FMEA-based agile analysis method

Abstract

The invention discloses an FMEA-based agile analysis method. The FMEA-based agile analysis method comprises the following steps: firstly, carrying out demand analysis; then incremental delivery: sequentially carrying out quantitative B graph, visual P graph, agility B graph, agility output and rapid iteration on the quantitative B graph, the visual P graph, the agility B graph and the agility B graph; and finally carrying out result closed loop. According to the FMEA-based agile analysis method, the FMEA compilation efficiency is improved through light weight, the single-time FMEA analysis time is shortened, and high-priority FMEA is output preferentially and delivered to the next link; visualization and improvement of FMEA compilation effect: a graphical mode is adopted, a B graph and a P graph are used for display, and data are associated through'connection watching ', so that on one hand, brainstorm is facilitated, and on the other hand, omission is avoided, actual combat is realized, and the reliability of system function design is improved: in combination with Lesson Learned, actual combat experience is integrated, reference is performed in new product design, prevention is performed in advance, and the reliability of design is improved; the FMEA analysis report document is continuously perfected, and the Master FMEA, the Master B graph, the Master P graph, the interference factor database and the like are iterated.

Description

Technical Field

[0001] The present invention relates to the technical field of failure analysis and risk assessment, and in particular to an agile analysis method based on FMEA. Background Art

[0002] FMEA (Failure Mode Effects Analysis) is a simple and efficient quality problem analysis method, in which the meaning of failure is not limited to "failure", but includes various quality problems. Since the scope of application of the FMEA method includes the analysis of various quality problems that occur in process design and product production processes, it can assist enterprises and engineers in making predictions and making corresponding countermeasures.

[0003] The existing FMEA analysis mainly relies on the AIAG-4 or AIAG-VDA FMEA manual standards, which are process-oriented and use a seven-step method to identify product and process risks. According to the size of the risk, targeted improvements are taken and error-proofing plans are implemented to achieve the expected prevention in advance. The FMEA manual requires that it must be carried out in accordance with the seven-step method: Step 1: Planning and preparation, creating a project and assembling a team, defining scope boundaries, determining the product to be analyzed, and achieving team collaboration; Step 2: Structural analysis, conducting an analysis through the product structure tree, and identifying the product interface / process flow relationship; Step 3: Functional analysis, identifying the functions of the system / component / process / element, and establishing the relationship between functions, that is, the functional network; Step 4: Failure analysis, defining the failure mode of the function, adding the cause of failure and the consequence of failure, establishing the failure association between the upper and lower levels, and forming a failure network; Step 5: Risk analysis, further distinguishing between preventive measures and detection measures, and calculating AP priority based on S, O, and D; Step 6: Optimization, determining the measures, responsibilities, deadlines, and risk reassessment after the measures to reduce risks; Step 7: Documenting the results, outputting the FMEA document, and communicating the risks to management, customers, and suppliers.

[0004] The above steps often take a lot of time to complete the preparation of FMEA, which cannot adapt to the fast-paced product iteration needs; at the same time, FMEA is highly professional, requiring not only understanding of the analysis logic of the FMEA manual and mastering basic analysis methods, but also rich practical experience in products / processes / flows. The traditional FMEA operation relies on the personal experience of engineers. On the one hand, companies lack experienced engineers, and on the other hand, experience will be lost with the flow of engineers; Therefore, the present invention provides an agile analysis method based on FMEA to solve the problems of low efficiency and poor effect. Summary of the invention

[0005] 1. Technical issues to be resolved In view of the deficiencies in the prior art, the present invention provides an agile analysis method based on FMEA, which has the advantages of being lightweight and improving the efficiency of FMEA compilation; being visualized and improving the effect of FMEA compilation; being practical and improving the reliability of system function design, thus solving the problems of low efficiency and poor effect.

[0006] (II) Technical solution In order to achieve the above-mentioned purpose of lightweighting, improving FMEA compilation efficiency; visualization, improving FMEA compilation effect; practicalization, improving the reliability of system function design, the present invention provides the following technical solutions: an agile analysis method based on FMEA, comprising the following steps: Step 1: Demand Analysis Identify high-risk areas and conduct gap analysis. The core is to find out the differences between the current project / product and similar products, so as to give priority to key analysis in the subsequent process; Step 2: Incremental delivery They are quantitative B-chart, visual P-chart, agile B-chart, agile output, and rapid iteration. Step 3: Result Closing Loop Continuously improve the FMEA analysis report documents, and iterate the Master FMEA, Master B diagram, Master P diagram, and interference factor database.

[0007] Preferably, the high-risk scope in step 1 includes new technologies, new applications, new solutions and new environments.

[0008] Preferably, the quantitative B diagram in step 2 is for the high-risk range identified in the previous step, that is, the differences, to carry out boundary analysis of the product and quantify the internal / external interfaces; lightweight, improve the efficiency of FMEA preparation: shorten the single FMEA analysis time, give priority to outputting high-priority FMEA and deliver it to the next link; visualization, improve the FMEA preparation effect.

[0009] Preferably, the visualized P-chart in step 2 is used to identify highly sensitive interference factors, and helps engineers to conduct visual brainstorming by associating historical failures and intelligent reminders of the interference factor database to associate high-frequency and high-impact interference factors with products / interfaces.

[0010] Preferably, the agile B chart in step 2 is based on the highly sensitive interference factors identified in the visualized P chart, combined with functional / safety regulations, to further carry out brainstorming and identify high-priority failures; visualization improves the FMEA preparation effect: a graphical method is used, with B chart and P chart displayed, and the data is associated through "connect the dots", which facilitates brainstorming on the one hand and avoids omissions on the other.

[0011] Preferably, the agile output in step 2 is to output prevention and detection control measures for the failure according to the failure identified in Figure B; practical application improves the reliability of system function design: combined with Lesson Learned, practical experience is integrated, and it is used as a reference in new product design and prevented in advance to improve the reliability of design.

[0012] Preferably, the rapid iteration in step 2 is to prioritize identification of differentiated, highly sensitive, and high-priority items to complete the FMEA analysis, and then continue to carry out differential analysis, continue agile output, continue to iterate FMEA, output a global complete FMEA, continuously improve the FMEA analysis report document, and iterate the Master FMEA, Master B chart, Master P chart, interference factor database, etc.

[0013] (III) Beneficial effects Compared with the prior art, the present invention provides an agile analysis method based on FMEA, which has the following beneficial effects: 1. This agile analysis method based on FMEA improves the efficiency of FMEA preparation by lightweighting: shortening the analysis time of a single FMEA, giving priority to outputting high-priority FMEAs and delivering them to the next link; visualization improves the effect of FMEA preparation: using a graphical method, using B-chart and P-chart to display, and associating data through "connect the dots", which facilitates brainstorming on the one hand and avoids omissions on the other.

[0014] 2. This agile analysis method based on FMEA is put into practice to improve the reliability of system function design: combined with Lesson Learned, it integrates practical experience, draws on it in new product design and takes precautions in advance to improve the reliability of design; continuously improves the FMEA analysis report document, and iterates Master FMEA, Master B diagram, Master P diagram, interference factor database, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 : Schematic diagram of the analysis / quantification B diagram of the present invention; Figure 2 : A schematic diagram of a visualized P-graph of the present invention; Figure 3 : Schematic diagram of the agile B diagram of the present invention; Figure 4 : Schematic diagram of the agile output of the present invention. DETAILED DESCRIPTION

[0016] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0017] An agile analysis method based on FMEA includes the following steps: Step 1: Demand Analysis Identify high-risk areas and conduct gap analysis. The core is to find out the differences between the current project / product and similar products, so as to give priority to key analysis in the subsequent process; High-risk areas include new technologies, new applications, new solutions and new environments.

[0018] Step 2: Incremental delivery They are quantitative B-chart, visual P-chart, agile B-chart, agile output, and rapid iteration. Quantification B diagram: Based on the high-risk areas identified in the previous step, that is, the differences, conduct boundary analysis of the product and quantify the internal / external interfaces; The visual P-chart is mainly used to identify highly sensitive interference factors. By associating historical failures with intelligent reminders of the interference factor database, engineers can conduct visual brainstorming and associate high-frequency and high-impact interference factors with products / interfaces. Improve FMEA preparation efficiency through lightweighting: shorten the single FMEA analysis time, give priority to outputting high-priority FMEAs, and deliver them to the next link; Agile B-diagram: Based on the highly sensitive interference factors identified in the visualized P-diagram, combined with functional / safety regulations, further brainstorming is carried out to identify high-priority failures; Visualization improves the FMEA compilation effect: using graphical methods, using B-chart and P-chart to display, and linking data through "connect the dots", which is convenient for brainstorming and avoids omissions; Agile output: Based on the failures identified in Figure B, output the prevention and detection control measures for the failures; Rapid iteration: Prioritize identification of differentiated, highly sensitive, and high-priority items. After completing the FMEA analysis according to the above process, repeat the above process for the remaining items to be analyzed: differential analysis-quantitative B-chart-visualized P-chart-agile B-chart-agile output until a complete global FMEA is output.

[0019] Step 3: Result Closing Loop Continuously improve FMEA analysis report documents, and iterate Master FMEA, Master B chart, Master P chart, and interference factor database; Practical application to improve the reliability of system function design: Combine Lesson Learned with practical experience, learn from it and take precautions in advance in new product design to improve the reliability of design; continuously improve FMEA analysis report documents, and iterate Master FMEA, Master B diagram, Master P diagram, interference factor database, etc.

[0020] Below through Figure 1 , 2 , 3, 4, we can see the actual process of demand analysis / quantification B diagram, visualization P diagram, agile B diagram, and agile output in turn: like Figure 1 As shown in Figure 1, through demand analysis and quantification of Figure B, it is identified that the main differences of this product compared to the previous generation of products are the following four parts: module a is new technology, module c is new design, bracket A is new environment, and actuator C is new application. These differences are the high-risk areas that need to be analyzed in the future.

[0021] like Figure 2 As shown in the visual P diagram, by associating historical failures and intelligent reminders from the interference factor database, high-sensitivity / high-occurrence interference factors are identified, such as the positioning structure, aging of electronic components, short circuits, and low temperature and high humidity in the example.

[0022] like Figure 3 As shown in the agile diagram B, the highly sensitive interference factors are “connected” with the structures / interfaces that are most sensitive to them, thereby forming high-priority failures. For example, in a low-temperature and high-humidity environment, module a that uses new technology will produce a failure mode of loss of a certain function.

[0023] like Figure 4 As shown, functional / failure analysis is performed on the high-risk areas identified in the demand analysis and quantitative B-diagram analysis. The high-severity failure modes identified and the high-priority failure modes identified in the agile B-diagram are unified as high-risk failure modes, and design prevention / detection measures are analyzed for them to efficiently improve the reliability of this product design.

[0024] The beneficial effects of the present invention are as follows: the FMEA-based agile analysis method improves the FMEA compilation efficiency by lightweighting: shortens the single FMEA analysis time, gives priority to outputting high-priority FMEAs, and delivers them to the next link; visualization improves the FMEA compilation effect: adopts a graphical method, uses B-charts and P-charts to display, and associates data through "connecting the dots", which is convenient for brainstorming on the one hand, and avoids omissions on the other hand; practicalization improves the reliability of system function design: combines Lesson Learned, integrates practical experience, draws on and prevents in advance in new product design, and improves the reliability of design; continuously improves the FMEA analysis report document, and iterates Master FMEA, Master B-chart, Master P-chart, interference factor database, etc.

[0025] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An agile analysis method based on FMEA, characterized in that: The following steps are involved: Step 1: Demand Analysis Identify high-risk areas, conduct gap analysis, and find out the different factors between the current project / product and similar products, so as to prioritize key analysis in subsequent processes; Step 2: Incremental delivery They are quantitative B-chart, visual P-chart, agile B-chart, agile output, and rapid iteration. Step 3: Result Closing Loop Form a FMEA analysis report document, and based on incremental delivery, iterate the corresponding difference points to the Master FMEA, Master B diagram, Master P diagram, and interference factor database.

2. The agile analysis method based on FMEA according to claim 1, characterized in that: The high-risk areas in step one include new technologies, new applications, new solutions and new environments.

3. The agile analysis method based on FMEA according to claim 1, characterized in that: The quantitative B diagram in step 2 is for the high-risk range identified in the previous step, that is, the boundary analysis of the product is performed for the different factors to quantify the internal / external interface.

4. The agile analysis method based on FMEA according to claim 1, characterized in that: The visualized P-chart in step 2 is used to identify highly sensitive interference factors, and the highly sensitive interference factors are associated with products / interfaces by associating historical failures and intelligent reminders of the interference factor database.

5. The agile analysis method based on FMEA according to claim 4, characterized in that: The agile B diagram in step 2 is based on the highly sensitive interference factors identified in the visualized P diagram, combined with functional / safety regulations, to identify high-priority failure predictions.

6. The agile analysis method based on FMEA according to claim 5, characterized in that: The agile output in step 2 is to output preventive measures and detection control measures for the high-priority failure predictions based on the high-priority failure predictions identified in Figure B.

7. The agile analysis method based on FMEA according to claim 1, characterized in that: The rapid iteration in step 2 is to prioritize the identification of differentiated, highly sensitive, and high-priority items, complete the FMEA analysis first, and then continue to conduct differential analysis of other items, continuously output in an agile manner, continuously iterate FMEA, and output a global complete FMEA analysis report document.

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