1、DFMEA-失效模式与后果分析(Design Failure Mode &Effect Analysis),Marian(Shenzhen)Co.,Ltd编制 ： 曹喜元 Formation By： Jack Cao 日期： Date： 1-Feb-2013,主要内容Main content,1.DFMEA 介绍 4.DFMEA 关键参数DFMEA Presentation DFMEA Key Parameter2.DFMEA 职责 5.DFMEA 表单填写说明DFMEA Responsibility DFMEA Form Filling Explanation3.DFMEA 制作流程 6.D
2、FMEA 案例DFMEA Make Process DFMEA Example,一、DFMEA 的介绍DFMEA Presentation,DFMEA 是FMEA 中的一种，FMEA分为：DFMEA 和PFMEADFMEA is in the FMEA one type, FMEA Contain :DFMEA & PFMEADFMEA 是由负责设计的工程师或小组，在产品设计阶段尽可能的范围内预估产品在设计上可能发生的缺点.DFMEA is Engineer or group to responsible scheme, As far as possible within the scope
3、of the estimated product design on the possible faults in the product design stage.PFMEA 是由负责制造装配的工程师或小组，预估产品在生产过程阶段或之前可能会发生的缺点.PFMEA is PE or group to responsible scheme , As far as possible the estimated product possible faults in the productive process or before.本章节重点讲述DFMEAThis chapter focuses o
4、n DFMEA.,DFMEA 的形成DFMEA Formation,DFMEA 是由负责设计的工程师或小组，在尽可能的范围内预估产品在设计上可能发生的缺点，衡量该项缺点或能造成的影响，并拟定为防止或检测该缺点应改善的设计控制，并推动其标准化作业，且必须配合设计发展之程序反复执行.DFMEA is Engineer or group to responsible scheme, As far as possible within the scope of the estimated product design on the possible faults in the product desi
5、gn stage, Measure the faults or can cause influence, and plan to prevent or testing the defect should be improved design control, and promote the standardized operation, and must fit in with the development of design program and implementation.最终成品及其所有相关的系统、子系统都应纳入评估.DFMEA是设计小组，即公司工程，运用设计，工程经验或分析方法等
6、而形成的.The final and all related system, subsystem should be included in assessment. DFMEA is the design team, namely the company project, the use of design, engineering experience or analysis methods and form.,DFMEA 必备条件DFMEA Essential Condition,确认已知及潜在的失效模式； Confirm the known and the potential failu
7、re mode. 确认每一个失效模式的效应和原因； Confirm each failure mode effect and reasons. 风险优先评估（严重性、发生频率、难检度）； Risk priority evaluation (severity, occurrence frequency and difficult to check degree) 提供问题的数据及改善行动； Provide problem of data and improvement action.,DFMEA 的动态链DFMEA Trends Catenation,DFMEA 是个循环过程，在设计方案最终形成
8、之时或之前开始.DFMEA is a cyclic process, the design scheme of final form or before the start.在产品开发各阶段中，当设计有变化或得到其他信息时，应及时，不断地修改，最终在产品加工图样完成之前全部结束。In every stage of product development, when the design change or get other information, should be prompt, constantly modified, finally, in product processing pa
9、ttern until all over.,二、DFEMA 职责DFMEA Responsibility,工程经理：DFMEA 总体负责人，负责组建DFMEA 团体，提出 DFMEA 实施计划，并组织召开DFMEA 会议，分配团队人员任务 组织DFMEA 评审，DFMEA 审核. Project manager: general manager, responsible for DFMEA, this paper puts forward a DFMEA group DFMEA implementation plan, and organize a DFMEA meeting, distrib
10、ution team personnel task Organization DFMEA review, DFMEA audit. 工程师：负责主导DFMEA文件编写、修改和升级. Engineer: responsible for leading DFMEA document preparation, modification and upgrade.,二、DFEMA 职责DFMEA Responsibility,工程助理：负责客户投诉问题，研发试产、量产中问题 的收集，及 时反馈到DFMEA团体负责人处，并参与O,S,D 参数评估，提供量 产CPK 数据. Project assistan
11、t: responsible for customer complaint problem, research and trial production, the quantity of collection, and render When the feedback to DFMEA group place, and participate in O, S,D parameter evaluation, Supply volume production CPK data. 试样工程师：负责研发产品测试过程 中所出现问题点的收集并及时 反馈到DFMEA负责人处，参与O,S,D参数评估. Sam
12、ple engineer: responsible for research and development in the process of product testing problems point collection and timely feedback to the DFMEA chief place, participate in O, S, D parameter evaluation.,二、DFEMA 职责DFMEA Responsibility,CQE：负责客户需求信息归纳整理，DFMEA建议措施监督实施、追 踪，实施效果反馈，根据DFMEA和客户需求等信息制定控制计划
13、， 并参与 O,S,D 参数评估. CQE: Be responsible for the customer demand information summary, DFMEA suggested measures supervision and implementation, tracking and effect feedback, according to the DFMEA and requirements for information such as control plan, and participate in O, S, D parameter evaluation.,三、D
14、FMEA 制作流程DFMEA Make process,注：团队制定目标，使团队清楚新产品或以改善为 目标，并需要了解客户需求。 Note: The team set goals, make the team clear new products or to improve as the goal, and need to understand customer needs. 使用方法；Method of application. 客户要求的设计/工程SPEC；Customer requested project & Engineering SPEC. 产品信赖；Product Trust.
15、制程、生产、装配 要求；Process, Production Assemble of Requirement. 品质目标. Quality Destination.,组成DFMEA团队Constitute DFMEA Team,确定目标Confirm Destination,三、DFMEA 制作流程DFMEA Make process,产品设计及类似产品设计的问题及原因； Product design and similar product design problems and reasons 制造工艺及类似产品制程中常及的不良原因； Manufacturing process and s
16、imilar products in process and bad reason. 类似产品的制程能力及原因； Similar products of process capability and the reason. 类似产品的客诉及原因； Similar products of customer complaint and the reason. 类似产品的依赖性失效及原因； Similar products the dependence of the failure and the reason. 类似产品的管理性问题； Similar products of managerial
17、problems.,资料收集Data Collection,三、DFMEA 制作流程DFMEA Make process,使用维修； Use Maintain. 环境. Environment. 表格格式 Table Format. 分层层次 Delamination Administrative levels. 失效定义 Failure Definition. 成果整合 Achievement Integration. 时机 Opportunity.,资料收集Data Collection,制订执行方案Formulate implement Plan,三、DFMEA 制作流程DFMEA Ma
18、ke process,分析制程特性Analysis Process Character,定义制造流程Definition production Process,分析产品特性Analysis Product Character,分析失效原因Analysis Failure Cause,分析现行控制方法Analysis Control Method,分析失效效应Analysis Failure Effect,分析发生率Analysis Occurrence Rate,分析难检度Analysis Detection,分析严重度Analysis Severity,计算风险优先数Calculated R
19、isk Priority Number,分析制程特性Analysis Process Character,三、DFMEA 制作流程DFMEA Make process,决定优先改善的失效模式Decide Ameliorative Failure Mode,建议改善措施Recommendation Improvement Measures,改善实施Improvement Implement,结果确认有效Result Notarize Effective,四、DFMEA 关键参数DFMEA Key Parameter,严重度、发生率、难检度、风险优生数Severity, Occurrence, D
20、etection, RPN,严重度 Severity-S发生率 Occurrence-O难检度 Detection-D风险优生数 Risk Priority Number-RPNRPN=S*O*D,四、DFMEA 关键参数DFMEA Key Parameter,严重度Severity,衡量失效的影响程度.Assessment failure incidence失效影响产品或制程，某一失效会对产品外观、结构、功能、性能稳定性、可靠性的影响；或对下一个制程，使用者和设备的影响；或对最终客户，政府法规、安全、环保等的违及.Failure affect product or process, a fa
21、ilure to product appearance, structure, function, performance stability and reliability of the influence; Or to the next process, the user and the influence of the equipment; Or to end customers, government regulations, safety, and environmental protection, and a default.,四、DFMEA 关键参数DFMEA Key Param
22、eter,严重度Severity,严重度的划分标准-主观判定Severity Classification Standard-Subjectivity Decide其大小由失效模式的影响程度而定，以1至10表示等级.Its size of the failure mode of the influence degree to decide, be 1 to 10 show level.1级最轻微，10级最严重. 1Level best slight , 10 Level best grave.1级-几乎不会有什么影响.1Level-Almost has no influence.10级-违反安
23、全和法规.10Level-Violation of safety and regulations.,四、DFMEA 关键参数DFMEA Key Parameter,严重度分类Severity Classify,耐火性、自然性、UL 、RHoS&HF Fire Resistance, Naturalness,UL,RHoS&HF一、 危险特性 Catastrophic 工业标准(无法满足而不能销售） Industry StandardIncapable Con not Market. 客户要求 Customer Request 内部工程需要由Critical测量项目 Internal ENG n
24、eed for critical measure project,四、DFMEA 关键参数DFMEA Key Parameter,严重度分类Severity Classify,客户及供应商共同制定特性； Customer and Supplier together formulate features.二、 重大特性 Significant 或客户指定特性，如导电或绝缘；(满足而不能销售给指定客户) Or customer appoint features, For instance EC & Insulation.Content Con not Market 设计工程指定的特性； Desig
25、nation Customer DE appoint features. 行业标准. Industrial standard.,四、DFMEA 关键参数DFMEA Key Parameter,严重度分类Severity Classify,可靠性测试，如拉拔力测试； . Reliability Testing, For example drawing force test .三、 主要特性 Major 产品制程不良率及分析 Product process reject ratio and analysis.,四、DFMEA 关键参数DFMEA Key Parameter,严重度等级标准Sever
26、ity Rank Standard,四、DFMEA 关键参数DFMEA Key Parameter,严重度等级标准Severity Rank Standard,四、DFMEA 关键参数DFMEA Key Parameter,严重度等级标准Severity Rank Standard,四、DFMEA 关键参数DFMEA Key Parameter,发生率Occurrence,某一原因而导致失效发生的几率.A reason to the odds of failure.划分标准：依据不良品出现的机率来定，以1至10表示等级.The division standard: according to t
27、he probability of bad product appeared to decide, be 1 to 10 show level.1级最轻微，10级最严重. 1Level best slight , 10 Level best grave.1级-几乎不会发生.1Level- Almost wont happen.10级-肯定会发生.10Level- Will happen,四、DFMEA 关键参数DFMEA Key Parameter,发生率Occurrence,划分标准-CPK、主观判定、统计资料Divide Standard-CPK, Subjective judge, st
28、atistical information,四、DFMEA 关键参数DFMEA Key Parameter,发生率Occurrence,划分标准-CPK、主观判定、统计资料Divide Standard-CPK, Subjective judge, statistical information,四、DFMEA 关键参数DFMEA Key Parameter,难检度Detection,在现行的控制措施下，侦测失效发生的能力.In the current control measures, the ability to detect failure happened.划分标准：依据失效模式检验的
29、难易程度来定，以1至10表示等级.The division standard: According to the failure mode of the test difficulty to set, be 1 to 10 show level.1级最容易，10级为几乎不可能发现. 1Level best easy , 10 Level for Almost impossibility find.1级-用有效的手段完全可以检测出来1Level-With effective means completely can be detected.10级-无任何手段可以检测出来.10Level-No m
30、eans can be detected.,四、DFMEA 关键参数DFMEA Key Parameter,难检度Detection,划分标准-主观判定、统计资料Divide Standard-Subjective judge, statistical information,四、DFMEA 关键参数DFMEA Key Parameter,风险系数Risk Priority Number,RPN=S*O*D风险系数RPN排出次序后，RPN越大越优先解决.RPN在100以上必须解决；50RPN100应尽可能解决，不能解决必须加严控制；RPN50可不加控制.当严重度(S)很高或发生率(O)很高时，
31、不管RPN大小如何，都必制定相应改善或控制措施，并指定责任人和改善完成日期.Risk coefficient RPN discharge order, the bigger the RPN priority. RPN in more than 100 must be solved; 50 RPN 100 should as far as possible to solve, cant solve must be tightened control; RPN 50 dont add control. When the severity (S) or high incidence (O) is v
32、ery high, no matter how RPN size will be formulate the corresponding improvement or control measures, and appoint responsible persons and improve the completion date.,如何制定改善措施How to make the improvement measures,针对预防/纠正措施，以降低评价等级的内容顺序为：严重度、发生率及侦测度；Aiming at preventing/corrective measures, in order t
33、o reduce the content of the evaluation grade order: (S), (O) ,(D).通过设计变更来消除或控制一个或多个失效模式的起因机理，能降低严重度等级；Through the design change to eliminate or control one or more of the cause of the failure mode mechanism, can reduce the severity level;透过设计变更，去除或管制某一或多个影响失效模式的原因或设备，只能降低发生率的等级.Through the change of
34、 the design, remove or control one or more of the cause of the failure mode effect or equipment, can reduce the incidence of grade.增加设计验证，修改测试计划，修改原物料规格，只可降低难检度.To increase the design verification, modifying the test plan, modify the original material specifications, can only reduce the difficult de
35、gree of test.,五、DFMEA 表单填写说明1DFMEA Notes on completing the form(1),DFMEA 编号：填入DFMEA文件的编号，以便要询； DFMEA Numbers: fill in the DFMEA file Numbers, so that to information; 项目：填入所分析的系统、子系统或零件的过程名称，编号； Project: fill in the analysis of the system, subsystem or parts of the process name, Numbers; 设计责任：部门、小组还应
36、包括供方的名称； Design responsibility: department, the team also should include the name of the supplier; 填入负责DFMEA 工作的工程师姓名、电话及所在公司名称； Fill in the responsible of the engineers DFMEA name, phone number and the name of the company; 填入将使用或正被分析的设计过程影响的预期的机型和料号； Fill in will use or are being analyzed the influ
37、ence of the design process of the expected type and material number; 关键日期：填入DFMEA初次预定完成日期，该日期不应超过计划开始设计生产发布日期. The key date: fill in the DFMEA first target completion date, this date shall not exceed the design plan to begin production release date.,五、DFMEA 表单填写说明2DFMEA Notes on completing the form(
38、2),DFMEA 日期：填入编制DFMEA原始稿的日期及最新修订日期； DFMEA date: fill in the draw up DFMEA date and latest revision date. 核心小组：列出有权确定和执行任务的责任部门和个人姓名，如果对某一特定原因无建议措施，那么 就在该栏中写“N/A”. The core team: list shall have the right to determine and implement the responsibility of the department and individual task name, if for
39、 A particular reason no suggested measures, then write in the column of N/A. 项目/功能：填入被分析项目的名称和编号，若该项目有多种功能，且有不同的失效模式，应把所有功 都单独列出. Project/function: fill in the name of the project are analyzed and Numbers, if the project has a variety of functions, and have different failure mode, we should put all
40、functions are listed separately. 潜在失效模式：对一个特定项目及其功能，应用规范化，专业性的术语来列出每一个潜在的失效模式 前提是这种失效可能发生，但不一定发生. Potential failure mode: for a specific project and its function, the application of standardized, professional terms to list each potential failure mode provided that failure may occur, but does not necessarily occur.,
