FMEA第四版(英文版)

POTENTIALFAILUREMODEANDEFFECTSANALYSIS(FMEA)ReferenceManualFourthEditionFirstEdition,February1993•SecondEdition,February1995•ThirdEdition,July2001,FourthEdition,June2008Copyright©1993,©1995,©2001,©2008ChryslerLLC,FordMotorCompany,GeneralMotorsCorporationISBN:978-1-60534-136-1www.bzxzw.comFOREWORD4thEditionTheFMEA4thEditionisareferencemanualtobeusedbysupplierstoChryslerLLC,FordMotorCompany,andGeneralMotorsCorporationasaguidetoassisttheminthedevelopmentofbothDesignandProcessFMEAs.Themanualdoesnotdefinerequirements;itisintendedtoclarifyquestionsconcerningthetechnicaldevelopmentofFMEAs.ThismanualisalignedwithSAEJ1739.SummaryofChangesinthe4theditionFMEAReferenceManualTheDFMEAandPFMEAmethodsdescribedinthe4theditionFMEAReferenceManualincludethoseassociatedwithdesignatthesystem,subsystem,interface,andcomponentlevelandtheprocessatmanufacturingandassemblyoperations.GeneralChangesCompany-•Theformattingusedinthe4theditionisintendedtoprovideeasierreading.oAnindexisincluded.oIconsareusedtoindicatekeyparagraphsandvisualcuesareused.•AdditionalexamplesandverbiagehavebeenprovidedtoimprovetheutilityofthemanualandtoprovideaclosertieintotheFMEAprocessOnlyasitdevelops.•Reinforcementoftheneedformanagementsupport,interest,andreviewoftheFMEAprocessandresults.Motor•DefineandstrengthentheunderstandingofthelinkagebetweenDFMEAandPFMEAaswellasdefiningthelinkagestoothertools.•ImprovementstotheSeverity,Occurrence,DetectionrankingtablessothattheyaremoremeaningfultorealworldanalysisandUseusage.•Alternativemethodsareintroducedthatarecurrentlybeingappliedinindustry.oAdditionalappendicesFordwhichhaveexampleformsandspecialcaseapplicationofFMEA.oThefocusonthe“standardform”hasbeenreplacedwithseveraloptionsthatrepresentofthecurrentapplicationofFMEAinindustry.•ThesuggestionthatRPNnotbeusedastheprimarymeansforassessingrisk.Theneedforimprovementhasbeenrevisedincludinganadditionalmethod,andtheuseofthresholdsonRPNisclarifiedasapracticethatisnotrecommended.InternalChapterIprovidesgeneralFMEAguidelines,theneedformanagementsupportandhavingadefinedprocessfordevelopingandmaintainingFMEAs,andtheneedforcontinuousimprovement.ChapterIIdescribesthegeneralapplicationoftheFMEAmethodology,whichiscommonbetweenDFMEAandPFMEAprocesses.Thisincludestheplanning,strategy,actionplans,andPropertytheneedformanagementsupportandresponsibilityinFMEAs.ChapterIIIfocusesonDFMEA(DesignFailureModeEffectsandAnalysis),establishingthescopeoftheanalysis,useofblockdiagrams,varioustypesofDFMEAs,formationoftheteams,basicprocedureforanalysis,actionplans,andfollow-up,alternativestoRPN,andconnectiontoPFMEAsandvalidationplans.iwww.bzxzw.comChapterIVfocusesonPFMEA(ProcessFailureModeEffectsandAnalysis),establishingthescopeoftheanalysis,useofflowdiagrams,formationofteams,basicprocedureforanalysis,actionplans,theconnectiontoDFMEAsandthedevelopmentofcontrolplans.TheAppendiceshaveseveralexamplesofformsforDMFEAandPFMEAandaddressesdifferentapplicationsandproceduresforaddressingdesignandprocessrisk.TheSupplierQualityRequirementsTaskForcewouldliketothankthefollowingindividuals,andtheircompanies,whohavecontributedtheirtimeandeffortstothedevelopmentofthiseditionoftheFMEAReferenceManual:MichaelDown,GeneralMotorsCorporationLawrenceBrozowski,GeneralMotorsCorporationHishamYounis,FordMotorCompanyDavidBenedict,ChryslerLLCJohnFeghali,ChryslerLLCMichaelSchubert,DelphiCompany-RhondaBrender,DelphiGregoryGruska,OmnexGlenVallance,ControlPlanningInitiativesMilenaKrasich,BoseWilliamHaughey,ReliaTrainOnlyThismanualisacopyrightofChryslerLLCMotor,FordMotorCompanyandGeneralMotorsCorporation,withallrightsreserved.AdditionalcopiesmaybeobtainedfromAIAG@www.aiag.org.SupplychainorganizationsofChryslerLLC,FordMotorCompanyorGeneralMotorsCorporationhavepermissiontocopyformsusedinthismanual.UseFordofInternalPropertyiiwww.bzxzw.comTABLEOFCONTENTSGeneralChanges..................................................................................................................................iChapterI.........................................................................................................................................................1GeneralFMEAGuidelines................................................................................................................1Introduction................................................................................................................................................2FMEAProcess....................................................................................................................................2PurposeofManual..................................................................................................................................3ScopeofManual.....................................................................................................................................4ImpactonOrganizationandManagement..................................................................................................4FMEAExplained........................................................................................................................................5Follow-upandContinuousImprovement...................................................................................................6ChapterII........................................................................................................................................................7OverviewofFMEAStrategy,PlanningandImplementation.............................................................7Introduction................................................................................................................................................8BasicStructure...........................................................................................................................................8Approach....................................................................................................................................................8IdentifytheTeam...............................................................................................................................Company-....9DefinetheScope...................................................................................................................................10DefinetheCustomer.............................................................................................................................11IndentifyFunctions,Requirements,andSpecifications.......................................................................11IdentifyPotentialFailureModes..........................................................................................................12IdentifyPotentialEffects......................................................................................................................12IdentifyPotentialCauses......................................................................................................................12IdentifyControls...............................................................................................................................Only....13IdentifyingandAssessingRisk............................................................................................................13RecommendedActionsandResults.....................................................................................................Motor13ManagementResponsibility.....................................................................................................................14ChapterIII....................................................................................................................................................15DFMEADesignFailureModeandEffectsAnalysis.......................................................................15Introduction...............................................................................................................................Use...............16CustomerDefined.................................................................................................................................16TeamApproach....................................................................................................................................17Manufacturing,AssemblyaFordndServiceabilityConsiderations..............................................................17DevelopmentofaDesignFMEA.............................................................................................................18Prerequisites.........................................................................................................................................18Block(Boundary)ofDiagrams.............................................................................................................18Parameter(P)Diagrams....................................................................................................................21FunctionalRequirements..................................................................................................................22OtherToolsandInformationResources...........................................................................................22ExampleDFMEA.................................................................................................................................25HeaderoftheDesignInternalFMEAForm(fieldsA-H)..............................................................................25BodyoftheDFMEAForm(fieldsa–n)..........................................................................................29MaintainingDFMEAs..........................................................................................................................64LeveragingDFMEAs...........................................................................................................................65Linkages...............................................................................................................................................65DesignVerificationPlan&Report(DVP&R).................................................................................66PFMEA.............................................................................................................................................66PropertyChapterIV....................................................................................................................................................67PFMEAProcessFailureModeandEffectsAnalysis.......................................................................67Introduction..............................................................................................................................................68CustomerDefined.................................................................................................................................69TeamApproach....................................................................................................................................69DesignConsiderations..........................................................................................................................69DevelopmentofaProcessFMEA............................................................................................................70iiiwww.bzxzw.comPrerequisites.........................................................................................................................................70ProcessFlowDiagramandlinkagetoPFMEA................................................................................70OtherToolsandInformationSources...............................................................................................73ResearchInformation.......................................................................................................................73ExamplePFMEAForm........................................................................................................................75HeaderoftheProcessFMEAForm(fieldsA-H).............................................................................75BodyofthePFMEAForm(fieldsa–n)..........................................................................................77MaintainingPFMEAs.........................................................................................................................110LeveragingPFMEAs..........................................................................................................................110Linkages.............................................................................................................................................111ToDFMEA.....................................................................................................................................111ToControlPlan..............................................................................................................................112APPENDICES............................................................................................................................................113AppendixA:SampleForms...................................................................................................................114DFMEAForms...................................................................................................................................114PFMEAForms....................................................................................................................................121AppendixB:SystemLevelFMEA.........................................................................................................130Interfaces............................................................................................................................................131Interactions.........................................................................................................................................131Relationships...............................................................................................................................Company-.......133MultipleLevelsofDesignFMEAs.................................................................................................133AppendixC:AlternativeRiskAssessments...........................................................................................135AlternativestoRPN............................................................................................................................135Alternative:SO(SxO)..................................................................................................................136Alternative:SOD,SD.....................................................................................................................136AppendixD:AlternativeAnalysesTechniques......................................................................................Only137FailureMode,EffectandCriticalityAnalysis(FMECA)...................................................................137DesignReviewBasedonFailureModes(DRBFM)Motor..........................................................................137FaultTreeAnalysis(FTA).................................................................................................................137ReferencesandSuggestedReadings......................................................................................................140Index.......................................................................................................................................................141UseFordofInternalPropertyivwww.bzxzw.comTABLESandFIGURESFigureIII.1aBlock(Boundary)DiagramExamples....................................................................................19FiguresIII.1b,cBlock(Boundary)DiagramExamples...............................................................................20FigureIII.2ExampleofaParameter(P)DiagramforaGenericCatalyticConverter.................................21TableIII.1SampleDFMEAFormwithMinimalInformationElements&ExampleEntries......................24TableIII.3ExamplePotentialFailureModes...............................................................................................32TableIII.4ExamplePotentialEffects..........................................................................................................35TableCr1SuggestedDFMEASeverityEvaluationCriteria........................................................................37TableIII.5ExamplePotentialCauses..........................................................................................................42TableCr2SuggestedDFMEAOccurrenceEvaluationCriteria...................................................................46TableIII.6ExamplesofPreventionandDetectionDesignControls............................................................51TableCr3SuggestedDFMEA/PFMEAPrevention/DetectionEvaluationCriteria.....................................54TableIII.7ExamplesofCauses,ControlsandRecommendedActions.......................................................64FigureIII.7DFMEAInformationInterrelationshipsFlow...........................................................................65FigureIV.1HighLeveltoDetailedProcessMaps.......................................................................................71FigureIV.2ExampleProcessFlowDiagram...............................................................................................72TableIV.1SamplePFMEAFormwithMinimalInformationElements&ExampleCompany-Entries......................74TableIV.2ExampleofProcessStep/Function/RequirementsColumnsonPFMEAFormincludingPotentialFailureModes.......................................................................................................................................81TableIV.3ExampleofEffects.....................................................................................................................85TableCr1SuggestedPFMEASeverityEvaluationCriteria.........................................................................88TableCr2SuggestedPFMEAOccurrenceEvaluationCriteria....................................................................93TableIV.4ExamplesofCausesandControls..............................................................................................96TableCr3SuggestedProcessFMEADetectionEvaluationCriteria..........................................................Only100TableIV.5ExamplesofCauses,ControlsandActions..............................................................................110FigureIV.5PFMEAInformationInterrelationshipFlowMotor...........................................................................111DFMEAFormA........................................................................................................................................115DFMEAFormB.........................................................................................................................................116DFMEAFormC.........................................................................................................................................117DFMEAFormD...............................................................................................................................Use.........118DFMEAFormE.........................................................................................................................................119DFMEAFormF.........................................................................................................................................120PFMEAFormA...............................................................................................................................Ford..........122PFMEAFormB.........................................................................................................................................123PFMEAFormC..........................................................