1、 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.1 Quality Basics 1)Quick Response Process 2)Layered Process Audits 3)Control of Non-Conforming Product 4)Probl
2、em Solving Process/Tools 5)RPN Risk Reduction(P-FMEA)6)Error-Proofing Devices and Verification 7)Workplace Organization/Visual Management 8)Verification Stations/Station Alarm Escalation Process Controls 1)Basic Statistics 2)Capability Studies 3)Control Charting(X-bar&R,Pre-Control.)4)Measurement Sy
3、stem Analysis 5)Set-Up Approval/Daily First Piece 6)Special Process Assessments 7)Practical Problem Solving for the Shopfloor 8)Standard Operation and Job Elements Program Management 1)Program Management Office 2)Program Manager Roles&Responsibilities 3)Cross-Functional Teams 4)Project Milestone Rev
4、iews 5)Phase-Gated Process Linked to APQP Phases 6)Executive Gate Reviews 7)Triple Constraint Management 8)Escalation/Change Management Process Continuous Improvement 1)Value Stream Mapping 2)Standardized Work 3)Continuous One-Piece Flow 4)Andon and Jidoka 5)Basic Total Productive Maintenance 6)Less
5、ons Learned/Read-Across Process 7)Bottleneck/Constraint Management 8)Sub-Supplier ManagementTRW Supplier Improvement StrategiesTRW Supplier Improvement Strategies TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Co
6、pyright 2011 TRW Automotive Inc.All Rights Reserved.Error-Proofing Devices/VerificationRPN Risk Reduction(P-FMEA)Verification Stations/Station Alarm EscalationControl of Non-Conforming ProductQuick Response ProcessLayered Process AuditsProblem Solving Process/ToolsWorkplace Organization/Visual Manag
7、ementTRW Supplier Improvement Strategies2 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.3RPN RISK REDUCTION PROCESS风风 险险 降降 低低 程程 序序TSIS:RVersion 1.0 2011-10
8、-12 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.4 What is RPN 什么是什么是RPN Severity Rank Sheet严重度分级严重度分级 Occurrence Rank Sheet 频度数分级频度数分级 Detection Rank Sheet
9、探测度分级探测度分级 How to get RPN 怎样计算怎样计算RPN RPN ReductionRPN降低降低 Proactive 主动式降低主动式降低 RPN tracking chartRPN降低追踪表降低追踪表 Reactive被动式降低被动式降低 Top Failures List最大失效清单最大失效清单Learning Outcome 学习内容学习内容 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automoti
10、ve Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.5海恩法则海恩法则/Herrens Principle:每一起严重事故的背后，必然有29次轻微事故和300起未遂先兆以及1000起事故隐患。Every serious accident follows by 29 minor accident,300 signed failures and 1000 potential defects.法则强调两点:2 stresses of the Principle：1.事故的发生是量的积累的结果；A qua
11、ntitative change causes a qualitative change.2.再好的技术，再完美的规章，在实际操作层面，也无法取代人自身的素质和责任心。At operational level,peoples capability and responsibility are much more important than any high-tech or perfect procedure.任何不安全事故都是可以预防的。任何不安全事故都是可以预防的。Any accident is preventable TRW Automotive Holdings Corp.2009 T
12、RW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.6风险优先数(RPN-Risk Priority Number)：指严重度数（S）和频度数（O）及不易探测度数（D）三项数字之乘积RPN=Severity(S)x Occurrence(O)x Detection(D)严重度Severity(S)：指一给定失效模式最严重的影响后果的级别，是单
13、一的FMEA范围内的相对定级结果。严重度数值的降低只有通过设计更改或重新设计才能够实现。Severity is the value associated with the most serious effect for a given failure mode.Severity is a relative ranking within the scope of the individual FMEA.Only a design revision can bring about a reduction in the severity ranking.频度数Occurrence(O)：指某一特定的
14、起因/机理发生的可能性，描述出现的可能性的级别数具有相对意义，但不是绝对的。Occurrence is the likelihood that a specific cause/mechanism will occur resulting in the failure mode within the design life.The likelihood of occurrence ranking number has a relative meaning rather than an absolute value 探测度Detection(D)：指对在现有设计控制探测栏中列出的最好的探测控制的
15、对应等级。Detection is the rank associated with the best detection control listed in the Detection Controls column.TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.7
16、 过程失效模式及后果分析过程失效模式及后果分析 PROCESS FAILURE MODE&EFFECTS ANALYSIS (PFMEA)定定 义义DEFINITION 是对每一个过程步骤进行分析的技术，以识别：是对每一个过程步骤进行分析的技术，以识别：An analytical technique for each process step that identifies:过程可能达不到要求的情形 ways a process may fail to meet requirements.对内部/外部顾客的影响(严重度)consequences to the internal/external
17、 customer(severity).失效可能发生的频率(发生频度)frequency the failure will/could happen(occurrence).当前控制的效果(预防和可探测度)effectiveness of current controls(prevention&detection).原因和结果的等级(风险顺序数)ranking of causes and effects(risk priority number).是一个格式化程序，用以识别和消除潜在的过程失效模式是一个格式化程序，用以识别和消除潜在的过程失效模式 A structured procedure
18、for identifying and eliminating process related failure modes.TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.8根据根据AIAG/PPAP手册第手册第4版版严严 重重 度度 分分 级级 TRW Automot
19、ive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.9Severity RankEffectCriteria:Severity of Effect on Product(Customer effect)Rank EffectCriteria:Severity of Effect on Proce
20、ss(Manufacturing/Assembly Effect)Failure to Meet Safety and/or regulatory RequirementsPotential failure mode affects safe vehicle and/or involves noncompliance with government regulation without warning 10 Failure to Meet Safety and/or regulatory RequirementsMay endanger operator(machine or assembly
21、)without warningPotential failure mode affects safe vehicle and/or involves noncompliance with government regulation with warning 9 May endanger operator(machine or assembly)with warningLoss or Degradation of primary functionLoss of primary function(vehicle inoperable,does not affect safe vehicle op
22、eration)8 Major disruptions100%of product may have to be scrapped.Line shutdown or stop shipDegradation of primary function(vehicle operable but at a reduced level of performance)7 Significant disruptionsA portion of the production may have to be scrapped.Deviation from primary process including dec
23、reased line speed or added manpowerLoss or Degradation of secondary functionLoss of secondary function(vehicle operable,but comfort/convenience functions inoperable)6 Moderate disruption100%of production run may have to be reworked off line and acceptedDegradation of secondary function(vehicle opera
24、ble but at a reduced level of performance)5 A portion of the production run may have to be reworked off line and acceptedAnnoyanceAppearance or audible Noise,vehicle operable,item does not conform and noticed by most customers(75%)4 Moderate disruption100%of production run may have to be reworked in
25、 station before it is processedAppearance or audible Noise,vehicle operable,item does not conform and noticed by many customers(50%)3 A portion of the production run may have to be reworked in station before it is processedAppearance or audible Noise,vehicle operable,item does not conform and notice
26、d by discriminating customers(25%)2 Minor disruptionSlight inconvenience to process,operation,or operator.No effectNo discernible effect 1 No effectNo discernible effectBased on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition TRW Automotive Holdings Corp.2009 TRW Auto
27、motive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.10根据根据AIAG/PPAP手册第手册第4版版频度数分级频度数分级 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive H
28、oldings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.11Occurrence RankBased on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th EditionLikelihood of failureCriteria:Occurrence of cause-PFMEA(incidents per items/vehicles)Rank Very High=100 per Thousand=1 in 10
29、 10High50 per Thousand1 in 20 920 per Thousand1 in 50 810 per Thousand1 in 100 7Moderate2 per Thousand1 in 500 60.5 per Thousand1 in 2,000 50.1 per Thousand1 in 10,000 4Low0.01 per Thousand1 in 100,000 3=0.001 per Thousand1 in 1,000,000 2Very lowFailure is eliminated through preventive control 1 TRW
30、 Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.12根据根据AIAG/PPAP手册第手册第4版版探测度分级探测度分级 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automot
31、ive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.13Detection RankBased on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th EditionOpportunity for DetectionCriteria:Likelihood of detection by Process Control RankLikel
32、ihood of Detection No detection OpportunityNo current process control;Cannot detect or is not analyzed 10Almost ImpossibleNot likely to detect at any stageFailure Mode and/or error(Cause)is not easily detected(e.g.,random audits)9Very RemoteProblem detection post processingFailure Mode detection pos
33、t-processing by operator through visual/tactile/audible means 8RemoteProblem detection at sourceFailure Mode detection in-station by operator through visual/tactile/audible means or post-processing through use of attribute gauging(go/no-go),manual torque check/clicker wrench,etc.)7Very lowProblem de
34、tection post processingFailure Mode detection post-processing by operator through use of variable gauging or in-station by operator through use of attribute gauging(go/no-go),manual torque check/clicker wrench,etc.)6LowProblem detection at sourceFailure Mode or error(Cause)detection in station by op
35、erator through use of variable gauging or by automated controls in-station that will detect discrepant part and notify operator light,buzzer,etc.).Gauging performed on set-up and first piece check(for set-up causes only)5ModerateProblem detection post processingFailure Mode detection post-processing
36、 by automated controls that will detect discrepant part and lock part to prevent further processing 4Moderately HighProblem detection at sourceFailure Mode detection in-station by automated controls that will detect discrepant part and lock part to prevent further processing 3HighError Detection and
37、/or problem PreventionError(Cause)detection in-station by automated controls that will detect error and prevent discrepant part from being made.2Very highDetection not applicable;Error PreventionError(Cause)prevention as a result of fixture design,machine design or part design.Discrepant parts can n
38、ot be made because item has been error proofed by process/product design.1Almost Certain TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.14 过程潜在失效模式及后果影响过程潜在失效
39、模式及后果影响(例例)B/P Level:001,7-NOV-02用传感器来探测轴承的型号Shad,B.#77 4 146安装新的激光台NA 73 242RECOMMENDEDACTION(S)RESPONSIBILITY&TARGETCOMPLETIONDATEACTION RESULTSACTIONSTAKENSEVOCCDETRPN失效原因的频率有多高？失效原因的频率有多高？失效模式的风失效模式的风险有多高？险有多高？会出现什么问题?它是怎样影响客户的?如果问题发生，有多大可能我们会注意到它？TRW Automotive Holdings Corp.2009 TRW Automotive
40、 Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.REVD DATE:MODEL YEAR/CARLINE:FMEA DATE:PRODUCTION PLANT:FMEA CONDUCTED BY:10 Install pilot bearingIncorrect part installedMisbuild:part does not function.7Manu
41、al:incorrect part selected7No preventionNo detection10 49020Correct sub-assyIncorrect or reversed sub-assemblyunable to install 7Machine Vision ID Incorrect3No preventionIn-line Audits6 126DETRPNPREVENTIONDETECTIONCURRENT CONTROLSSEVCLASSPOTENTIAL CAUSE(S)/MECHANISM(S)OF FAILUREOCCPROCESS NAME/NUMBE
42、RPROCESS FUNCTIONPOTENTIAL FAILURE MODEPOTENTIAL EFFECT(S)OF FAILUREB/P Level:001,7-NOV-02Sensor to detect bearing typeShad,B.3/1/0277 4 146New Laser Station.NA 73 242RESPONSIBILITY&TARGET COMPLETION DATEACTION RESULTSACTIONS TAKENSEVOCCDETRPNRECOMMENDED ACTION(S)What can go wrong?How does it affect
43、 customer?How often does this cause happen?How likely are we to notice if this happens?How high is the risk?PROCESS FAILURE MODE&EFFECTS ANALYSIS(Example)15 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyrigh
44、t 2011 TRW Automotive Inc.All Rights Reserved.16降降 低低 风风 险险 程程 序序主主 动动 式式 PROACTIVE RPN RPN 降低流程降低流程:RPN REDUCTION PROCESS:降低潜在质量失效的风险降低潜在质量失效的风险Reducing the risk of aPOTENTIAL QUALITY FAILURE 被被 动动 式式REACTIVE 对已发生的质量失效建立防错装置对已发生的质量失效建立防错装置ERROR PROOFING PAST QUALITY FAILURES TRW Automotive Holdings
45、 Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.17主动式降低风险的要求主动式降低风险的要求根据质量体系要求，根据质量体系要求，PFMEA必须必须包括所有制造过程及与相关的支持职能。包括所有制造过程及与相关的支持职能。PFMEAs shall be completed for all manufacturing p
46、rocesses and support functions as required by the Quality Management System.支持职能包括如下方面：进料检验，厂内物料运输，标识和发运，修理，返工等。支持职能包括如下方面：进料检验，厂内物料运输，标识和发运，修理，返工等。Support functions include:(receiving inspection,material handling,labeling,shipping,repair,rework,etc).PFMEA必须必须:PFMEAs shall:符合当前的符合当前的AIAG要求和顾客的要求。要求和
47、顾客的要求。conform to current AIAG guidelines and customer requirements.定期更新（动态文件）。定期更新（动态文件）。be updated on a regular basis(living documents).包括所有的生产线包括所有的生产线/零件号零件号 exist for all product lines/part numbers.包括所有的过程和过程步骤。包括所有的过程和过程步骤。include all processes and process steps.用于持续改进。用于持续改进。be utilized for Co
48、ntinual Improvement.正确的严重度正确的严重度/发生频度发生频度/可探测度打分。可探测度打分。have accurate Severity/Occurrence/Detection ratings.TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009 TRW Automotive Holdings Corp.2009Copyright 2011 TRW Automotive Inc.All Rights Reserved.18P
49、FMEA 评评 审审 必须必须建立多功能小组进行定期的建立多功能小组进行定期的PFMEA评审评审 Multi-disciplinary teams shall perform periodic PFMEA Reviews.PFMEA审核的频率或次数审核的频率或次数必须必须由供应商的领导层依据如下决定：由供应商的领导层依据如下决定：客户的期望客户的期望 (PPS,Safe Launch Audit,等）等）customer expectations (PPS，SLA,etc)过程能力过程能力(一次下线合格率一次下线合格率,SPC,等）等）process capability(FTQ,SPC,et
50、c)过程更改（采用防错方法，更换二级供应商，等）过程更改（采用防错方法，更换二级供应商，等）changes to the process(Error proofing,Tier 2 changes,etc)PFMEA审核优先级次序的标准应包括：审核优先级次序的标准应包括：Criteria to prioritize which PFMEA to review include:外购的产品，工装移动或分供方变更。外购的产品，工装移动或分供方变更。product from an acquisition,tool move or change in supplier.PFMEA 制定时没有多功能小组参
