failure mode and effect analysis-FMEA

今天，我们将讨论FMEA - 故障模式和效果分析。

没有人想要有缺陷的产品。缺陷昂贵，令人沮丧，并且对公司的声誉造成了破坏。

As a project manager, you will try to avoid failure in your deliverable using every possible technique. One such technique is Failure Mode and Effect Analysis, or FMEA. This technique helps you locate potential issues with a product or process and allows you to take纠正措施。

FMEA - 失败模式和效果分析

The US military developed FMEA to design better weapons, and this methodology was successful. Later it was adopted by NASA, automobile companies, and then other industries.

FMEA是一种方法，可以通过确定设计或制造过程中的所有可能的故障来帮助组织在设计阶段预测系统或产品故障。

FMEA was one of the earliest methods of systematically looking at the potential problem in a product or process.

它着眼于类似的产品或流程，并审查了他们过去的失败。它还考虑了材料的物理特征。根据分析，您可以对流程或产品进行更改以避免错误。

Failure modes are the ways in which the product or process can fail. Effects are the ways these failures can lead to defects. Failure Mode and Effects Analysis aims to identify, prioritize and control these failure modes.

该技术也被称为“失败模式效应和批判性分析”（FMECA），有时仅仅是“故障模式”。

The FMEA can improve your systems, design processes, and production processes.

FMEA是一种直接，定性的技术，涉及与专家进行头脑风暴，并将其评论列在表格中。它类似于创建一个过程概率和冲击矩阵。

Here, experts identify possible causes for product failure, the chances of these happening, the impact, how easy it is to detect failure, etc. These opinions are noted in a table for further review.

This helps you identify many failures that can affect the deliverable.

FMEA类型

FMEA可以大致分为两类：

  1. Design FMEA
  2. Process FMEA

设计FMEA（DFMEA）

DFMEA在设计阶段发现可能的故障模式，例如：

  • Tolerance
  • Material properties
  • 产品几何形状
  • EEF

Process FMEA (PFMEA)

PFMEA finds possible failure modes that can occur during the product development process, such as:

  • 程序
  • 人为错误
  • Equipment used
  • Inspection

When to Use FMEA

FMEA is useful for avoiding future errors and improving the reliability of the process and the product. You can use it in the following cases:

  • During the development of a new product or process.
  • Before you make changes to a product or process.
  • 在确定过程或产品中的错误之后。
  • 收到客户的众多投诉时。
  • When sales support costs are unusually high.
  • When a company’s credibility is at stake.

This technique is not confined to any industry or technology; you can this method in all industries.

如何使用FMEA

This technique requires expert judgment. You will call experts for one or more brainstorming sessions. They will help you identify, collect, and evaluate the potential defects, their causes, and their impact.

专家应属于所有功能区域，以便您可以涵盖完整的product life cycle。

FMEA Example

您可以使用下表记录专家的输入。您将更多地关注分析可能的设备故障的原因。

Failure Mode and Effect Analysis (FMEA) table

FMEA技术使用三个参数：严重性，发生和检测。

缺陷的严重程度(股票)显示了严酷on the user. Occurrence (OCC) predicts how often the issue may happen. Detection (DET) represents how easily you can find the problem.

Experts will assign a value from one to ten for each potential error or defect, where one is extremely unlikely, and ten is extremely likely. After the brainstorming session ends, you will compile the problems, causes, and ratings. Afterward, you will enter this information into a table.

最后，您将每个缺陷的严重程度，发生和检测乘以生成RPN。这代表风险概率编号，并为每个缺陷提供总体风险影响评分。在我们的示例表中，故障的RPN为81。

You will decide the thresholds of each risk level after generating the RPN for all possible defects and failures. The threshold can be high, medium, or low. Using the RPN number, you will decide if a defect cause is high, medium, or low-level priority.

您将处理高优先级RPN，以减轻或消除缺陷。

例如，第二个表显示了您针对已确定的故障的推荐行动，谁将负责该操作以及何时应实施。

您将记录此故障以及一旦发生的动作。

How to Implement FMEA

You have a list of possible errors and their potential corrective actions. Now, you will assign responsibility to your team members to implement these actions to reduce the RPN of these errors.

You will review them again after the corrective actions have been implemented to assess the effectiveness of the action plan. If necessary, a new FMEA will be generated to re-assess the risks and defects.

使用帕累托法在使用此技术的同时。专注于少数原因创造大多数问题或缺陷。在使用最少的资源时，这提供了最大的影响。新万博登录手机版一旦解决了这些高影响力问题，您就可以按照资源允许来承担其他缺陷。新万博登录手机版

You can plan a new corrective action to mitigate the problem if you see that a particular issue is not being resolved currently.

Importance of FMEA

早期发现和纠正故障的成本要比以后的阶段要少得多。后来的错误会影响品牌认可和不满意的客户，因此更具破坏性。

FMEA可让您在产品开发的早期阶段发现失败。

它减少了售后支持并提高客户满意度。

FMEA的好处

A few benefits of FMEA are:

  • 改进和更可靠的产品。
  • Less after-sale support.
  • Increased customer satisfaction.
  • Improved brand reputation.
  • 减少失败和保修费用。
  • 通过减少售后费用来最大化利润。

结论

FMEA是一种主动技术，可帮助您在发生之前识别潜在的缺陷和失败。这是一种绝妙的定性方法，如果正确使用，可以为您的组织带来许多好处。尽管由于参与various stakeholders，它将导致您的项目成功结束。

请在评论部分中分享您使用故障模式和效果（FMEA）分析技术的经验。