Potential Failure Mode Effects Analysis FMEA 2001 11

Potential Failure Mode Effects Analysis (FMEA) 잠재적 고장 형태 및 영향 분석 2001. 11. 1 / 108 QS-9000 FMEA

FMEA - Types System 개념 FMEA 설계 FMEA Sub-System Component System Assembly Sub-System Component 공정 FMEA System Manufacturing Sub-System Component 2001. 11. 9 / 108 QS-9000 FMEA

QS-9000 CHART Requirements CUSTOMER NEEDS Feed Back DFMEA SPECIAL CHARACTERISTICS DESIGN VERIFICATION DESIGN INPUT PROTOTYPE CONTROL PLAN DESIGN OUTPUT PFMEA PRE-LAUNCH CONTROL PLAN SPECIAL CHARACTERISTICS PRODUCTION CONTROL PLAN PRODUCTION PART APPROVAL PRODUCTION CONTINUOUS IMPROVEMENT 2001. 11. 10 / 108 QS-9000 FMEA

( ) CRITICAL CHARACTERISTICS 특성 SIGNIFICANT CHARACTERISTICS 모든 다른 특성 2001. 11. 12 / 108 QS-9000 FMEA

특별특성 확인 DESIGN FMEA 5 S 8 & O 4 S>8 PROCESS FMEA S>8 5 S 8 & O 4 특별관리가 요구되는가 ? NO 일반특성 YES CRITICAL 특성 선정 2001. 11. SIGNIFICANT 특성 선정 16 / 108 QS-9000 FMEA

작업 Model -- 안내 Potential Failure and Effect Analysis ISOS INSPECT What can go wrong? What is the • No Function? • Partial Function • Interittent Function • Over Function • Degraded Function How bad is it? What is the Effect(s)? What can be done? How often does it happen? What is the Cause(s)? How good is this method of finding it? TAKEN ACTION • Design Changes • Process Changes • Special Controls How can this be found? DETECT 2001. 11. 18 / 108 QS-9000 FMEA

고장 유형, 영향, 원인의 상호 관계 CONCEPT FMEA Failure Mode Cannot generate light Effect Customer dissatisfied Cause Output from input mechanism missing DESIGN FMEA Failure Mode Switch (Input mechanism) falls -open circuit Effect Customer dissatisfied; Lighting System fails ; Switch inoperative Cause Switch orientation tab dimensions not specified correctly PROCESS FMEA Failure Mode Switch orientation tab dimension incorrect or tab missing 2001. 11. Effect Customer dissatisfied ; Lighting System fails ; Switch inoperative 19 / 108 Cause -Mold temperature too low -Insufficient material injected into mold QS-9000 FMEA

고장 유형, 영향, 원인의 상호 관계 PROCESS FMEA LAST OPERATION Failure Mode Light Switch inoperative Effect Customer dissatisfied Cause Switch installed improperly - wrong orientation PROCESS FMEA NEXT OPERATION Failure Mode Switch installed improperly wrong orientation Effect Customer dissatisfied; Switch inoperative Cause Orientation tabs missing PROCESS FMEA FIRST OPERATION Failure Mode Orientation tabs missing 2001. 11. Effect Customer dissatisfied ; Switch inoperative Switch installed improperly 20 / 108 Cause -Mold temperature too low -Insufficient material injected into mold QS-9000 FMEA

FMEA 작성 시시 Recommended Timing Events Concept FMEA Program Definition <PD> 시작 Program Implementation <Pl> 완성 Process FMEA 시작 시작 Theme Decision <TD> 개정 Prototype Readiness <PR> 완성 Sign-off <SO> 2001. 11. Design FMEA 개정 완성 22 / 108 QS-9000 FMEA

FMEA 결과물 2001. 11. 23 / 108 QS-9000 FMEA

팀 접근 -- FMEA Process Engineer Support Team 책임 Engineer 설계 Engineer 제조 Engineer 품질 Engineer 서비스 Engineer Test Engineer CORE TEAM 협력업체 전문가 조립 Engineer 2001. 11. 24 / 108 QS-9000 FMEA

Multi-Disciplinary Team 구성 고객요구 파악 Product Quality Timing Plan 수립 1. FMEA 개발 및 검토 2. 특별특성 개발 3. Control Plan 개발 및 검토 Production Part Approval 2001. 11. A. 1 설계, 제조, 자재, 구매, 품질, 영업, 서비스, 협력업체, 고객등 A. 2 Team Leader 선정 A. 3 역할과 책임을 정의 B. 1 고객 요구사항의 정의 B. 2 고객의 기대 파악 B. 3 Feasibility Review(계약체결 이전) C. 1 시작 및 완료일 표기 C. 2 Training Program 수립 C. 3 Management Support D. 1 DFMEA 및 PFMEA D. 2 설계/공정 특별특성 D. 3 Control Plan(Prototype/Pre-lunch/Production) E. 1 Management Support E. 2 Production Quality Planning Summary and Sign-off 25 / 108 QS-9000 FMEA

Design Failure Mode Effects Analysis (DFMEA) 설계 FMEA 2001. 11. 26 / 108 QS-9000 FMEA

FMEA 서식 2001. 11. 29 / 108 QS-9000 FMEA

Design FMEA -- Scope q 기능 Bock Diagram 작성 q 분석 범위 설정 q 팀 협의 2001. 11. 30 / 108 QS-9000 FMEA

Simple Block Diagram q Block으로 System, Subsystem, 혹은 부 품을 나타냄 q 다른 System, Subsystem, 혹은 부품을 나타냄 Service Screw Assembly Component / Assembly Weld Adhesive q Interfaces를 확인함 Other Systems User 2001. 11. 31 / 108 QS-9000 FMEA

Potential Failure Modes Failure Mode Type No function Not operational Partial function Not all of function operating Degraded function Loss of ideal function over time Over function Operates in excess of intent Intermittent function 2001. 11. Potential Failure Mode Occasionally does not function 40 / 108 QS-9000 FMEA

Failure Modes -- Headlamp Failure Mode Type No function No light emitted Partial function Light less intense than specs Degraded function Loss of intensity over time Over function Light too intense Intermittent function 2001. 11. Potential Failure Mode Lights some time, not at others 41 / 108 QS-9000 FMEA

DFMEA Effects Table Failure Part Trimr Assembly System Headlamp LT System Vehicle (-) Customer Driver Gov Regs Thread Doesn’t Not Misaligned Impaired Road Doesn’t Retain Fixed in LIightbeam Night/Fog Vehicle Maintain Setting Position Performance Light Performance Regs ‘ 89 Adjustment 2001. 11. 44 / 108 QS-9000 FMEA

특별특성 분류 보안특성 중요특성 (Critical Characteristics) (Significant Characteristics) 8 심각도(Severity ; S) 5 심각도(Severity ; S) > 8인 특성 and 발생도(Occurrence ; O) 4인 특성 안전 및 법규 특성 2001. 11. 발생도가 많은 고객불만 특성 48 / 108 QS-9000 FMEA

Root Causes of Failure Use a WHY Ladder Support area too small Bending overstress Materia l cracked Level 1 Why? 2001. 11. Level 3 Why? Level 2 Why? 52 / 108 QS-9000 FMEA

고장의 원인 Use a Fishbone Diagram Corrosion Loose Thread No Adjustment Thread Fusion Material Propagation Screw Thread Oversize Engine Heat Thread Contamination Thread Seizure 2001. 11. 53 / 108 QS-9000 FMEA

FMEA 전개 기술 과 고장 유형 결 원인 2001. 11. 영향 (Effect) 원인 (Cause) 54 / 108 QS-9000 FMEA

위험도 평가 - 예 S × O × D = RPN 2 × 10 = 200 10 × 2 × 10 = 2001. 11. 63 / 108 QS-9000 FMEA

위험도 평가 - 예 S × O × D = RPN 3 × 10 × 2 = 60 2001. 11. 9 × 2 = 36 10 × 2 × 1 = 20 64 / 108 QS-9000 FMEA

Process Failure Mode Effects Analysis (PFMEA) 공정 FMEA 2001. 11. 68 / 108 QS-9000 FMEA

FMEA 서식 2001. 11. 70 / 108 QS-9000 FMEA

기법 1. 공정흐름도 작성 PROCESS FLOW DIAGRAM Dept, No. : K 1583 Incoming Sources or Variation Material Feed Conveyor Speed Fluid Temperature Material Composition Material Contamination Pneumatic Pressure Dimension 3 Operator Variability Inspection Method Dimension 5 & 6 Part Variance Tool Wear Dimension 17 & 20 Operator Variability Inspection Method 2001. 11. Part Name: Piezoelectric Switch Process Flow 10 Incoming Sources or Variation 작업 Material Feed Conveyor Speed 검사 Fluid Temperature Material Composition Material Contamination Pneumatic Pressure Dimension 3 40 작업자 이송 45 Inspect for existence of tabs Operator Variability Inspection Method Dimension 5 & 6 Part Variance Tool Wear Dimension 17 & 20 80 85 Operator Variability Inspection Method 76 / 108 QS-9000 FMEA

2. 특성 Matrix 작성 CHARACTERISTIC MATRIX Part Characteristics Housing Material Specific Gravity Process Operations 10 20 30 40 50 60 70 80 85 X X X Housing Diameter X Tab Length X X Switch Orientation 주 : 1) DFMEA의 Root Cause(부품 특성) 기입 2) 모든 특별 특성 고려 3) 특성에 영향을 미치는 고정 확인 예 작업 #20 Drill Hole 작업 #30 Dart A를 Pant B에 용접 작업 #40 서브어셈블리 X를 어셈블리 Y에 조립 2001. 11. 77 / 108 QS-9000 FMEA

특별특성 분류 보안특성 중요특성 (C/C ; Critical Characteristics) (S/C ; Significant Characteristics) 8 심각도(Severity ; S) 5 심각도(Severity ; S) > 8인 특성 and 발생도(Occurrence ; O) 4인 특성 안전 및 법규 특성 2001. 11. 발생도가 많은 고객불만 특성 86 / 108 QS-9000 FMEA