流程图,失效模式分析,控制计划

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1、 Process Planning,Analysis&ControlPFDPFMEAPCPCTIS#305132PFD-PFMEA-PCP Training-AgendauuAgenda(8am-5pm)Agenda(8am-5pm)Day 1Welcome and Introductions15 minWhy We are Here(including pre-test)30 minPFDClass Lecture(including break)60 min1st Class PFD Activity(including break)45 minuPFD getting the detai

2、lsClass Lecture 10 minPFMEAClass Lecture(including lunch break)90 min1st Class PFMEA Activity(including break)30 minuPFMEA-FunctionsFailure ModesEffectsClass Lecture 60 min2nd Class PFMEA Activity (including break)45 minuPFMEA-CausesControls3uuAgenda(8am-5pm)Agenda(8am-5pm)Day 2PFMEA(cont.)Class Lec

3、ture(including re-cap of Act#2)60 min3rd Class PFMEA Activity(including break)45 minuPFMEA Risk AssessmentAction Plans Timing ResponsibilityClass Lecture15 minProcess Control Plan(PCP)Class Lecture(including break)60 min1st Class PCP Activity(including break)60 minuPCP defining the actionsClass Lect

4、ure and Summary 10 minProcess Documents(Std Cell&EOP)Class Lecture15 min 1st Class STD Cell Docs Activity(including break)40 minWrap-up(including post-test&eval)40 minNext Steps for“On-Site”Workshop15 minPFD-PFMEA-PCP Training-Agenda4uuEstablish“The Day”for Follow-up Plant Focused Establish“The Day”

5、for Follow-up Plant Focused WorkshopWorkshopEstablish date for workshop(preferably day after the training session)Determine area of focus for the workshopMultiple processes&groups may be selectedCollect process documentation for the focus areaIf Plant Focused Workshop is the day following the 2-day

6、training,this step needs to be completed before the workshop beginsuuPlant Focused Workshop AgendaPlant Focused Workshop AgendaWhy We are HerePFD,PFMEA,PCP,Process Monitoring,Work Instructions,etc.How good is the planning&execution(in the documents&results)PFD-PFMEA-PCP TrainingPlant Focused Worksho

7、p5uuPlant Focused Workshop Agenda(Contd)Plant Focused Workshop Agenda(Contd)PFDWalk the process and observe actual vs.documented process steps and flow.Look for hidden factory processes that may not be documentedPFMEAHave all potential Failure Modes been identified?Are ratings appropriate?PCPAre all

8、 controls identified in the PFMEA included on the PCP?Are reaction plans adequately defined?Wrap Up&Next StepsCompare PFD and PFMEA and PCP to ensure appropriate linkageDevelop a plan for updating the documents based on review findingsPFD-PFMEA-PCP TrainingPlant Focused Workshop6The Delphi Absolutes

9、 of ExcellenceFocus:Your customerPerformance Goal:Do It Right The First Time,Every TimeMethod:Innovation and Continuous ImprovementTHE DELPHIABSOLUTES of EXCELLENCEControl:Customer FeedbackPeople:CaringStyle:TeamworkReward:Recognition and Security7ObjectivesThis Training will allow you to:know the c

10、orrect use of Process Flow Diagrams(PFD)in process planningunderstand the need for including“hidden factories”and material handling in PFDsknow the definition&purpose of Process Failure Mode and Effects Analysis(PFMEA)be able to perform all steps in the PFMEA processuse the PFMEA as a tool in Proces

11、s Developmentknow how to take information from PFD&PFMEA in the creation of Process Control Plans(PCP)know the relationships between PFD,PFMEA,&PCPbe able to follow through to Process Documents(Std Cell,EOP,Monitoring forms,etc.)Introduction8Quality SystemsStandards and GuidelinesWork InstructionsOt

12、her DocumentationINDIVIDUAL SUPPLIERSQuality ManualProceduresINTERNATIONAL STANDARDS ISO 9000Customer RequirementsQS-9000 or ISO/TS16949 Production Parts Approval ProcessCompany Specific RequirementsCustomer Reference ManualsAPQP&Control Plan FMEA MSA SPCReference:PFDs,FMEAs,PCPs 9PPAP Required Docu

13、mentation Standards and Guidelines 1.Design Records of Saleable Product 2.Engineering change documents(if any)3.Customer Engineering Approval(if required)4.Design FMEA 5.Process Flow Diagrams 6.Process FMEA 7.Dimensional Results 8.Material,Performance Test Results 9.Initial Process Study10.Measureme

14、nt System Analysis Studies11.Qualified Laboratory Documentation12.Process Control Plan13.Part Submission Warrant(PSW)14.Appearance Approval Report(AAR)(if applicable)15.Bulk Material Requirements Checklist(for bulk material PPAP only)16.Sample Product17.Master Sample18.Checking Aids19.Records of Com

15、pliance with Customer-Specific Requirements10Delphi Common Procedure RequirementsDelphi Business SystemStandards and GuidelinesRegion,Unit/Location and Staff Procedures and Work InstructionsDivisional ProceduresDelphi Common Procedure RequirementsCorporate,Divisional/Staff and Regional Policy Supple

16、mentsDelphi Business System Manual(together with customer-specific requirements)Address PFD,FMEA&PCP within the Division/Location11Product CharacteristicsReference DP 272&KCDS Reference ManualStandards and GuidelinesSpecialCareAdditional CareDefined CareStandard Care(usual and customary care)Safety/

17、ComplianceS/C KPCFit/FunctionF/F KPCVariation Reduction not Required ifCapable,Mean Centeringmay be RequiredMean Centering andVariation ReductionRequiredQuality/CustomerInterface QCIStandard ProductCharacteristicsNo designation or symbolSpecial or KeyProductCharacteristicsImportantProductCharacteris

18、tics12Execution of PFMEAs*Failure mode not identified in PFMEA 52%48%GM NAO summary(all suppliers)Execution of PFMEAs*Failure mode not identified in PFMEA66%34%We are going to be focusing on what we can address NOW execution of PFMEAs,including:SpillsEmerging Issues*Predict Phase(Process Planning)of

19、 Drill Deep&WideuPFMEA not updateduNot identified in APQP planuPFMEA team lacks traininguLow(incorrect)RPN value in PFMEA planuPFMEA plan not updated&revieweduPFMEA planning bypassedWhat Our Largest Customer is Telling Us13lFailure Modes,Effects,and Causes must be more specificTypical failure modes

20、and controls for specific process technologies must be documented and used as PFMEA input lA common format for all PFMEAs must be utilizedFormatting and AIAG guideline interpretation differences resulted in a“red”status.lPrimary focus on detection versus prevention Products and Processes must better

21、 facilitate preventing versus detecting failureslRisk reduction must be an on-going activityLarge number of line items with the detection ranking too low.lPast problems that impacted customer not comprehendedlMaterial Certifications must appear as control in the receiving dock PFMEAEffects of the fa

22、ilure not focused on the customer(including severity)lIn-depth PFD-PFMEA-PCP training for all functions(ME,PE,PC&L,Quality)is requiredGM Review PFMEAsLessons Learned14lInvest effort Early(Have an Impact)lDrive to Detail(Define correct Controls)lConsistent/Common Usage of Rankings(Set Priorities)Need

23、 to Focus on High Value Aspectsof PFD-PFMEA-PCP$Approach15ApproachThe mindset required to when creating PFD,PFMEA,Control Plan,and Operator Instructions is to be able to answer the questionHow do you know every part shipped to our customer meets all requirements?16 Process DocumentationPFDPFMEAEquip

24、ment Operating ProcedureStandard CellControl PlanProcess Monitor FormsData RecordingHow To InstructionsInformation flows from the PFD to the PFMEA to the Control Plan.These documents define what the process is,the analysis of the process,and the control of the process.Process Flow Diagram(PFD)Energy

25、&Chassis SystemsPFD Training18Product Definition:Characteristics:KPCs,QCIs,DFMEAProcess Definition:Process Flow Diagram(PFD),Failure Mode Analysis:PFMEA,Line side Review ProcessControl Strategy:Control Plan,Error proofingCustomer Requirements:Characteristic Verification Matrix(CVM)Manufacturing:Proc

26、ess Monitoring,Standard Cell,Layered AuditInformation FlowSOR,Vehicle Tech Specs,System Technical SpecsKCCs,QCCs19Some TheorylInputs and OutputsAll processes have inputs and outputsInputs control outputsINPUTSOUTPUTSPROCESSFACT:If you dont control the inputs,you cant control the outputs.20What is a

27、PFD?lDefinition:A Process Flow Diagram is a flow chart linking individual process steps to form a manufacturing system.lScope:Identify every possible path a part can take through the anticipated manufacturing process DP268 Encompasses the“Hidden Factory”Quality AuditsRework ProcessesAlternative Proc

28、essesScrap Tool ChangesPart BuffersChangeoversPart Ident./LabelingTeardownGauging StationsReject HandlingPart movement21Backgroundl“Hidden Factory”issues continually affect Delphis quality performance and remains essentially undocumentedRework parts bypass process controlsMixed parts at changeoversQ

29、uality audit and scrap parts finding their way back into the processlNeed for common systemsPart of the overall Delphi Business StrategyInclusion into the Delphi Engineering Systemcommon content,common format,common approachExtend the approach to our suppliersconsidered an extension of the Delphi pr

30、ocesses22Process Flow DiagramlProcess Flow Diagram is the foundationThe process must be defined step by stepThe inputs and outputs are also definedThe PFD provides the structure to start thinking about what product characteristics(OUTPUTS)are affected by a given operation and how these characteristi

31、cs are controlled(INPUTS)If a process step is missing from the PFD,there is no reason to believe it will get evaluated for risk or adequate process control The PFD is the trigger for PFMEA and control method discussions.23Why a PFD?lA comprehensive and detailed PFD is the starting point for document

32、ing the manufacturing process.Graphical representation of the manufacturing processEssential foundation for a PFMEA-“Roadmap”Springboard for process documentation-PFMEA,PCP,Operator Instructions,etc.lHelps in developing equipment specifications.How should the process control non-conforming material?

33、How will inspections be performed,what is required?How will parts be re-introduced into the process?24Why a PFD?How does an enhanced PFD help develop the PFMEA?Organized to help see the entire processchangeover,fab,inspect,rework,scrap,move,store,auditIdentifies Significant Product and Process Chara

34、cteristicsProduct Characteristics=Outputs=Potential Failure ModesalsoProcess Requirements=Outputs=Potential Failure ModesProcess Characteristics=Inputs=Potential CausesNote:Significant Product and/or Process Characteristics may(or may not)be KPCs/KCCs8 025Dock to Dock PFD/PFMEAlA“Dock to Dock”PFD/PF

35、MEA is a collection of PFD/PFMEAs for the material movement processes and manufacturing processes associated with a particular part or part family.lThe Material Movement Processes include:Receiving dock activitiesMovement of material to/from Mfg.ProcessMovement between Mfg.ProcessesShipping dock act

36、ivitiesMaterial StoragelPFD/PFMEA s must be developed for each Material Movement process as well as each Mfg.ProcesslMaterial movement processes PFD/PFMEAs are linked to the Mfg Processes via an index sheet26Preliminary PFDlA preliminary PFD is typically a simple block diagram that shows the main op

37、erations.Generated during Manufacturing Systems Design workshops27PFD Excel WorksheetlInstructions and reference information can be found by viewing the commented cells(those with the small red triangle in the corner).lThe Excel workbook also contains a Help worksheet for instructions on drawing sym

38、bols,connectors,etc.8 028Operation-Sequence#l“Operation”Op-seqmajor process steps(by tens):10-,20-,30-,40-.established by a preliminary PFD(process block diagram)l“Sequence”op-Seqindividual detailed steps within a given operation.Sequenced by one:#-5,#-10,#-15,.lNote:The PFD establishes the Op-Seq n

39、umbers and they must match the PFMEA,Control Plan,and other process documentation.lOperation Description:describe what is happening to the part.not a machines sequence of operation or an operators standardized work.29PathslDashed paths show the“Hidden Factory”rework,scrapauditserrorproofing verifica

40、tion part flowalternative(backup)processeslRed paths:Reject part flowRework part flowlPaths between symbols are drawn using Excel AutoShape Connectors-not lines30Fabl“Fab”value-added activities that change the state of the partmachining,chemical,assembly,welding,paint,etc.labeling,part identificatio

41、n,etc.lSignificant CharacteristicsWhat product characteristic(s)are a result(output)of the fab step?Are they KPCs or QCIs?What process characteristic(s)create and/or control the associated product characteristic?Are they KCCs or QCCs?QCC-1QCCQCC-3QCC-231PFMEA Link(Fab)Process Characteristics(Inputs)

42、translate intoPotential Causes Product Characteristics(Outputs)translate intoPotential Failure Modes 8 2QCIQCIQCI32Store/Get and Movel“Move”parts are moved within the process parts in a storage device are relocated(dock to supermarket)l“Get”starting point-parts are introduced to the process from a s

43、torage or presentation devicel“Store”ending point-parts are returned to a storage device parts are located in a buffer33InspectionslRed,Yellow,Green shading can be used to show test results and their respective pathslNotice the flow of Master parts into and out of automatic inspectionsShow where par

44、ts go if they are removed from a nest to perform the errorproofing verification.lLetter inside the box indicates type of inspectionV=operator visualM=operator manual gagingQ=quality auditA=automatic34Reworkl“Rework”replace,repair,reload,tear-down,retest,etc.rework can take place online or offlinecon

45、sidered part of the processlReminders:take into account the moves to offline operationsshow inspections that take place during rework show re-entry point to the main process flow35Scrap/Containl“Scrap”rejected material is permanently removed from the process and contained in a designated scrap conta

46、inerlNotes:consider parts in/on a rack,chute,conveyor,bench,nest still alive.include moves required to get the part to the reject container(i.e.operator walk)l“Contain”suspect material is removed from the process and contained until it is classified as scrap or rework.Scrap/Contain points on the PFD

47、 should correspond to FTQ data collection points8 036PFMEA Link(Scrap)How do you know the defective part made it to the scrap container?was ok)37ChangeoverlFlag each step that requires a“Changeover”P=ProductT=Tool ChangeS=SoftwareD=DunnageL=LabelslImproper changeovers translate to the PFMEA causeslC

48、aution:consider processes(adjacent cells)that may have similar components,tooling,or dunnage thereby providing an opportunity for error(mixed parts).38PFMEA Links(Changeover)Incorrect Changeoveris a Potential Cause 7 8439The PFD is not the end,but a very important step toward having a robust control

49、 plan in manufacturingProduct Definition:Characteristics:KPCs,QCIs,DFMEAProcess Definition:Process Flow Diagram(PFD),Failure Mode Analysis:PFMEA,Line side Review ProcessControl Strategy:Control Plan,Error proofingCustomer Requirements:Characteristic Verification Matrix(CVM)Manufacturing:Process Moni

50、toring,Standard Cell,Layered AuditSOR,Vehicle Tech Specs,System Technical SpecsKCCs,QCCsInformation Flow40Zero PPM,Customer Complaints,Disruptions:Its in the Details!Summarizing41A bicycle product and manufacturing process will be used as an example to illustrate the Process FMEA methodRequirements

51、will be described,and the current process will be illustratedA proposed change to the design/process will be presented and used for the example in the PFD,FMEA and PCP.Process Example PFD Example42lAssume an imaginary Delphi Bicycle DivisionProduct is a mens bicycleCustomer is also the userlRequirem

52、ents are defined by customers and government regulationslProduct Engineering is responsible for design and validation of all product requirementslManufacturing Engineering is responsible for process development and validationlManufacturing is responsible for product conformance to all design specifi

53、cationsThe Delphi Bicycle DivisionPFD Example43lGeneral organization of Delphi Bicycle OperationsHandle Bar assemblyFront Wheel assemblyRear Wheel assemblySprocket assemblySeat assemblyChain assemblyClean and prepare for paintingPaint Cure OvenProcess LevelsFrame assemblyMove to Final AssemblyManual

54、ly load tubes into assembly fixtureInitiate weld sequenceRemove frame assemblyMove to Cleanand PaintBicycle AssemblyFrameSubassemblyFrame Welding Frame WeldingPaint and TrimPFD Example44Delphi Bicycle OperationslA wide number of bicycle types are produced in the manufacturing operationslThe specific

55、 product considered for the example is a trail bikelDue to the high investment costs in robotic welders,a variety of models are produced in each welding cellThis necessitates different setups,changeovers and parts management schemesOperations has tried to optimize flow and minimize WIP Many cells ar

56、e at or near one-piece flow45PFD ExampleMens Road and Trail bicyclelObjectives for MY 2006Modify design to accommodate 95th percentile Provide for increase in rider leg lengthMaintain safety and durability with 225 pound riderPerform reliably during off-road trail ridinglProcess Planning ApproachIde

57、ntify changes to product requirementsDetermine process steps affected by changesPerform PFMEA to identify and prevent problemsUse PFMEA to develop process Control PlanProcess Objectives and Approach46Process ControlslOur example will include analysis of the existing weld operationMore stringent prod

58、uct specifications will require improvement of the process capabilityDifferent Models will be run in this same operation requiring tooling and part changeoverlThe PFD will be used to identify potential problems related to missing informationlThe objective will be to improve the current process and d

59、eliver zero defectsPFD Example47lCritical Bicycle Process Requirements Frame welds must fail in the parent material when pull tested.Welds must be visually confirmed to be distributed/located equally on parts welded.Process Parameters/RequirementsWeld voltage¤tWeld wire feed rateInert gas flow

60、 rateand gas compositionWeld electrode angleTorch cleanlinessElectrode holder towork distanceGood ground connectionsto weld fixtureProcess ControlsPFD ExampleWeld2 Seatstay WeldsWeldWeldWeldWeld2 Chainstay WeldsSeatstay Tubes(2)Chainstay Tubes(2)Seat TubeUpper TubeLower TubeFork TubeSprocket Hub48lT

61、eams use the Process Flow Diagram to identify all elements of the process plus inputs and outputslPFDs are tools that identify all process steps and help set the PFMEA scopeStep 1 Process Flow Diagram80Process Flow diagrams help ensure all steps and functions are considered in the FMEA and PCPTube E

62、xtrusionOp.120Injection MoldingOp.110Final AssemblyOp.300Stamping/FormingOp.140Clean and PaintOp.220Incoming MaterialSubassemblyOp.200Assemble Seat TopOp.250Frame Tubes and Handlebar TubeBrake and Shift CablesOp.370Rear Wheel&Gear Asm.to Frame Op.320Seat Asm.to FrameOp.330Sprocket Asm.to FrameOp.340

63、Handlebar to FrameOp.360Pedal Crank to SprocketOp.350Inspect and PackOp.380Front Wheel to FrameOp.310Attach Seat Post to TopOp.260Paint Cure OvenOp.230Frame Tube ButtingOp.130Rims/HandlebarSeat Top and Handlebar Grips PlatingOp.150FabricationOp.100Frame WeldingOp.210Assemble Seat FrameOp.240PFD Exam

64、ple49lProcess Flow Diagram for Bicycle ManufacturingPFD for the Delphi BicycleProcess Flow DiagramSeat Top and Handlebar Grips Frame WeldingOp.210FabricationDept.100Tube ExtrusionOp.120Rims/HandlebarInjection MoldingOp.110Final AssemblyDept.300Stamping/FormingOp.140PlatingOp.150Clean and PaintOp.220

65、Assemble Seat FrameOp.240Incoming MaterialSubassemblyDept.200Assemble Seat TopOp.250Frame Tubes and Handlebar TubeBrake and Shift CablesOp.370Rear Wheel&Gear Asm.to Frame Op.320Seat Asm.to FrameOp.330Sprocket Asm.to FrameOp.340Handlebar to FrameOp.360Pedal Crank to SprocketOp.350Inspect and PackOp.3

66、80Front Wheel to FrameOp.310Attach Seat Post to TopOp.260Paint Cure OvenOp.230Frame Tube ButtingOp.13050Seat Top and Handlebar Grips Frame WeldingOp.210FabricationDept.100Tube ExtrusionOp.120Rims/HandlebarInjection MoldingOp.110Final AssemblyDept.300Stamping/FormingOp.140PlatingOp.150Clean and PaintOp.220Assemble Seat FrameOp.240Incoming MaterialSubassemblyDept.200Assemble Seat TopOp.250Frame Tubes and Handlebar TubeBrake and Shift CablesOp.370Rear Wheel&Gear Asm.to Frame Op.320Seat Asm.to Frame