The Application ofpfmeain Manufacturing of Automobile Part Abstract Due to the purpose of reliability promotion and to reduce redesign cost, enterpris

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1 FMEA PFMEAProcess Failure Mode and Effects Analysis FMEAFMEAFMEA FMEAFMEA FMEA FMEA FMEA FMEA Risk Priority Number, RPNFMEA

2 The Application ofpfmeain Manufacturing of Automobile Part Abstract Due to the purpose of reliability promotion and to reduce redesign cost, enterprises use the methodology of failure mode and effects analysis (FMEA) to develop new product. However, there lays sequential considerations need to be taken into account, such as procedure arrangement for mass production, precautious recovery for product damage and equipment break down, and a critical first aid management for operators to reduce harm in process. The FMEA of process has ensured the reliability of product in process. This research is used FMEA to study the key assembling process of auto engine oil pump before in mass production. In order to find the critical points and sequence of process improvement, FMEA team under member meeting to find risk priority number in risk evaluation adopts a brainstorming. In this meeting, the FMEA team selects the bigger risk priority numbers as the key process or proposes the critical points for quality control. After adopted the above improvement, which under the continuous improvement of Deming PDCA (planning, doing, checking, and action), it is available to revalue the RPN of engine oil pump assembling process. In addition to revaluate the index of RPN to confirm upon improved result as for dealing with modifying strategy feasibility in the secondary item of RPN. Product manufactured by the most appropriate process may be achieved to the maximum satisfaction of customer requirement. Key WordsFailure Mode and Effects Analysis, Risk Priority Number. Tsan-Ming Chang Lecturer of Department of Industrial Management, HIT Ying-Wei WuAssociate Professor, Depratment of Industrial Management, HIT Tseng-Fung HoPhD. candidate of Depaetment of Industrial Management, National Chiao Tung Jui-Kun ChiangLecturer of Depaetment of Industrial Management, HIT

3 1. Failure Mode and Effects AnalysisFMEA FMEA FMEAFMEA FMEA FMEA FMEA FMEA FMEA 1 FMEA 2 FMEA 313 GMFord Chrysler AIAG Potential Failure Mode and Effects Analysis Reference Manual 4 QS 000 FMEA Oil Pump FMEA FMEA Risk

4 Priority Number, RPN RPN SPC x-r FMEA FMEA FMEA FMEA150 Grumman Co. FMEA 160 NASA 163NPC250-1 FMEA 5 174FMEA MIL-STD-162FMECA Failure Mode Effects and Criticality Analysis180 MIL-STD-162A6 2.2 FMEA 177 FMEA 7 (International Electronical CommissionIEC185 MIL-STD-162A FMEA 8 13

5 QS000FMEA 7 FMEA QS000 CE15 FMEA FMEA 10ISO FMEA FMEA FMEAFMEA FMEA 12 FMEA FMEA FMEA 1FMEA 2 FMEA3 FMEA4FMEA13 FMEA FMEA 6 CPK=2FMEA

6 QCC FMEA FMEA FMEA 2.4 FMEA (RPN) (Risk Priority Number RPN) 7 (RPN) (Risk Assessment) RPN= SOD S O D (Criticality Score Evaluate) 14 1 C s C s i C C... C 1 Ci C E F 1 F 2 F 3 F 4 F 5 F 1 F 2 i

7 F 3 F 4 F (Level of Risk) DINV S-A-G-W ( 2.1) Harnly, J.A., Risk Base Prioritization of Maintenance Repair Work, Process Safety Progress, Vo1.17, No.1, pp.32-38, S A G S1 S2 S3 S4 A1 A2 G1 G2 W W1 W2 W3 Harnly, J.A., Risk Base Prioritization of Maintenance Repair Work, Process Safety Progress, Vo1.17, No.1, pp.32-38, FMEA Oil Pump FMEA RPN QS 000 FMEA FMEA 3.1FMEA FMEA TQM

8 FMEA IE FMEA FMEA FMEA 3.2 FMEA FMEA FMEA 3.1~3.7

9 SOD RPN 1 (3.1) 1 "." "."NG 2 1 a.b.c. d.e. 1 1 "a."

10 1 () 3.1 ( ( S O ) ) a. b. c. d. e. f. g. 5 4 ( ) ( NG) D RPN ( ) S O D PRN 2 72

11 2 3.2 ( ) a. b. c. ( ) S O ( ) 2. OK,NG ( ) ( ) D RPN S O D PRN ( S ( O ) ) a. b. c D RPN S O D PRN

12 4 3.4 ( ) a. b. c. d. ( ) S O D RPN 5 0 () 5 0 OK NG 5 0 ( ) S O D PRN ( ) a. b. 3.5 ( ) S O 5 3 D RPN S O D PRN

13 6 ( ) a. 3.6 ( S O ) b. 2 ( ) D RPN S O D PRN ( S O ) ( ) a b c. 5 2 ( /3 ) S O D PRN D RPN

14 3.4 RPN RPN FMEA SO D FMEA ~2 12 ~10 1~4 7~12~ 12~10 10FMEA O D 3.5 RPN FMEA SO D FMEA SOD S O DSOD RPN RPN (3.7) RPN ab cb

15 (S)~104 FMEA3.8 "" (O) 3. "5" (D) 3.10 "1" (D) "2"RPN*5*1 = 45 *5*2 = 0 RPN=0RPN= RPN (S) (O) (D)S*O*D RPNRPN 3.8 (S) ( ) 1 1~2 2() 3() 3~4 4() 5~ ~8 8, ~10 10() 11,. 12,

16 3. O 1~2 1 3~4 2 5~6 3 7~8 4 ~ (D) 1. 1~2 a b 2. 3~4 a, b 5~6 3(...) 7~8 4 5 ~10 a. 3.6 FMEA FMEA PDCA FMEA RPN 3.7 QS 000 FMEA 4.

17 1 FMEA 2 FMEA 3 FMEA FMEA FMEA 4 FMEA SOPPDCA RPN 5 FMEA FMEA FMEA FMEA 6 FMEA FMEAFMEA FMEAFMEAFMEA FMEA FMEA

18 1 FMECA pp Ireson, W. G. and Coombs, C. F., Handbook of Reliability Engineering and Management, McGraw-Hill Inc., Deshpande, V. S. and Modak, J. P., Failure Mode and Effect Analysis," Proceedings Annual Reliability and Maintainability Symposium, pp.70-74, MIL-STD-162A, Military Standard Procedure for Performing a Failure Mode, Effects and Criticality Analysis, Department of Defense, Washington, DC, Ford Motor Company, Potential Failure Mode and Effects Analysis, Instruction Manual, Ford Motor Company, IEC 812, Analysis Techniques for System Reliability-Procedure for Failure Mode and Effects Analysis (FMEA), Geneva, Switzerland, 185. "Application of RCM to a Medium Scale Industry," Reliability Engineering & System Safety, Vol.77, No.1, pp.31-43, Chrysler, Ford Motor and GM., Mattson, F., "An Introduction to Risk Analysis for Medical Devices", Compliance Engineering, 11/12, pp.47-57, 15. Potential Failure Mode and Effects 10 Benjamin, D. M., "Reducing Analysis (FMEA), Automotive Industry Action Group, Crown, P.L., "Design Effective Medication Errors and Increasing Patient Safety: Case Studies in Clinical Pharmacology," Journal of

19 Clinical Pharmacology, vol. 43, no. 7, pp (16), Vandenbrande, Willy W., "How to Use FMEA to Reduce the Size of Your Quality Toolbox," Quality Progress, Vol.31, No.11, pp.7-100, FMEA pp FMEA FMEA FMEAFTA Harnly, J. A., "Risk Base Prioritization of Maintenance Repair Work," Process Safety Progress, Vo1.17, No.1, pp.32-38, 18.

892213E006146

892213E006146 Modular Design of Quality Control Systems NSC89-2213-E006-146 89 8 1 90 7 31 ( ) ISO14000, and OHSAS18000. Keywords: ISO9000; ISO14000; OHSAS18000; Quality ISO9000 ISO14000 OHSAS18000 Management; Environment