DFMEA培训资料-设计失效模式与后果分析

1DFMEA-1DesignFailureModeandEffectsAnalysis(DFMEA)DFMEA-2FormsandFormats+2DFMEA-3DesignFMEA(forComponents)()+DFMEA-4DesignFMEA+++3DFMEA-5++DFMEA-6...+(APQP)“”4DFMEA-7+4(PFMEA)(DFM)...DFMEA-844...5DFMEA-9...DFMEA(DFMEA)++DFMEA-10...+++PPAP()+6DFMEA-11+44+DFMEA-12+5-9444444447DFMEA-13+DFMEA+DFMEA-14+4theseverityoftheeffect(S)4thelikelihoodoftheoccurrence(O)4andtheabilityofdesigncontrolstodetectfailuremodesand/ortheircauses(D)/8DFMEA-15+Calculatetheriskprioritynumber(RPN)toprioritizecorrectiveactions(RPN)DFMEA-16+Plancorrectiveactions+Performcorrectiveactionstoimprovetheproduct+RecalculateRPN(RPN)9DFMEA-17+FMEA4usefishboneandtreediagramsliberallyDFMEA-184tryingtousetheFMEAformasaworksheetleadstoconfusionandmessed-upFMEAsFMEAFMEA10DFMEA-191.+44+()FMEA4FMEADFMEA-202.+4()4411DFMEA-212.+componentcomponentcomponentcomponentcomponentcomponentDFMEA-223.++Verb+Object+Qualifier++12DFMEA-23+4insulatescore4assuresterminalpositioninconnector4protectstangfromsmashing,etc.3.DFMEA-243.+Don'tforgetauxiliaryfunctionsaswellaprimaryfunctions+Often,componentsworktogethertoperformafunction+Hint:UsetheBlockDiagram!13DFMEA-254.+acustomerwantordesire+couldseriouslyaffectcustomerperception+couldleadtoacustomercomplaint+Hint:UseQFDDFMEA-265.+adefect,flaw,orotherunsatisfactoryconditionintheproductthatiscausedbyadesignweakness14DFMEA-275.+-breaks-cracks-corrodes-sticks-unseats-deforms/melts/DFMEA-285.+4415DFMEA-29+AIAG5“”DFMEA-305.+failure=nofunction=failure=notenoughfunction=failure=toomuchfunction=16DFMEA-31+4failure=noqualityrequirement,etc.=5.DFMEA-325.+:4“”4/44“”17DFMEA-335.++++=+=44+=44+=44DFMEA-346.++444+18DFMEA-356.+44++“”DFMEA-366.++FMEA419DFMEA-376.+=DFMEA-386.+=20DFMEA-396.+=DFMEA-406.+21DFMEA-417.+AIAGDFMEA-427.SeverityRating(S):9-10unsafe7-8lossofprimaryfunction5-6discomfort2-4noticeable1noeffect22DFMEA-43AIAGSeverityTableSeverityofEffect(S):10unsafeoroutofcompliance,withnowarningtothecustomer9unsafeoroutofcompliance,butawarningisgiven8inoperable7operable,butatreducedperformanceDFMEA-446comfortorconvenienceitemisinoperable5comfortorconvenienceitemisoperable,butatreducedperformance4noticeablebymostcustomers3noticeablebyaveragecustomer2noticeablebydiscriminatingcustomerAIAGSeverityTable23DFMEA-451noeffect0THEREISNOSCOREOFZERO.AIAGSeverityTableDFMEA-467a.Classifyspecialproductcharacteristics(910)occurrenceordetection(3)...24DFMEA-477a.Classifyspecialproductcharacteristics+ControlPlanControlPlanDFMEA-488.+44+25DFMEA-498.+4+“”420A10A+DFMEA-508.++426DFMEA-518.+failuremodecausecauseDFMEA-528.+4427DFMEA-538.DFMEA+“”“”4DFMEA-54+8.DFMEA28DFMEA-559.++++DFMEA-569.OccurrenceRating(O):(0)9-10failureisalmostinevitable7-8repeatedfailureslikely4-6occasionalfailureslikely2-3relativelyfewfailures1failureisunlikely29DFMEA-57AIAGOccurrenceTableOccurrenceRating(O):(0)101in2failureisalmostinevitable2191in33181in8repeatedfailureslikely8171in20201DFMEA-5861in80occasionalfailureslikely80151in400400141in20002000131in15,000relativelyfewfailures15,000121in150,000150,000111in1,500,000failureisunlikely1,500,0001AIAGOccurrenceTable30DFMEA-599.+Beconservativeinassigningnumbers.+Noclue?Assumeascoreof10toflagtheRPN.10“”RPNDFMEA-6010.+4DFMAnalysis4SneakCircuitAnalysis(SystemFMEA)(FMEA)4/4FiniteElementAnalysis4Simulation431DFMEA-6110.+444+...DFMEA-6210.+4nofalsenegatives4nofalsepositives4(doctorprefersprevention)()32DFMEA-63+Tocontinuetheanalogy,theFMEAislikealistofsuspicionsthatadoctorhasbasedonthesymptomshesees.Thedesigncontrolsaretheteststhatthedoctorproposestoeitherconfirmorthrowoutthosesuspicions.FMEADFMEA-6410.+(1)(2)(3)+FMEA+41234“”33DFMEA-6511.+----234441“”DFMEA-66DetectionRating(D):(D)9-10remotechanceofdetectingfailure7-8verylowchance5-6lowtomoderatechance2-4goodchance11.34DFMEA-671willalmostcertainlydetectfailure(ifitpassesthis,itwon’tfail)()11.DetectingfailureDFMEA-68+++Controlsdesignedtoforcefailuremaymaskrealfailuremodes!4()35DFMEA-6912.(RPN)+RPN=SxOxDRPN=SeverityofEffectxOccurrenceRatingxDetectionRatingRPN=xx+RPNDFMEA-70+RPN4“”36DFMEA-7113.+DFMEA-7213.+--+--+--+910+RPN4“”+PFMEA37DFMEA-7314.+FMEA+++FMEADFMEA-7415.+44“”+38DFMEA-7516.RPN++4severity,4/occurrence,and/or4detection.4RPN4+44