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1、Property of Ford Motor Company Internal Use Only The content of this document is the technical equivalent of SAE J-1739. Potential Failure Mode and Effects Analysis (FMEA) should be used by suppliers to companies subscribing to QS-9000 or equivalent document. POTENTIAL FAILURE MODE AND EFFECTS ANALY
2、SIS (FMEA) REFERENCE MANUAL First Edition Issued February, 1993 Second Edition, February, 1995 Third Edition, July, 2001 Copyright 1993, 1995, 2001 DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation Property of Ford Motor Company Internal Use Only FOREWORD 1st and 2nd Editio
3、n This reference Manual and Reporting Format was developed by the Failure Mode and Effects Analysis (FMEA) teams at Chrysler, Ford and General Motors, working under the auspices of the Automotive Division of the American Society for Quality Control (ASQC) and the Automotive Industry Action Group (AI
4、AG). The ASQC/AIAG Task Force charter is to standardize the reference manuals, procedures, reporting formats and technical nomenclature used by Chrysler, Ford, and General Motors in their respective supplier quality systems. Accordingly, this manual and format, which is approved and endorsed by Chry
5、sler, Ford and General Motors, should be used by suppliers implementing FMEA techniques into their design/ manufacturing processes. In the past, Chrysler, Ford and General Motors each had their own guidelines and formats for insuring supplier FMEA compliance. Differences between these guidelines and
6、 formats resulted in additional demands on supplier resources. To improve upon this situation, Chrysler, Ford and General Motors agreed to develop, and, through AIAG, distribute this Manual. The work group responsible for the Manual was led be George Baumgartner of Ford Motor Company. This Manual pr
7、ovides general guidelines for preparing an FMEA. It does not give specific instructions on how to arrive at each FMEA entry, a task best left to each FMEA team. This Manual also is not intended to be a comprehensive FMEA reference source or training document. While these guidelines are intended to c
8、over all situation normally occurring either in the design phase or process analysis, there will be questions that arise. These questions should be directed to your customers Supplier Quality Assurance (SQA) activity. If you are uncertain as to how to contact the appropriate SQA activity, the buyer
9、in your customers Purchasing office can help. The Task Force gratefully acknowledges: the leadership and commitment of Vice Presidents Thomas T. Stallkamp at Chrysler, Norman F. Ehlers at Ford, and J. Ignasio Lopez de Arriortua of General Motors; the assistance of the AIAG in the development, produc
10、tion, and distribution of the Procedure; the guidance of Task Force principals Russ Jacobs (Chrysler), Steve Walsh (Ford), Dan Reid (General Motors), and Rad Smith; and the assistance of the ASQC Automotive Division Reading Team. This team, led by Tripp Martin (Peterson Spring), reviewed the Manual
11、for technical content and accuracy and made valuable contributions to form and content. Since the Manual was developed to meet specific needs of the automotive industry, the ASQC voluntary standards process defined by ASQC policies and procedures was not used in its development. Additional copies ca
12、n be ordered from AIAG and/or permission to copy portions of this Procedure for use within supplier organizations should be obtained from AIAG at 248-358-3003. Property of Ford Motor Company Internal Use Only Property of Ford Motor Company Internal Use Only ? Property of Ford Motor Company Internal
13、Use Only FOREWORD 3rd Edition The FMEA 3rd Edition (QS-9000) is a reference manual to be used by suppliers to DaimlerChrysler, Ford Motor Company, and General Motors Corporation as a guide to assist them in the development of both Design and Process FMEAs. This reference manual is intended to clarif
14、y questions concerning the techni- cal development of FMEAs. This reference manual is consistent with the Supplier Quality Requirements Task Force charter to standard- ize the reference manuals, procedures, reporting formats and technical nomenclature used by suppliers to DaimlerChrysler, Ford Motor
15、 Company, and General Motors Corporation. Accordingly the FMEA, 3rd Edition Manual is written to provide guidance for the supplier. The manual does not define requirements, it does provide general guidelines intended to cover situations normally occurring when preparing FMEAs during the design phase
16、 or process analysis phase. This manual is the technical equivalent of SAE J1739, for Design and Process FMEAs. However, it does not include an application for Machinery FMEA. Interested parties in Machinery FMEA may refer to SAE J1739 for a related example. The Supplier Quality Requirements Task Fo
17、rce would like to thank the following individuals, and their companies, who have contributed their time and efforts to the development of either this edition of the FMEA manual or earlier editions. 3rd Edition Kevin A. Lange - DaimlerChrysler Steven C. Leggett - General Motors Corporation Beth Baker
18、 - AIAG Earlier Editions Howard Riley - DaimlerChryslerMark T. Wrobbel - DaimlerChrysler George R. Baumgartner - Ford Motor CompanyRebecca French - General Motors Lawrence R. McCullen - General MotorsMary Ann Raymond - Bosch Robert A. May - GoodyearWilliam Ireland - Kelsey-Hayes Tripp Martin - Peter
19、son Spring In addition, the Supplier Quality Requirements Task Force would like to thank the following individuals from the SAE J1739 work group who contributed significantly to the technical changes and improvements in this edition. William D. Carlson - DaimlerChrysler Glen R. Vallance - Ford Motor
20、 Company Carl S. Carlson - General Motors Corporation This manual is a copyright of DaimlerChrysler, Ford Motor Company and General Motors Corporation, with all rights reserved. Additional copies may be obtained from AIAG, Southfield, Michigan, by calling 248-358- 3003. Supply chain organizations of
21、 DaimlerChrysler, Ford Motor Company or General Motors Corporation have permission to copy forms used in this manual. ? Property of Ford Motor Company Internal Use Only ? Property of Ford Motor Company Internal Use Only TABLE OF CONTENTS Page Number General Information . 1 Overview . 1 What Is an FM
22、EA 1 Manual Format 1 FMEA Implementation 2 Follow Up . 4 Design FMEA 7 Introduction . 9 Customer Defined . 9 Team Effort . 9 Development of a Design FMEA . 10 1) FMEA Number 13 2) System, Subsystem, or Component Name and Number . 13 3) Design Responsibility . 13 4) Prepared By 13 5) Model Year(s)/Pr
23、ogram(s) 13 6) Key Date . 13 7) FMEA Date . 13 8) Core Team 15 9) Item/Function 15 10) Potential Failure Mode . 15 11) Potential Effect(s) of Failure . 17 12) Severity (S) . 17 Suggested DFMEA Severity Evaluation Criteria 19 13) Classification 19 14) Potential Cause(s)/Mechanism(s) of Failure 19 15)
24、 Occurrence (O) . 21 Suggested DFMEA Occurrence Evaluation Criteria 23 16) Current Design Controls . 23 17) Detection (D) 25 Suggested DFMEA Detection Evaluation Criteria . 27 18) Risk Priority Number (RPN) . 27 19) Recommended Action(s) 29 20) Responsibility for the Recommended Action(s) . 29 21) A
25、ction(s) Taken 31 22) Action Results . 31 Follow-Up Actions 31 Process FMEA 33 Introduction 35 Customer Defined . 35 Team Effort . 35 I ? Property of Ford Motor Company Internal Use Only TABLE OF CONTENTS - continued Page Number Development of a Process FMEA . 37 1) FMEA Number . 37 2) Item . 39 3)
26、Process Responsibility 39 4) Prepared By 39 5) Model Year(s)/Program(s) 39 6) Key Date 39 7) FMEA Date 39 8) Core Team 39 9) Process Function/Requirements . 39 10) Potential Failure Mode 39 11) Potential Effect(s) of Failure 41 12) Severity (S) 41 Suggested PFMEA Severity Evaluation Criteria . 43 13
27、) Classification . 45 14) Potential Cause(s)/Mechanism(s) of Failure . 45 15) Occurrence (O) . 47 Suggested PFMEA Occurrence Evaluation Criteria . 49 16) Current Process Controls 49 17) Detection (D) . 51 Suggested PFMEA Detection Evaluation Criteria 53 18) Risk Priority Number (RPN) 53 19) Recommen
28、ded Action(s) . 55 20) Responsibility for the Recommended Action(s) 57 21) Action(s) Taken . 57 22) Action Results 57 Follow-Up Actions 57 APPENDICES A Design FMEA Quality Objectives 59 B Process FMEA Quality Objectives . 60 C Design FMEA Block Diagram Example . 61 D Standard Forms for Design FMEA (
29、1 and 2 column for controls) . 62 E Design FMEA Example 64 FSystem FMEA 65 G Standard Forms for Process FMEA (1 and 2 column for controls) 68 H Process FMEA Example 70 ISuggested PFMEA Occurrence Evaluation Criteria With Ppk Values 71 Glossary 72 Il ? Property of Ford Motor Company Internal Use Only
30、 Ill ? Property of Ford Motor Company Internal Use Only ? Property of Ford Motor Company Internal Use Only 1 OverviewThis manual introduces the topic of Potential Failure Mode and Effects Analysis (FMEA) and gives general guidance in the application of the technique. What Is an FMEAAn FMEA can be de
31、scribed as a systematic group of activities intended to: (a) recognize and evaluate the potential failure of a product/process and the effects of that failure, (b) identify actions that could eliminate or reduce the chance of the potential failure occurring, and (c) document the entire process. It i
32、s complementary to the process of defining what a design or process must do to satisfy the customer. All FMEAs focus on the design, whether it be of the product, or process. Manual FormatThis reference document presents two types of FMEA: Design FMEA, and Process FMEA. This manual should be used by
33、suppliers that subscribe to QS- 9000 or its equivalent. FMEA teams are allowed to use the guidelines listed herein in the manner that will be most effective for a given situation. GENERAL INFORMATION ? Property of Ford Motor Company Internal Use Only 2 FMEA ImplementationBecause of the general indus
34、try trend to continually improve products and processes whenever possible, using the FMEA as a disciplined technique to identify and help minimize potential concern is as important as ever. Studies of vehicle campaigns have shown that fully implemented FMEA programs could have prevented many of the
35、campaigns. One of the most important factors for the successful implementation of an FMEA program is timeliness. It is meant to be a “before-the-event” action, not an “after-the-fact” exercise. To achieve the greatest value, the FMEA must be done before a product or process failure mode has been inc
36、orporated into a product or process. Up-front time spent properly completing an FMEA, when product/process changes can be most easily and inexpensively implemented, will minimize late change crises. An FMEA can reduce or eliminate the chance of implementing a preventive/corrective change that would
37、create an even larger concern.Communication and coordination should occur among all FMEA teams. Figure 1 depicts the sequence in which an FMEA should be performed.It is not simply a case of filling out the form but rather of understanding the FMEA process in order to eliminate risk and plan the appr
38、opriate controls to ensure customer satisfaction. There are three basic cases for which FMEAs are generated, each with a different scope or focus: Case 1:New designs, new technology, or new process. The scope of the FMEA is the complete design, technology, or process. Case 2:Modifications to existin
39、g design or process (assumes there is an FMEA for the existing design or process). The scope of the FMEA should focus on the modification to design or process, possible interactions due to the modification, and field history. Case 3:Use of an existing design or process in a new environment, location
40、, or application (assumes there is an FMEA for the existing design or process). The scope of the FMEA is the impact of the new environment or location on the existing design or process. Although responsibility for the preparation of the FMEA is usually assigned to an individual, FMEA input should be
41、 a team effort. A team of knowledgeable individuals should be assembled(e.g., engineers with expertise in design, analysis/ testing, manufacturing, assembly, service, recycling, quality, and reliability). The FMEA is initiated by the engineer from the responsible activity, which can be the Original
42、Equipment Manufacturer (i.e., produces the final product), a supplier, or a subcontractor. ? Property of Ford Motor Company Internal Use Only 3 Figure 1. FMEA Process Sequence Potential Failure Mode Potential Effect(s) of Failure C l a s s S e v O c c u r D e t e c R. P. N. S e v R. P. N. O c c D e
43、t Action Results Actions Taken Responsibility & Target Completion Date Current Controls Potential Cause(s)/ Mechanism(s) of Failure Subsystem Function Reqts Recommended Action(s) POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS SEQUENCE What are the Functions, Features or Requirements? What can go wrong?
44、 - No Function - Partial/Over/ Degraded Function - Intermittent Function - Unintended Function What are the Effect(s)? How bad is it? What are the Cause(s)? How good is this method at detecting it? What can be done? - Design Changes - Process Changes - Special Controls - Changes to Standards, Proced
45、ures, or Guides PreventionDetection How often does it happen? How can this be prevented and detected? ? Property of Ford Motor Company Internal Use Only 4 It is not appropriate to compare the ratings of one teams FMEA with the ratings of another teams FMEA, even if the product/ process appears to be
46、 identical, since each teams environment is unique and thus the respective individual ratings will be unique (i.e., the ratings are subjective). A review of the FMEA document against FMEA quality objectives (see Appendix A and Appendix B) is recommended, including a management review. Follow-UpThe n
47、eed for taking effective preventive/corrective actions, with appropriatefollow-uponthoseactions,cannotbe overemphasized. Actions should be communicated to all affected activities. A thoroughly thought-out and well-developed FMEA will be of limited value without positive and effective preventive/corr
48、ective actions. The responsible engineer is in charge of ensuring that all recommended actions have been implemented or adequately addressed. The FMEA is a living document and should always reflect the latest level, as well as the latest relevant actions, including those occurring after the start of
49、 production. The responsible engineer has several means of assuring that recommended actions are implemented. They include, but are not limited to the following: a. Reviewing designs, processes, and, drawings, to ensure that recommended actions have been implemented, b. Confirming the incorporation of changes to design/assembly/ manufacturing documentation, and, c. ReviewingDesign/ProcessFMEAs,specialFMEA applications, and Control Plans. ? Property of Ford Motor Company Internal Use Only 5 ? Property of Ford Motor Company Internal Use Only