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PFMEA’s
A
1 Hour Overview
Revised By: Lawrence Brozowski 09-2004
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
THE REAL VALUE OF FMEA PROCESS
QUALITY
• SAVE RESOURCES
• COMMUNICATE REQUIREMENTS
• IMPROVE PRODUCTIVITY AND RELIABILITY
• FOCUS PRODUCT ON CUSTOMER CONCERNS
AND ERROR PROFFING
• CAPTURE LESSONS LEARNED
• TRAIN NEW PERSONNEL
• DRIVES TO ZERO DEFECTS
• REDUCE THE COST OF QUALITY
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
QUALITY POLICY
QUALITY CREATES
CUSTOMER ENTHUSIASM
JOB DESCRIPTION
FIRST TIME QUALITY
QUALITY AT RATE
EXPECTION IS ZERO
MANUFACTURING DEFECTS
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
THE PROBLEM WITH
VERBALLY EXPRESSED
TECHNICAL DATA
A major problem with verbally expressed technical data is that
various company functions use local vocabularies that are not
understood by other functions.
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
INFORMATION
ACCOUNTABILITY
Information we have plenty of, but what’s really necessary
to your work, and what form should it take? Don’t expect an
information manager to tell you. The big thing to learn is not how
to use the computer, or even how to organize information, but how
to take responsibility for the information you have.
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
RETENTION OF
TECHNICAL MEMORY
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
Manufacturing System
Fundamental Value
FMEA
Control Plan
MRP Financial
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
• Purpose
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
93% OF OUR
PROBLEMS ARE
WHERE THE
REQUIREMENTS
ARE:
Missing
Misunderstood
Wrong
Ignored
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
USE STANDARD
BASIC QUALITY TOOLS
TO ACHIEVE THE
REQUIRED RESULTS
DRIVE DISCIPLINE
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
FMEA Process Overview
Knowledge Transfer
OEM
Responsibility
Sourcing GD&T To add print
P SSTS Final Print
RFQ DFMEA Picking H
R KPC’s
APQP I
E PPAP
Base
N
V ge
n owled D
E K
S
N
I
T
G
I
H
O
T
N Supplier APQP
PFMEA
Responsibility Control Plan
0 1 2 3
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
VIEW POINT’S
for
FMEA IMPLEMENTATION
0 1 2 3
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PFMEA 14799 Revised L Brozowski 6-2004
Feedback Loop Worldwide Purchasing
QUALITY
DO AS YOU SAY
SAY AS YOU DO
YES THIS MEANS EVERYTHING YOU DO
KEY DEFINITIONS
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
IMPORTANCE OF PFMEA's
• Systematic Method to Analyze a Process
• The Process Potential FMEA:
– Identifies potential product related process failure modes
– Assesses the potential customer effects of the failures
– Identifies the potential manufacturing or assembly process
causes and identifies process variables on which to focus
controls for occurrence reduction or detection of the failure
conditions
– Develops a ranked list of potential failure modes, thus
establishing a priority system for corrective action
considerations
– Documents the results of the manufacturing or assembly
process
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
UNDERSTANDING FAILURE
MODE RELATIONS
• Every problem is preceded by the error and the source of the
error (cause).
• The cause is that which produces an incorrect action
(something done poorly) or an omission of a required action
(something not done).
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
FLOW DIAGRAM
STEP
STORE
MOVE
OPER
INSP.
#
5 PFMEA’s
6 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
FMEA Number 1
Core Team 8
Requirements Mode of Failure V A Mechanism(s) of C Current Process Control T N. Action(s) & Target Taken E C O P.
9 10 11 12 S Failure U 16 E 18 19 Completion Date 21 V C T N.
S 14 R C 20
13 15
17
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
Proc es s C Potential O D
Func tion/ Potential Potential S l Caus e(s )/ c Current Current e R. Rec ommended Res pons ibility A c tion Res ults
Failure Ef f ec t(s ) of e a Mec hanis m(s ) c Proc es s Proc es s t P. A c tions & Target A c tions S O D R.
Mode Failure v s of Failure u Controls Controls e N. Date Taken e c e P.
Requirements s r Pr e ve n tio n De te ctio n c v c t N.
9 10 11 12 13 14 15 16 16 17 18 19 20 21 22
POTENTIAL POTENTIAL
FAILURE MODE CAUSES RECOMMENDATIONS
CURRENT
POTENTIAL CONTROLS
EFFECTS
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
PO T E N T IA L
F A IL URE M O DE A ND EF F EC T S A NAL YS IS
(P RO CES S F M EA ) F M E A N um ber:
1
Proc es s C Potential O D
Func tion/ Potential Potential S l Caus e(s )/ c Current Current e R. Rec ommended Res pons ibility A c tion Res ults
Failure Ef f ec t(s ) of e a Mec hanis m(s ) c Proc es s Proc es s t P. A c tions & Target A c tions S O D R.
Mode Failure v s of Failure u Controls Controls e N. Date Taken e c e P.
Requirements s r Pr e ve n tio n De te ctio n c v c t N.
9 10 11 12 13 14 15 16 16 17 18 19 20 21 22
POTENTIAL
CAUSE IS CURRENT
DIRECT CONTROL =
RELATIONSHIP DETECTION
TO PROCESS CAPABILITY
CAPABILITY
ERROR PROOFING
TYPES OF INSPECTION
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
SOURCE INSPECTION
Mistake CANNOT Be Created
Source
“Cannot Make”
PREVENTION
Location of check
• Occurs before the processing station
• Cannot proceed with further processing
Human inspection
• Source inspection through product or process design
• PFMEA Detection code = 1
• PFMEA Occurrence code = 1
SELF INSPECTION
Mistake CAN Be Created
Self
“Cannot Pass”
DETECTION
Location of Check
• Occurs within the processing station – or - immediately after
processing
• Part still remains in the processing station
Human Inspection
• Visual or manual inspection
• PFMEA Detection code = 5 through 9
Technology/Equipment/Tooling Checks
• Error Detection** per AIAG FMEA Reference Manual
• PFMEA Detection code = 2 with auto stop
• PFMEA Detection code = 3 with warning only
** Other definitions offered by various authors, e.g., mistake proofing, mistake
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detection, Poka-Yoke, etc..
PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
SUCCESSIVE INSPECTION
Mistake CAN Be Created Successive
“Cannot Accept”
DETECTION
Location of Check
• Occurs in next processing station OR
in downstream processing station(s)
Human Inspection
• Visual or manual inspection
• PFMEA Detection code = 5 through 9
Technology/Equipment/Tooling Checks
• Error Detection** per AIAG FMEA Reference Manual
• PFMEA Detection code = 4
• PFMEA Detection code = 3 with redundant checks
** Other definitions offered by various authors,
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e.g., mistake proofing, mistake
detection, Poka-Yoke, etc.
PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
RISK PRIORITY NUMBER (RPN)
QUALITY
S C O D R. Action Results 22
Process Function Potential Failure Potential Effect(s) E L Potential Cause(s)/ C E P. Recommended Responsibility Actions S O D R.
Requirements Mode of Failure V A Mechanism(s) of C Current Process Control T N. Action(s) & Target Taken E C O P.
S Failure U E Completion Date V C T N.
9 10 11 12 16 21
S R C 18 19
14 20
13 15 17
YES
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
OCC
DET
RPN
OCC
DET
SEV
SEV
SYM BOL P ro c N a m e Char F a ilu re P ro c e ss ty & T a r g e t Control Method Mach. D es criptio R&R
N um ber S h ift T r a n s M o d e C h a r . C la s s F a ilu re M e c h a n is m d e d A c ti o n s TAKEN Specs Frequency SIZE n
Plan
D e s c r ip tio n M ode C o n tr o ls D a te Number & Date
M ode (s) o f
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
KEY POINTS ON
PFMEA DEVELOPMENT
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
STORE
STEP
MOVE
OPER
INSP.
#
1
2
KEY POINTS
3
Flow Diagram
❍ Should Provide A General Sequential Picture Of The
Process.
• Shows Progression Of The Manufacturing Process
• Organizes the Process
❍ Keeps the Group Focused
❍ Physical Appearance Of The Flow Document
• Should Have Legend(s) Explaining Symbolism used.
• Operations Should Be Numbered.
• Label or Title Of Operation Or Manufacturing Process
Should Appear On Paperwork.
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
KEY POINTS ON
PFMEA’s PFMEA
DEVELOPMENT
POTENTIAL FMEA Number 1
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA) Page of
Core Team 8
S C O D R. Action Results 22
Process Function Potential Failure Potential Effect(s) E L Potential Cause(s)/ C E P. Recommended Responsibility Actions S O D R.
Requirements Mode of Failure V A Mechanism(s) of C Current Process Control T N. Action(s) & Target Taken E C O P.
9 10 11 12 S Failure U 16 E 18 19 Completion Date 21 V C T N.
S 14 R C 20
13 15
17
PFMEA
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
Item
Model Year(s)/Vehicle(s)
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
2 Process Responsibility 3
PFMEA's
FMEA Number
Page
Prepared By
of
1
4
KEY POINTS
5 Key Date 6 FMEA Date (Orig.) 7
Core Team 8
S C O D R. Action Results 22
Process Function Potential Failure Potential Effect(s) E L Potential Cause(s)/ C E P. Recommended Responsibility Actions S O D R.
Requirements Mode of Failure V A Mechanism(s) of C Current Process Control T N. Action(s) & Target Taken E C O P.
9 10 11 12 S Failure U 16 E 18 19 Completion Date 21 V C T N.
S 14 R C 20
13 15
17
PFMEA (continued)
❍ All Material Or Sub-assemblies Entering Each
Operation Are Considered Good Parts.
• Sub-assemblies, if manufactured at same location require
separate PFMEA.
• Purchased parts are considered good; incoming inspection
should address characteristics or operation addresses through
error proofing.
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
FMEA IMPLEMENTATION
KEYS
MAJOR INPUTS TO FMEA Development
LANGUAGE IS CRITICIAL
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
OPERATIONAL SEQUENCE
• The operational sequence numbering must
be the same in the FLOW CHART, PFMEA
and the CONTROL PLAN
O p e ra tio n a l S e q u e n c e M a trix
C o m m e n ts
X X X - X X X F ie ld le n g t h 7 d ig it s
W o r k C e n t e r # b y P la n t L o c a t i o n
1 0 - 4 w a l l fl o w
A - A lp h a F ie ld / T a s k C o d e
- 0 0 1 P ro c e s s s te p n u m b e r
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
FAILURE MODES
THERE ARE 6 MAIN CAUSES OF FAILURE
RELATING TO PROCESS FAILURE MODES
•TOO MUCH
•TOO LITTLE It is rare for a failure mode
•INCOMPLETE to have more then five (5)
•MISSING important causes and three
•WRONG important effects.
•CYCLE TIME
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
LANGUAGE IS CRITICIAL
BE SPECIFIC
USE COMMON LANGUAGE
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
KEY
POINTS
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY RPN Reduction RPN
Strategy RPN
The Advanced Product Quality PlanRPN(APQP)
for each product should include the strategy
for reducing the risk identified through the
PFMEA process;
RPN numbers.
•This is referred to as your RPN Reduction Strategy.
•This is an organized method for prioritizing and using the
PFMEA to gain maximum benefit.
KEY
POINTS
REACTION PLANS O
A LT
• Often a weakness in the system
• They need to be clear
• The Reaction Plan provides the direction to
Drive Appropriate Action
• We Spend Time and Energy Developing
Them; If Not Followed We Waste Time and
We Lose an Obvious Opportunity for
Success
• They Are the Final Detour Sign That Leads
Us Back to the Correct Route.
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing
QUALITY
PFMEA’s ARE A LIVING
DOCUMENT
The PFMEA is referred to as a living document because the
intent is to use the document throughout the life of the
product
– Once the product enters the “normal” production cycle any revisions
to the design or manufacturing process should be reflected
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PFMEA 14799 Revised L Brozowski 6-2004
Worldwide Purchasing