Test第二層分析第三層分析第二層分析第三層分析鎖螺絲過長套管短零件本体大Layout 面積小測試條件設錯O/I寫錯測試線接錯11 of 33nullHi-Pot Failure AnalysisFault Tree Analysis For Hi-Pot Failure5. 板 邊 零 件 傾 斜 踫 Case, 造 成 安 規 距 離 不 夠b. Socket 上 Y 電 容 線 腳 靠 近 馬 口 鐵a. Socket FG 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 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Design 2. 元 件 之 間 安 規 距 離 不夠 3. Arcing 規 格 過 嚴c. 鎖 螺 絲 過 長 b. 套 管 短a. 原 件 本 体 大 Layout 面 積 小4. 板 邊 零 件 與 Case 安 規 距 離 不 夠 1. Layout 安 規 距 離 不 夠Material9. 變 壓 器 PFC ︵ 電 感 ︶ 8. 膠 雜 質 過 多7. Y 電 容 不 良6. 線 材 Power Cable 破5. PCB4. EMI Socket3. Case 2. 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 体 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1. Socket Y 電 容 線 腳 斷5. 油 墨, 黑 色 Mark 筆, 在 初 級 側 導 電 12 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNThis column is used to list the part name and function. List all the functions for the functional blockFMEA 格式逐項解說1.2.10.4.3.5.6.8.7.9.12.11.15.14.13.13 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPN2.In the failure mode column, list each of the failure modes for the function.FMEA 格式逐項解說1.10.4.3.5.6.8.7.9.12.11.15.14.13.14 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceDetectionDetectionRPNRPNOccurrence3.List the effects of failure for each of the failure modes.FMEA 格式逐項解說1.10.4.2.5.6.8.7.9.12.11.15.14.13.15 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNFor each one of the effects, list the severity (scale from 1 to 10)4.FMEA 格式逐項解說1.10.3.2.5.6.8.7.9.12.11.15.14.13.16 of 33null 符合需求 ,17 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNThe Class column is optional. It is typically used if the severity is 9 or 10.5.FMEA 格式逐項解說1.10.3.2.4.6.8.7.9.12.11.15.14.13.18 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPN In the Cause column, list the causes for each failure mode6.FMEA 格式逐項解說1.10.3.2.4.5.8.7.9.12.11.15.14.13.19 of 33nullFMEA ModelLinking Failure Mode to Cause and EffectCauseFailure Mode (Defect)Effect20 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNEstimate the likelihood of the “causes” happening on a “1 to 10” scale. The higher the number the more likely the “causes” will occur.7.FMEA 格式逐項解說1.10.3.2.4.5.8.6.9.12.11.15.14.13.21 of 33null22 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNList the prevention, design validation/ verification, or other activities which will assure the design adequacy for the failure mode and/or cause / mechanism under consideration. Tests Design reviews, Mathematical studies, Fail/safe (Example: redundant power supplies)8.FMEA 格式逐項解說1.10.3.2.5.4.6.7.9.12.11.15.14.13.23 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNEstimate the likelihood of the detection on a “1 to 10” scale. The lower the number the more likely the cause will be detected.9.FMEA 格式逐項解說1.10.3.2.5.4.8.7.6.12.11.15.14.13.24 of 33null25 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNRPN (Risk Priority Number) is the product of Severity, Occurrence, and Detection. The higher the number, the higher the risk.10.FMEA 格式逐項解說1.2.4.3.5.6.8.7.9.12.11.15.14.13.26 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNWhat actions need to be taken to prevent the Failure Mode? If no action is taken, record “none” 11.FMEA 格式逐項解說1.10.4.3.5.6.8.7.9.12.2.15.14.13.27 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNAssign appropriate individual, area, function or team. Set a realistic target for completion Target date could be established by development program12.FMEA 格式逐項解說1.10.4.3.5.6.8.7.9.2.11.15.14.13.28 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNList the results of the actions taken. Always enter a reference such as data or test reports.13.FMEA 格式逐項解說1.10.4.3.5.6.8.7.9.12.11.15.14.2.29 of 33nullPart Failure Mode Effect(s) Cause(s) Current or Action(s) to Area or Action(s) Name * Control(s) be taken Individual taken Function responsible Energy Management Cannot Customer Software Monitor dissatisfaction Failure Monitor Battery Battery alert Battery user of status connections spec. wrong Incorrect battery used Cannot Customer Software accurately dissatisfaction failure ID status Battery Connections damage spec. wrong Unable to detect battery Faults SeveritySeverityOccurrenceOccurrenceDetectionDetectionRPNRPNWhen reassess
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