RPN风险评估及降低课件.ppt
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- RPN 风险 评估 降低 课件
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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
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