RPN-FMEA-的输出教学讲解课件

•RPN:FMEA的输出•RPN

的计算:•潜在的失败模式（FM）•失败模式的影响（FME）•在一个制品到达顾客那里之前，发现失败模式（FM）的可能性。RiskPrioritynumber:RPN•RPN:FMEA的输出•RPN的计算:RPN=（严重度）Severity*（发生度）Occurrence*(检出度）Detection•RPN不是制品的原始值.影响原因控制RPN

的计算RPN=（严重度）Severity*（发生度）Occur级别

severity

occurrence

detection

10无预警危险

9

8

7

6

5

4

3

2

1

ex)RPN级有预警危险主要功能损失主要作用执行的减少2nd

执行减少2nd

作用，执行减少被大多数顾客注意到被部分顾客注意到少部分顾客注意到无影响很高:不可避免的失败高:反复失败中度:偶尔失败低:很低失败没有失败没有检出检出可能性非常小几乎不可能检出检出度很低低检出度中度检出度适度高检出度高检出度非常高检出度几乎确认检出级别severityoccurrencedetectRecommendedactionResponsibleperson,FinishdateActuallytakedactionseverityoccerrenceRPNUsingStstisticaltoolBB2000/1/15Samplingtestof1time在对策实施或，输入变化后的结果step13.活动职责 -负责人

.接触点 .部门 -完成日程step14.对策实施-实际活动-日程step15.RPN计算

-severity -occurrence -detection

detectionRecommendedResponsibleperson,111111101010101101011101010101101101•完成以下表格:5min•讨论结果:10minoccurrence

severitydetection

result

behavior

练习!111111101010101101011101010101111111101010101101011101010101101101NoactionNoactionAction一般情况确保控制主要问题操作者未受失败影响频繁的失败，检出，成本要求occurrenceseveritydetection

结果

行为

Quiz!(结果)Noaction操作者受失败影响ActionActionActionAction频繁失败，操作者受影响频繁失败，主要影响111111101010101101011101010101•如果RPN大于100

或失败发生度，严重度，检出度大于8的评价等级☞

需建立改善措施。•在相关FMEA表格中标注*。•如果不要求改善措施，在相关表格中标注NOR。

根据RPN

采取的对策•如果RPN大于100或失败发生度，严重度，检出度6.ProcessFMEAchecklist准备工作组成FMEA队?相关信息确认?Processmap（工序图）制作processmap?在每一道工序找出Y因子？在每道工序中作Y因子表格？一般项目基本项目都包括了吗？输入函数每一道操作都清楚地标明函数了吗？FailureMode由FM可以清楚地得出这部分错了吗？一些由于FM造成的错误的特性表做出来了吗？在FM中包括的检出检查和试验的表?缺陷部分的接受度对好的制品的拒绝度如果FM对下一道操作有不好的影响.一个FM记录可以作为下一道操作的发生原因？一个失败在下一道操作中能区分出来吗?6.ProcessFMEAchecklist准备工失败影响对于设备，人员，顾客的危险影响考虑了吗？以下这些影响记录了吗？下一道操作下一个顾客,最终顾客传递方法政府限制条文失败原因/机理在工序中可能出现的错误记录了吗？工序特点考虑了吗？设计的弱点考虑了吗？每道操作中资材考虑了吗？操作人员考虑了吗？当时的管理状况次品可以被检查出来在结束一道工序后次品可以别检出严重度根据FM标准的严重度分类了吗？它与顾客产生的影响一致吗？发生度预防控制考虑了吗？检出度在结束一道操作前，现有的控制条件下，根据检出的可能性可以决定吗？失败影响当时的管理状况等级分类-主要特征和特有的相关控制已经确认了吗？主要特征都由倒三角标识了吗？对于一个工序或某部分特征分析主要特征了吗？主要特征和相关特殊控制措施通知负责设计的人员了吗？RPN根据RPN大小顺序排列了吗？建议考虑到的主要特征产生的严重不良，采取的对策降低这种不良了吗？对主要的特征进行特别控制了吗？所有的主要特征都考虑到拉吗？负责执行的人员指定了吗？优先考虑预防措施了吗？措施消除或减少了危险的FM了吗？等级分类建议FMEA(example)-1根据FMEA流程..主要工程录入变量：刻度精确度，DICY

用蒸汽加热的水箱。processPrimaryprocessinputeffectcausecontrolFailuremodeDICYtankheatedwithsteamScaleaccuracyFMEA(example)-1根据FMEA流程.scale>0ScaleinaccurateScaleisnotsetwith0FMEA(example)-2•

根据录入的主要工程的变量，记录FM。processPrimaryprocessinputeffectcausecontrolFailuremodeDICYtankheatedwithsteamScaleaccuracyscale>0ScaleinaccurateScalFillinglowDMFFMEA(example)-3•

记录由FM产生的影响。processPrimaryprocessinputeffectcausecontrolFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFFillinglowDMFFMEA(example)FMEA(example)-4WaterinJacketTankdelayimperfectfilling

记录FM的原因。FillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolFMEA(example)-4WaterinJaFMEA是在最初的控制里面找到最初的不良。VisualcheckofJacket(SOP5681)Visualcheck(SOP5681)NoneFMEA(example)-5对每一个原因录入现有管理方法。WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolFMEA是在最初的控制里面找到最初的不良。VisualcInstallationDMFwrongDMFfillingDMFinstallationaccuracyFMEA(example)-6Visualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolVisualcheckofJacket(SOP5681)NoneInstallationwrongDMFfillingViscositydeviatedfromstandardFMEA(example)-7InstallationDMFwrongDMFfillingDMFinstallationaccuracyVisualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolVisualcheckofJacket(SOP5681)NoneViscositydeviatedFMEA(exampNoneSystemfailureCan’tfollowSOPstandardFMEA(example)-8ViscositydeviatedfromstandardInstallationDMFwrongDMFfillingDMFinstallationaccuracyVisualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolNoneSystemfailureCan’tfolloKeep,repairprocedure(SOP5821)/visualcheckWorkercertification/processauditFMEA(example)-9NoneSystemfailureCan’tfollowSOPstandardViscositydeviatedfromstandardInstallationDMFwrongDMFfillingDMFinstallationaccuracyVisualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolKeep,repairprocedure(SOP582process/inputcauseoccurrencecontroldetectionRPNseverityFailuremodeeffectVisualcheckofJacket(SOP5681)Visualcheck(SOP5681)NoneDMFfilling/DMFinstalaccuracyWorkercertification/processauditscale>0InaccuratescalelowDMFfillingwrongDMFfilling3337722225163935185442175highDMFfillingFMEA(example)-10•

由产生原因分配严重度，发生度，检出度等级。•RPN计算DICYtankheatedwithsteamScaleisnotsetwith0wrongDMFfillingViscositydeviatedfromstandardSystemfailureCan’tfollowSOPstandardWaterinJacketTankdelayimperfectscaleKeep,repairprocedure(SOP5821)/visualcheckprocesscauseoccurrencecontroldwrongDMFfilling755175ImperfectscaleNone32954Systemfailure72342DMFfilling/DMFinstalaccuracy

Tankdelay32318WaterinJacketscale>03216FMEA(example)RPN大小排列process/inputcauseOccurrencecontrolDetectionRPNseverityFailuremodeeffectDMFfilling/DMFinstalaccuracyViscositydeviatedfromstandardScaleisnotsetwith0wrongDMFfillingInaccuratescalewrongDMFfillingViscositydeviatedfromstandardhighDMFfillinglowDMFfillingDICYtankheatedwithsteam/scaleaccuracyDICYtankheatedwithsteam/scaleaccuracyDICYtankheatedwithsteam/scaleaccuracyCan’tfollowSOPstandardWorkercertification/processauditKeep,repairprocedure(SOP5821)/visualcheckVisualcheck(SOP5681)VisualcheckofJacket(SOP5681)wrongDMFfilling755175ImperfFoolproofdesignConfirmscaledaybydayprocess/inputnecessarymeasure7551753295472342323183216FMEA(example)-11•

必要测定的决定(假设只有高分数的RPN)causeOccurrencecontrolDetectionRPNSeverityFailuremodeeffectDMFfilling/DMFinstalaccuracyDICYtankheatedwithsteam/scaleaccuracyDMFfilling/DMFinstalaccuracy

DICYtankheatedwithsteam/scaleaccuracyDICYtankheatedwithsteam/scaleaccuracywrongDMFfillingscale>0Scaleisnotsetwith0wrongDMFfillingInaccuratescaleViscositydeviatedfromstandardwrongDMFfillingViscositydeviatedfromstandardhighDMFfillinglowDMFfillingImperfectscaleSystemfailureTankdelayWaterinJacketCan’tfollowSOPstandardNoneWorkercertification/processauditKeep,repairprocedure(SOP5821)/visualcheckVisualcheck(SOP5681)VisualcheckofJacket(SOP5681)FoolproofdesignConfirmscalecauseOccurrencecontrolDetectionRPN55175295423422318216necessarymeasure721400001OccurrenceDetectionRPNAuto-DMFfillingmachine8/96takenactionseveritySZPQFoolproofdesignResp.FMEA(example)-12•相关的测定，文件•RPN重新计算ImperfectscaleSystemfailureTankdelayWaterinJacketCan’tfollowSOPstandardNoneWorkercertification/processauditKeep,repairprocedure(SOP5821)/visualcheckVisualcheck(SOP5681)VisualcheckofJacket(SOP5681)ConfirmscaledaybydaycauseOccurcontrolDetecRPN55175

方法1:C&EMatrixFocus-在C&Ematrix分析中从分数最高的输入因子开始。-以上输入因子需记录在FMEA表格中。-计算RPN,以最高的RPNFM来改善控制方法.-对于其他的输入因子，FMEA也要记录。method2:FMEAFocus-在FMEA中记录失败模式和影响。-关于高严重度，多发原因的失败模式，要评价发生可能性。-关于高严重度（发生度*严重度），评价现今的控制情况。-关于最高的RPN项目，改善控制方法。FMEA使用方法方法1:C&EMatrixFocusm

方法3:理解方法途径-对小型工程有益-从第一道一直到最后一道工程都需记录在FMEA工作表中。-对所有的原因，进行严重度，发生度，检出度的分数计算。-对分数最高RPN，改善控制方式。

方法4:SuperFocused-制作Pareto图,对主要不良进行分类,纳入FM。-对于不良或失败模式，集中于FMEA.-目标:FM终结。方法3:理解方法途径方法4:SuperFocu•RPN:FMEA的输出•RPN

的计算:•潜在的失败模式（FM）•失败模式的影响（FME）•在一个制品到达顾客那里之前，发现失败模式（FM）的可能性。RiskPrioritynumber:RPN•RPN:FMEA的输出•RPN的计算:RPN=（严重度）Severity*（发生度）Occurrence*(检出度）Detection•RPN不是制品的原始值.影响原因控制RPN

的计算RPN=（严重度）Severity*（发生度）Occur级别

severity

occurrence

detection

10无预警危险

9

8

7

6

5

4

3

2

1

ex)RPN级有预警危险主要功能损失主要作用执行的减少2nd

执行减少2nd

作用，执行减少被大多数顾客注意到被部分顾客注意到少部分顾客注意到无影响很高:不可避免的失败高:反复失败中度:偶尔失败低:很低失败没有失败没有检出检出可能性非常小几乎不可能检出检出度很低低检出度中度检出度适度高检出度高检出度非常高检出度几乎确认检出级别severityoccurrencedetectRecommendedactionResponsibleperson,FinishdateActuallytakedactionseverityoccerrenceRPNUsingStstisticaltoolBB2000/1/15Samplingtestof1time在对策实施或，输入变化后的结果step13.活动职责 -负责人

.接触点 .部门 -完成日程step14.对策实施-实际活动-日程step15.RPN计算

-severity -occurrence -detection

detectionRecommendedResponsibleperson,111111101010101101011101010101101101•完成以下表格:5min•讨论结果:10minoccurrence

severitydetection

result

behavior

练习!111111101010101101011101010101111111101010101101011101010101101101NoactionNoactionAction一般情况确保控制主要问题操作者未受失败影响频繁的失败，检出，成本要求occurrenceseveritydetection

结果

行为

Quiz!(结果)Noaction操作者受失败影响ActionActionActionAction频繁失败，操作者受影响频繁失败，主要影响111111101010101101011101010101•如果RPN大于100

或失败发生度，严重度，检出度大于8的评价等级☞

需建立改善措施。•在相关FMEA表格中标注*。•如果不要求改善措施，在相关表格中标注NOR。

根据RPN

采取的对策•如果RPN大于100或失败发生度，严重度，检出度6.ProcessFMEAchecklist准备工作组成FMEA队?相关信息确认?Processmap（工序图）制作processmap?在每一道工序找出Y因子？在每道工序中作Y因子表格？一般项目基本项目都包括了吗？输入函数每一道操作都清楚地标明函数了吗？FailureMode由FM可以清楚地得出这部分错了吗？一些由于FM造成的错误的特性表做出来了吗？在FM中包括的检出检查和试验的表?缺陷部分的接受度对好的制品的拒绝度如果FM对下一道操作有不好的影响.一个FM记录可以作为下一道操作的发生原因？一个失败在下一道操作中能区分出来吗?6.ProcessFMEAchecklist准备工失败影响对于设备，人员，顾客的危险影响考虑了吗？以下这些影响记录了吗？下一道操作下一个顾客,最终顾客传递方法政府限制条文失败原因/机理在工序中可能出现的错误记录了吗？工序特点考虑了吗？设计的弱点考虑了吗？每道操作中资材考虑了吗？操作人员考虑了吗？当时的管理状况次品可以被检查出来在结束一道工序后次品可以别检出严重度根据FM标准的严重度分类了吗？它与顾客产生的影响一致吗？发生度预防控制考虑了吗？检出度在结束一道操作前，现有的控制条件下，根据检出的可能性可以决定吗？失败影响当时的管理状况等级分类-主要特征和特有的相关控制已经确认了吗？主要特征都由倒三角标识了吗？对于一个工序或某部分特征分析主要特征了吗？主要特征和相关特殊控制措施通知负责设计的人员了吗？RPN根据RPN大小顺序排列了吗？建议考虑到的主要特征产生的严重不良，采取的对策降低这种不良了吗？对主要的特征进行特别控制了吗？所有的主要特征都考虑到拉吗？负责执行的人员指定了吗？优先考虑预防措施了吗？措施消除或减少了危险的FM了吗？等级分类建议FMEA(example)-1根据FMEA流程..主要工程录入变量：刻度精确度，DICY

用蒸汽加热的水箱。processPrimaryprocessinputeffectcausecontrolFailuremodeDICYtankheatedwithsteamScaleaccuracyFMEA(example)-1根据FMEA流程.scale>0ScaleinaccurateScaleisnotsetwith0FMEA(example)-2•

根据录入的主要工程的变量，记录FM。processPrimaryprocessinputeffectcausecontrolFailuremodeDICYtankheatedwithsteamScaleaccuracyscale>0ScaleinaccurateScalFillinglowDMFFMEA(example)-3•

记录由FM产生的影响。processPrimaryprocessinputeffectcausecontrolFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFFillinglowDMFFMEA(example)FMEA(example)-4WaterinJacketTankdelayimperfectfilling

记录FM的原因。FillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolFMEA(example)-4WaterinJaFMEA是在最初的控制里面找到最初的不良。VisualcheckofJacket(SOP5681)Visualcheck(SOP5681)NoneFMEA(example)-5对每一个原因录入现有管理方法。WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolFMEA是在最初的控制里面找到最初的不良。VisualcInstallationDMFwrongDMFfillingDMFinstallationaccuracyFMEA(example)-6Visualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolVisualcheckofJacket(SOP5681)NoneInstallationwrongDMFfillingViscositydeviatedfromstandardFMEA(example)-7InstallationDMFwrongDMFfillingDMFinstallationaccuracyVisualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolVisualcheckofJacket(SOP5681)NoneViscositydeviatedFMEA(exampNoneSystemfailureCan’tfollowSOPstandardFMEA(example)-8ViscositydeviatedfromstandardInstallationDMFwrongDMFfillingDMFinstallationaccuracyVisualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolNoneSystemfailureCan’tfolloKeep,repairprocedure(SOP5821)/visualcheckWorkercertification/processauditFMEA(example)-9NoneSystemfailureCan’tfollowSOPstandardViscositydeviatedfromstandardInstallationDMFwrongDMFfillingDMFinstallationaccuracyVisualcheck(SOP5681)WaterinJacketTankdelayimperfectfillingFillinglowDMFprocessPrimaryprocessinputeffectcauseFailuremodescale>0DICYtankheatedwithsteamScaleaccuracyScaleinaccurateScaleisnotsetwith0FillinghighDMFFillingwrongDMFcontrolKeep,repairprocedure(SOP582process/inputcauseoccurrencecontroldetectionRPNseverityFailuremodeeffectVisualcheckofJacket(SOP5681)Visualcheck(SOP5681)NoneDMFfilling/DMFinstalaccuracyWorkercertification/processauditscale>0InaccuratescalelowDMFfillingwrongDMFfilling3337722225163935185442175highDMFfillingFMEA(example)-10•

由产生原因分配严重度，发生度，检出度等级。•RPN计算DICYtankheatedwithsteamScaleisnotsetwith0wrongDMFfillingViscositydeviatedfromstandardSystemfailureCan’tfollowSOPstandardWaterinJacketTankdelayimperfectscaleKeep,repairprocedure(SOP5821)/visualcheckprocesscauseoccurrencecontroldwrongDMFfilling755175ImperfectscaleNone32954Systemfailure72342DMFfilling/DMFinstalaccuracy

Tankdelay32318WaterinJacketscale>03216FMEA(example)RPN大小排列process/inputcauseOccurrencecontrolDetectionRPNseverityFailuremodeeffectDMFfilling/DMFinstalaccuracyViscositydeviatedfromstandardScaleisnotsetwith0wrongDMFfillingInaccuratescalewrongDMFfillingViscositydeviatedfromstandardhighDMFfillinglowDMFfillingDICYtankheatedwithsteam/scaleaccuracyDICYtankheatedwithsteam/scaleaccuracyDICYtankheatedwithsteam/scaleaccuracyCan’tfollowSOPstandardWorkercertification/processauditKeep,repairprocedure(SOP5821)/visualcheckVisualcheck(SOP5681)VisualcheckofJacket(SOP5681)wrongDMFfilling755175ImperfFoolproofdesignConfirmscaledaybydayprocess/inputnecessarymeasure7551753295472342323183216FMEA(examp