QSB过程失效模式及后果分析

GeneralMotorsCorporation.Allrightsreserved.QSBWORKSHOPREV.111406FR&PSNCMWPOSWI(SOS)OI(JES)SOT(JIT)RiskReductEPVLPAVSContamSCM1降低风险的程序主动式RPN降低流程:降低潜在质量失效的风险被动式对已发生的质量失效建立防错装置GeneralMotorsCorporation.Allrightsreserved.QSBWORKSHOPREV.111406FR&PSNCMWPOSWI(SOS)OI(JES)SOT(JIT)RiskReductEPVLPAVSContamSCM2过程失效模式及效果分析定义•是一个格式化程序，用以识别和消除潜在失效模式•是一个识别每一个过程步骤的分析技术–过程可能达不到要求的情形–对内部/外部顾客的影响(严重度)–失效可能发生的频率(发生频度)–当前控制的效果(预防和可探测度)–原因和结果的等级(风险顺序数)GeneralMotorsCorporation.Allrightsreserved.QSBWORKSHOPREV.111406FR&PSNCMWPOSWI(SOS)OI(JES)SOT(JIT)RiskReductEPVLPAVSContamSCM3严重度分级EffectCriteria:SeverityofEffectThisrankingresultswhenapotentialfailuremoderesultsinafinalcustomerand/oramanufacturing/assemblyplantdefect.Thefinalcustomershouldalwaysbeconsideredfirst.Ifbothoccur,usethehigherofthetwoseverities.(CustomerEffect)Criteria:SeverityofEffectThisrankingresultswhenapotentialfailuremoderesultsinafinalcustomerand/oramanufacturing/assemblyplantdefect.Thefinalcustomershouldalwaysbeconsideredfirst.Ifbothoccur,usethehigherofthetwoseverities.(Manufacturing/AssemblyEffect)RankingHazardouswithoutwarningVeryhighseverityrankingwhenapotentialfailuremodeaffectssafevehicleoperationand/orinvolvesnoncompliancewithgovernmentregulationwithoutwarning.Ormayendangeroperator(machineorassembly)withoutwarning.10HazardouswithwarningVeryhighseverityrankingwhenapotentialfailuremodeaffectssafevehicleoperationand/orinvolvesnoncompliancewithgovernmentregulationwithwarning.Ormayendangeroperator(machineorassembly)withwarning.9VeryHighVehicle/iteminoperable(lossofprimaryfunction).Or100%ofproductmayhavetobescrapped,orvehicle/itemrepairedinrepairdepartmentwitharepairtimegreaterthanonehour.8HighVehicle/itemoperablebutatareducedlevelofperformance.Customerverydissatisfied.Orproductmayhavetobesortedandaportion(lessthan100%)scrapped,orvehicle/itemrepairedinrepairdepartmentwitharepairtimebetweenahalf-hourandanhour.7ModerateVehicle/itemoperablebutComfort/Convenienceitem(s)inoperable.CustomerDissatisfied.Oraportion(lessthan100%)oftheproductmayhavetobescrappedwithnosorting,oravehicle/itemrepairedinrepairdepartmentwitharepairtimelessthanahalf-hour.6LowVehicle/ItemoperablebutComfort/Convenienceitem(s)operablebutatareducedlevelofperformance.Or100%ofproductmayhavetobereworked,orvehicle/itemrepairedoff-linebutdoesnotgotorepairdepartment.5VeryLowFitandFinish/SqueakandRattleitemdoesnotconform.Defectnoticedbymostcustomers(greaterthan75%).Ortheproductmayhavetobesorted,withnoscrap,andaportion(lessthan100%)reworked.4MinorFitandFinish/SqueakandRattleitemdoesnotconform.Defectnoticedby50%ofcustomers.Oraportion(lessthan100%)oftheproductmayhavetobereworked,withnoscrap,on-linebutout-of-station.3VeryMinorFitandFinish/SqueakandRattleitemdoesnotconform.Defectnoticedbydiscriminatingcustomers(lessthan25%.Oraportion(lessthan100%)oftheproductmayhavetobereworkedwithnoscrap,on-linebutin-station.2NoneNodiscernibleeffect.Orslightinconveniencetooperationoroperator,ornoeffect.1(AIAGPFMEAThirdEdition)GeneralMotorsCorporation.Allrightsreserved.QSBWORKSHOPREV.111406FR&PSNCMWPOSWI(SOS)OI(JES)SOT(JIT)RiskReductEPVLPAVSContamSCM4发生频度分级PpKRanking0.55100.5590.7880.8670.9461.0051.1041.2031.3021.671ProbabilityLikelyFailureRates100perThousandPieces50perThousandPieces20perThousandPieces10perThousandPiecesVeryHigh:PersistentFailuresHigh:FrequentFailures5perThousandPieces2perThousandPieces1perThousandPiecesModerate:OccasionalFailure0.5perThousandPieces0.1perThousandPiecesRemote:FailureisUnlikely0.01perThousandPiecesLow:RelativelyFewFailures(AIAGPFMEAThirdEdition)GeneralMotorsCorporation.Allrightsreserved.QSBWORKSHOPREV.111406FR&PSNCMWPOSWI(SOS)OI(JES)SOT(JIT)RiskReductEPVLPAVSContamSCM5探测度分级RatingDetectionCriteriaErrorProofedGaugedManualInspectionSuggestedrangeofdetectionmethods10AlmostImpossibleAbsolutecertaintyofnon-detection.XCannotdetectorisnotchecked.9VeryRemoteControlswillprobablynotdetect.XControlachievedwithIndirectorrandomchecksonly.8RemoteControlshavepoorchanceofdetection.XControlisachievedwithvisualinspectiononly.7VeryLowControlshavepoorchanceofdetection.XControlisachievedwithdoublevisualinspectiononly.6LowControlsmaydetect.XXControlisachievedwithchartingmethods,suchasSPC.5ModerateControlsmaydetect.XControlisbasedonvariablegaugingafterpartshaveleftthestation,orgo/no-gogaugingperformedon100%ofthepartsafterpartshaveleftthestation.4ModeratelyHighControlshaveagoodchancetodetect.XXErrordetectioninsubsequentoperations,ORgaugingperformedonset-upandfirstpiececheck(forset-upcausesonly).3HighControlshaveagoodchancetodetect.XXErrordetectioninstation,ORerrordetectioninsubsequentoperationsbymultiplelayersofacceptance:Supply,select,install,verify.Cannotacceptdiscrepantpart.2VeryHighControlsalmostcertaintodetect.XErrordetectionin-station(automaticgaugingwithautomaticstopfeature).Cannotpassdiscrepantpart.1CertainControlscertaintodetect.XDiscrepantpartscannotbemadebecauseitemhasbeenerrorproofedbyprocess/productdesign.(AIAGPFMEAThirdEdition)GeneralMotorsCorporation.Allrightsreserved.QSBWORKSHOPREV.111406FR&PSNCM