德国汽车工业质量标准VDA Kapitel 4-03_en

VDA-Volume 4: System-FMEA 1 Preface The System FMEA, which is a further development of the Design and Process FMEA, is a risk analysis that accompanies the development and planning and that is integrated in the companys departments. The System FMEA is an important methodical instrument that allows potential failures to be detected and prevented at an early stage, particularly in the case of new concepts. The System FMEA supports team and project work, especially through its rigorous structuring of the system's failure potentials. The System FMEA is used to analyze and evaluate the development and planning quality during the development and planning phase. This makes it a potential “maturity monitor“ and an important management instrument that supports interdisciplinary cooperation. For all critical points in the concept, the System FMEA points out how the risk has already been reduced or will have to be reduced in the future by using experience, calculation, trials and tests, depending on the project progress. The System FMEA structured documentation can be used for tasks that occur later, for example, for diagnosis and maintenance and during the type test and certification. When there are further developments or new developments at a later time, the documentation helps the user to become familiar with the system and to prevent failures. The project process plan for quality assurance activities (process plan, Appendix 11.5) shows when the System FMEA is necessary as a total quality management (TQM) method during development and planning and when it is required by the quality management system (QM system). The System FMEA belongs to the set of methods specified in the VDA document Volume 4, Part 1, in Section 5 of the overview. VDA-Volume 4: System-FMEA 2 We would like to thank all the companies and their staff who have contri- buted to this workgroup: BMW AG, Munich Robert Bosch GmbH, Stuttgart Fichtel it examines the develop- ment or planning status valid at that time in terms of potential errors, in order to initiate preventative actions for avoiding such errors. VDA-Volume 4: System-FMEA 8 The System FMEA is a team-oriented method for risk minimization in the development and planning processes. It promotes interdisciplinary coope- ration among the areas involved at an early stage. Furthermore, it provides documentation of a company's expert knowledge. 1.3 Further Development of the FMEA Method Different disadvantages came to light when the FMEA was used in the past: In the Design FMEA, failures were examined at the component level. The functional correlation of all components with one another was not examined systematically. In the Process FMEA, potential failures were examined in separate process steps. There was no systematically structured analysis of the complete manufacturing process, including the design of tools and machines, where needed. The FMEA was drawn up using the FMEA form, which did not permit a structured description of the correlations among functions and potential failures in systems. This necessitated further development of the method, in the direction of the Product System FMEA and Process System FMEA. Failure Modes and Effects Analysis Page of Type/model/Production/lot: Part number: Change status: Responsibility: Firm: Dept.: Date: Part number: Change status: Responsibility: Firm: Dept.: Date: Component/ characteristic Potential failure Potential failure effects Potential failure causes V/P O S D RPN Improved condition R/D O S D RPN Creating an FMEA in the VDA ´86 form System instieg in die System-FMEA die Struktur des zu betrachtenden ystems einschl. neuem Formblatt VDA ´96 eiterentwicklung E über S W Advance Entry into the system FMEA via the structure of the system to be considered, incl. the new form VDA 96 FMEA no.: Failure Modes and Effects Analysis Product System FMEA Process System FMEA Page of Type/model/Production/lot: Part number: Change status: Responsible: Firm: Dept.: Date: System no./system element: Function/task: Part number: Change status: Responsible: Firm: Dept.: Date: Potential failure effects S Potential failure Potential failure causes Preventative actions O Detection actions D RPN R/D Figure 1.1 Further development of the FMEA method VDA-Volume 4: System-FMEA 9 VDA-Volume 4: System-FMEA 10 2 Fundamentals of the System FMEAs for Products and Pro- cesses The following chapter describes the fundamental procedure for the System FMEA. 2.1 Definition of the System FMEA In addition to the previous Design or Process FMEA, the following steps are necessary for drawing up the System FMEAs for products and processes: Structuring of the system that is to be examined into system elements and demonstration of functional correlations among these elements. Derivation of conceivable malfunctions (potential failures) for a system element from its previously described functions. This is followed by the logical connection of the related malfunc