Creating the future hope of manufacturing industry

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Build the future hope of manufacturing industry! Fmea+plm


at the time of globalization and the maturity of the collaborative cooperation model between the two sides of the Taiwan Straits, we have heard a lot about the positioning of Taiwan's manufacturing manufacturers, from the industry proposed to take greater China as the manufacturing center and Taiwan as the design center ten years ago, to the "enterprise operation headquarters" five years ago, to the "innovation center" advocated by the government at present. However, in the end, the manufacturing manufacturers in Taiwan are facing the biggest problem, that is, what is the "competitiveness"

we all know that Taiwanese manufacturers have the advantages of rapid response, cost reduction and high customer cooperation, but we all ignore the biggest problem, which is the ability to deal with crisis. When there are major problems or defects in an enterprise's products, the almost consistent solution is to return and replace the goods. We can observe that many manufacturing industries pay special attention to the organization of customer service personnel and the RMA system, and emphasize the guarantee that they can be handled within 3 days, 1 day, or even 8 hours. However, this reflects an in-depth problem. These practices are symptoms rather than root causes. The same problem is repeated and repeated, The labor and parts costs of these processes are considerable. In contrast, Japanese and European and American manufacturers' handling methods are quite different. They have adopted the "fmea+plm" approach. I believe most readers already know what PLM is, but what FMEA is

The origin and spirit of FMEA

fmea is translated into Chinese as failure mode analysis. For today's industrial environment, risk management is a very important work, and the most used product risk management technology in the world is failure mode & Effects Analysis [FMEA]. In some industries, such as automobile, aerospace, military, medical equipment and other industries, failure mode analysis and control plans (FMEAs and control plans) have long been a necessary condition in the standards that must be met; FMEA is the core tool of APQP (advanced product quality planning). FMEA is a method commonly used in design, development and preventive analysis. In the design and development stage, it can systematically predict the factors that may cause failure in the system, explain the possible causes of the factors that cause failure, evaluate the possibility of various occurrences, select the key influencing factors, formulate solutions in advance, control and track the implementation of error improvement, In order to take preventive measures against the predicted possible failures and failures, and reduce the risk and uncertainty of product use. As for the content of APQP, due to its large scope and complexity, it will not be explained in this article for the time being

compared with ISO 9001 auditing standards and specifications, the manufacturing industry used to follow another set of standards TS 16949 (QS-9000). At present, TS 16949 has become the quality system of the automotive industry commonly recognized by major automotive manufacturers all over the world The center lines of the upper and lower clamps shall meet the requirements of the coincidence system. This quality system will continue the existing QS-9000 (automotive industry quality system, which will officially expire on December 15, 2006) and VDA, avsq, eaqf and other quality systems, and become a single global automotive industry quality system certification standard in the future

the spirit of ISO 9001 is to "practice every correct and appropriate institutionalized work step". All activities and processes must achieve objectives in a controlled state, and always emphasize that management is the key. In contrast, the spirit of TS16949 is "to provide guidance for those who have recently issued the new policy of early elimination subsidy for yellow standard vehicles when deciding on unexpected conditions, and to standardize all possible conditions", covering process approach, customer orientation, cost control and lean production

types and connotation of FMEA

strictly speaking, FMEA has several classifications according to its management objectives. The common ones are SFMEA (system level), DFMEA (design level) and PFMEA (process level). They are interrelated, which can help managers to explore step by step, find out the causes of failure and improve the implementation of errors

- system FMEA (SFMEA). SFMEA refers to system failure mode and effect analysis. It is to analyze the possible potential failure modes of future products in the design, development and manufacturing stages at the early product concept formation stage

- Design FMEA (DFMEA). DFMEA refers to the Design FMEA, which includes design changes in the product development stage and analyzes possible potential failure modes of the product

- Process FMEA (P material testing machine is an indispensable and important testing instrument FMEA). PFMEA refers to Process FMEA, which analyzes possible potential failure modes of the process in the manufacturing stage

fmea implementation concept

fmea main implementation concept is the professional experience and customer complaint items accumulated in the past, which are taken into consideration for product/process design and development. Therefore, the possible adverse causes, impacts and occurrence probability can be effectively recorded as an important basis for future continuous improvement. The use of FMEA tools can effectively prevent and reduce the adverse conditions during mass production, and can be used as an experience reference for the next development of similar products

the truly effective FMEA must achieve the benefits of information integration, information automation, and language standardization through the system integration method, combined with the existing customer complaint (customer complaint) processing mechanism, engineering change process and corrective action (car) processing process of the enterprise, so that the implementation of FMEA can be more smooth and expand the substantive benefits. Finally, the comprehensive effect of customer satisfaction improvement and product development knowledge accumulation can be achieved

the necessity of FMEA combined with PLM system

in fact, FMEA documents can become the focus of customer audit instructions and one of the quality requirements documents of upstream suppliers. In particular, they are very helpful in FMEA and product development related information. In addition to quickly identifying the phenomenon and causes of problems, they can also immediately obtain past experience and countermeasures, taking into account the dual quality assurance of prior prevention and rapid handling

however, various data versions in the product development process are variable and complex. Therefore, the appropriate time for FMEA establishment recommended by the consulting team is:

1 When completing the construction of PLM system

2. Parallel planning and construction of PLM system

the main reason for consideration is that when the basic product documents (such as design drawings, engineering change documents, SOPs, etc.) have not been established and improved version management and audit, the time and complexity of manual data input will improve the threshold and difficulty of FMEA system promotion, and the target benefits cannot be presented immediately

therefore, FMEA combined with PLM system platform is an inevitable and necessary strategy! (end)

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