Multi-system integrated PFMEA analysis method and system

Abstract

The invention provides a multi-system integrated PFMEA analysis method and system, and relates to the technical field of manufacturing industry quality analysis. According to the method, a PFMEA system is integrated with front and rear end systems such as DFMEA, BOP, QMS, PR and the like, end-to-end service data flow is constructed, and automatic transmission and consistency management and control of data are achieved. The method specifically comprises the steps of system association planning, cross-system data connection, full-process execution management and control, experience library dynamic updating and the like, solves the problems of low writing efficiency, data splitting, difficulty in measure landing and the like of a traditional PFMEA, and remarkably improves the effectiveness and risk management and control capability of PFMEA analysis.

Description

Technical Field

[0001] This invention relates to the field of manufacturing quality analysis technology, specifically to a multi-system integrated PFMEA analysis method and system. Background Technology

[0002] PFMEA, a commonly used risk analysis tool in manufacturing, aims to reduce quality risks in the production process by identifying potential failure modes, analyzing their causes and effects, and developing preventative and detection measures. With the widespread adoption of AIAG & VDA FMEA, the manufacturing industry commonly uses software to write PFMEAs. This involves building a structure tree of process items, process steps, and process work elements, combined with basic PFMEAs and product / process documents, to complete the writing process and simultaneously output process flowcharts, process characteristic lists, control plans, and other documents.

[0003] However, existing technologies have significant shortcomings: First, they are inefficient, requiring manual construction of a structure tree and confirmation of the technical requirements of each product and process characteristic, which is time-consuming and labor-intensive; second, the data chain is fragmented, with the FMEA system disconnected from other business systems (such as product design, process planning, and quality management systems), requiring repeated manual data entry and making it difficult to ensure consistency; third, the risk control loop is weak, customer complaint experience is not disseminated in a timely manner, and the implementation of optimization measures lacks systematic tracking, affecting the effectiveness of PFMEA analysis.

[0004] Therefore, there is an urgent need to provide a completely new technical solution to address the above problems. Summary of the Invention

[0005] The purpose of this invention is to overcome at least one technical problem existing in the prior art and to provide a PFMEA analysis method and system that integrates multiple systems.

[0006] On one hand, embodiments of the present invention provide a PFMEA analysis method for multi-system integration. The analysis method includes: Step S1, responding to project tasks and generating project number and product number; Step S2, during the data freezing phase, obtaining the process path from the BOP system in the TC system using the project number, and automatically generating a structure tree composed of process steps; Step S3, automatically obtaining the product characteristic list from the project DFMEA in the FMS system using the project number and product number, including product characteristics, technical requirements, and characteristic levels; Step S4, comparing the product characteristics of the project DFMEA in the FMS system with the product characteristics of the project PFMEA in the FMS system using pre-coded unique numbers, automatically aligning when characteristics are the same, and adding new characteristics and triggering a basic PFMEA update when characteristics are different; Step S5, the project PFMEA, for the identified potential failure modes, combines the product characteristic list transmitted by the project DFMEA with the basic PFMEA... Step S6: Identify high-risk items in the failure cause and mitigation measures, and assign optimization measures to the corresponding projects; Step S7: Transmit the optimization measures to the problem management module of the TC system through the project number to generate a project problem list; Step S8: Perform closed-loop management of the optimization measures through the TC system for the project problem list. After the problem is closed, the TC system will send the problem status and actual completion date back to the project PFMEA; Step S9: Based on the control plan output by the project PFMEA, generate inspection specifications and component inspection methods in the TC system through the project number, OP number, and process name, and transmit the component inspection methods or inspection specifications to the QMS system to generate specific inspection items for direct use in the quality inspection of the production process; Step S10: Receive customer complaint feedback after mass production; Step S11: The QMS system analyzes the customer complaint to obtain structured experience data, transmits it to the basic PFMEA, and triggers the synchronous update of the project PFMEA.

[0007] Furthermore, step S2 includes: the process steps are process step data obtained by decomposing the process path, including process level and process level.

[0008] Furthermore, step S4 includes: step S401, assigning a unique number to the product characteristic; step S402, selecting the required part or interface product characteristic at the process step level; step S403, comparing the product characteristic data of the project DFMEA with that of the project PFMEA using the unique number; step S404, displaying the same product characteristics on the same line, and confirming whether replacement is needed by the engineer based on the technical requirements and characteristic level; step S405, displaying different product characteristics on different lines, and the engineer providing feedback to the library administrator to add the different product characteristics to the basic PFMEA library.

[0009] Furthermore, step S5 includes: step S501, obtaining the risk priority number composed of the three key parameters severity, frequency of occurrence and detectability contained in the PFMEA output results; step S502, engineers construct optimization measures for projects with high risk priority values, including assigning them clear responsibilities and task completion dates.

[0010] Furthermore, step S7 includes: step S701, assigning a project issue list to the corresponding engineer through the PR system and setting a completion deadline; step S702, the engineer implementing measures based on the project issue list and updating the work order status; step S703, the PR system synchronously transmitting the work order status back to the project PFMEA in real time.

[0011] Furthermore, step S8 also includes: before mass production, the project PFMEA actively obtains process parameter items in the BOP system and reflects them in the control plan in the form of an appendix.

[0012] Furthermore, step S8 includes: step S801, extracting the characteristic description, control method, and sampling frequency fields from the control plan; step S802, converting the characteristic description, control method, and sampling frequency fields into the inspection items, inspection methods, and inspection frequency fields required by the QMS system according to preset mapping rules.

[0013] Furthermore, step S8 also includes: after the structured inspection specification is transmitted to the QMS system, a specific inspection task is generated and associated with the MOM system. The operator enters the inspection result through the SN barcode. The system automatically determines whether to accept or reject the inspection and returns the data to the QMS experience database. The summary in the experience database confirms whether the basic PFMEA needs to be updated.

[0014] Furthermore, step S10 includes: step S1001, parsing the failure mode, root cause and preventive measures fields in the structured experience data; step S1002, automatically matching the knowledge base corresponding to the basic PFMEA; step S1003, automatically notifying the project engineer to update the current project PFMEA when the basic PFMEA is updated, to avoid the recurrence of similar problems.

[0015] Secondly, embodiments of the present invention provide a multi-system integrated PFMEA analysis system. This system employs the aforementioned multi-system integrated PFMEA analysis method. The multi-systems include a TC system, an FMS system, and a QMS system. The analysis system comprises: an initialization module, suitable for responding to project tasks and generating project and product numbers; an automatic PFMEA structure tree generation module, suitable for automatically obtaining process paths from the BOP system in the TC system using project numbers during the data freezing phase, generating a structure tree composed of process steps; a product characteristic list acquisition module, suitable for automatically obtaining a product characteristic list from the project DFMEA in the FMS system using project and product numbers, including product characteristics, technical requirements, and characteristic levels; a characteristic data alignment module, suitable for comparing product characteristics in the project DFMEA of the FMS system with product characteristic data in the project PFMEA of the FMS system using pre-coded unique numbers, automatically aligning when characteristics are the same, and adding new characteristics and triggering a basic PFMEA update when characteristics are different; and an optimization measure generation module, suitable for project PFMEA... For identified potential failure modes, high-risk items are identified by combining the product characteristic list transmitted from the project DFMEA and the failure causes and measures in the basic PFMEA. Optimization measures are assigned to the projects corresponding to these high-risk items. A project issue list generation module is used to transmit the optimization measures to the issue management module of the TC system via project number, generating a project issue list. A closed-loop control module is used to manage the optimization measures through the TC system based on the project issue list. After an issue is closed, the TC system sends the issue status and actual completion date back to the project PFMEA. A quality control module is used to generate inspection specifications and component inspection methods in the TC system based on the control plan output from the project PFMEA, using project number, OP number, and process name. The component inspection methods or inspection specifications are then transmitted to the QMS system to generate specific inspection items for direct use in the production process. A knowledge feedback module is used to receive customer complaints after mass production. The QMS system analyzes the customer complaints to obtain structured experience data, transmits it to the basic PFMEA, and triggers a synchronous update of the project PFMEA.

[0016] Thirdly, embodiments of the present invention also provide an electronic device, including: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the computer program, when executed by the processor, implements the above-described multi-system integrated PFMEA analysis method.

[0017] Fourthly, embodiments of the present invention also provide a readable storage medium, wherein when the instructions in the storage medium are executed by the processor of an electronic device, the electronic device is able to execute the above-described multi-system integrated PFMEA analysis method.

[0018] The advantages of this invention compared to the prior art are: (1) Improve writing efficiency: Through multi-system integration, data can be automatically captured and transmitted, reducing manual construction of structure trees and repetitive input of feature requirements, and significantly shortening the PFMEA writing cycle.

[0019] (2) Ensure data consistency: Connect the data chains of multiple systems such as FMS, TC, and QMS to achieve end-to-end data flow of product characteristics, process parameters, control requirements, etc., and avoid deviations caused by manual transmission.

[0020] (3) Enhance risk management capabilities: Support severity scoring through DFMEA feature levels, promptly analyze customer complaints using the QMS experience base, and track the implementation of measures through the PR system to improve the effectiveness of risk identification and control.

[0021] (4) Realize dynamic accumulation of experience: Establish a linkage mechanism between QMS and PFMEA knowledge base to quickly transform improvement experience into PFMEA prevention / detection measures to prevent problems from recurring. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Figure 1 This is a flowchart of a multi-system integrated PFMEA analysis method provided in Embodiment 1 of the present invention.

[0024] Figure 2 This is a schematic diagram of data flow between multiple systems provided in Embodiment 1 of the present invention.

[0025] Figure 3 This is a schematic diagram of the data connection between project DFMEA and project PFMEA provided in Embodiment 1 of the present invention.

[0026] Figure 4 This is a schematic diagram of the BOP system and project PFMEA data connection provided in Embodiment 1 of the present invention.

[0027] Figure 5 This is a schematic diagram illustrating the data integration between the project PFMEA and PR issue management modules provided in Embodiment 1 of the present invention.

[0028] Figure 6 This is a schematic diagram illustrating the data integration between a control plan and a QMS (Quality Management System) provided in Embodiment 1 of the present invention.

[0029] Figure 7 This is a schematic diagram illustrating the data integration between the QMS lessons learned library and the project PFMEA provided in Embodiment 1 of the present invention.

[0030] Figure 8 This is a complete flowchart of project PFMEA writing provided in Embodiment 1 of the present invention.

[0031] Figure 9 This is a schematic diagram of a multi-system integrated PFMEA analysis system provided in Embodiment 2 of the present invention.

[0032] Figure 10 This is a partial block diagram of the electronic device provided in Embodiment 3 of the present invention. Detailed Implementation

[0033] Before discussing the exemplary embodiments in more detail, it should be noted that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although the flowcharts describe the operations as sequential processes, many of these operations can be performed in parallel, concurrently, or simultaneously. Furthermore, the order of the operations can be rearranged. The process can be terminated when its operation is completed, but may also have additional steps not included in the figures. The process can correspond to a method, function, procedure, subroutine, subroutine, etc.

[0034] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0035] The present invention will now be described in detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0036] For ease of understanding, the following technical terms are explained here: FMS (FMEA Management System): An FMS is a computer software-based automation technology for multi-variety, small-batch production. Its main advantages include high equipment utilization, short production cycles, flexible production, and good production efficiency and economy.

[0037] DFMEA (Design Failure Mode and Effects Analysis) refers to the analysis of potential failure modes during the design phase. It is a means of preventing product quality issues from the design stage and a control tool for ensuring that products meet quality standards during the formal production and delivery process to customers.

[0038] PFMEA (Process Failure Mode and Effects Analysis) is an analytical technique primarily used by engineers / teams responsible for manufacturing / assembly to ensure that all potential failure modes and their associated causes / mechanisms have been fully considered and discussed to the greatest extent possible.

[0039] TC System: TeamCenter System (Siemens PLM Product Lifecycle Management Platform).

[0040] BOP system (Bill of Process) is the process design module in TC.

[0041] QMS system: (Quality Management System).

[0042] PR System (Problem Report) is the problem management module in the TC system.

[0043] Example 1 To facilitate understanding, before detailing the specific solutions of this embodiment, the overall inventive concept of this invention is described here: The overall inventive concept is to construct an end-to-end PFMEA data chain and a full-process control mechanism through multi-system integration, solving the problems of low efficiency, data fragmentation, and difficulty in implementing measures in traditional PFMEA analysis, and achieving high efficiency, data consistency, and closed-loop risk control in process potential failure mode and impact analysis. The specific core idea is as follows: 1. Break down data barriers through system integration: Analyze PFMEA and related business flows, identify core integrated systems, establish cross-system data associations through unified coding rules (such as project number, product number, OP number), define data interaction rules (content acquisition, transmission path), and connect data chains in design, process, quality and other links to avoid manual duplication of data entry and data deviation.

[0044] 2. Achieve cross-system integration of key data: Design and process linkage: By uniquely identifying product characteristics in DFMEA and PFMEA, characteristic matching, technical requirement confirmation, and dynamic supplementation are achieved, supporting the accuracy of failure mode analysis. Process and procedure integration: Based on BOP, process paths are automatically transferred to generate PFMEA structure trees, integrating process parameters into control plans, reducing the cost of manual structure building and parameter entry. Closed-loop implementation and inspection: PFMEA optimization measures are transferred to the PR system for tracking implementation, and control plans generate inspection specifications through TC and are synchronized to QMS, ensuring the effective execution of risk control measures.

[0045] 3. Build a dynamic experience accumulation mechanism: Connect the QMS experience and lessons learned base with the PFMEA knowledge base to automatically transfer structured improvement experience to the basic PFMEA and update it. Through communication component notification and other mechanisms, experience can be quickly disseminated to avoid the recurrence of problems and improve risk prevention capabilities.

[0046] 4. Full-process control ensures effective implementation: Standardize the entire PFMEA process of the project (initialization, optimization and improvement, delivery and approval), and ensure controllability of all aspects from data synchronization and measure formulation to experience updating through deliverable feedback, status tracking and closed-loop management, so as to ultimately improve the effectiveness of PFMEA analysis and process risk management capabilities.

[0047] In short, this invention upgrades PFMEA from an independent tool into a risk management platform that links multiple business processes through an integrated design of "system integration - data connectivity - process closure - experience accumulation".

[0048] The specific implementation method is as follows: like Figure 1-2 The diagram shown is a flowchart and data flow diagram of a multi-system integrated PFMEA analysis method provided by the present invention.

[0049] As an example, the analysis method includes: Step S1, responding to project tasks and generating project number and product number; Step S2, during the data freeze phase, obtaining the process path from the BOP system in the TC system using the project number, and automatically generating a structure tree composed of process steps; Step S3, automatically obtaining the product characteristic list from the project DFMEA in the FMS system using the project number and product number, including product characteristics, technical requirements, and characteristic levels; Step S4, comparing the product characteristics of the project DFMEA in the FMS system with the product characteristics of the project PFMEA in the FMS system using pre-coded unique numbers, automatically aligning when characteristics are the same, and adding new characteristics and triggering a basic PFMEA update when characteristics are different; Step S5, the project PFMEA identifies high-risk failure modes based on the identified potential failure modes, combined with the product characteristic list transmitted by the project DFMEA and the failure causes and measures in the basic PFMEA. For high-risk items, allocate optimization measures to the corresponding projects; Step S6: Transmit the optimization measures to the problem management module of the TC system through the project number to generate a project problem list; Step S7: Perform closed-loop management of the optimization measures through the TC system for the project problem list. After the problem is closed, the TC system will send the problem status and actual completion date back to the project PFMEA; Step S8: Based on the control plan output by the project PFMEA, generate inspection specifications and component inspection methods in the TC system through the project number, OP number, and process name. Transmit the component inspection methods or inspection specifications to the QMS system to generate specific inspection items for direct use in the quality inspection of the production process; Step S9: Receive customer complaint feedback after mass production; Step S10: The QMS system analyzes the customer complaint to obtain structured experience data, transmits it to the basic PFMEA, and triggers the synchronous update of the project PFMEA.

[0050] In some feasible implementations, combined with Figure 2 As shown, the business flow related to PFMEA is outlined, mainly connecting the three major systems: FMS (DFMEA & PFMEA), TC (BOP, PR), and QMS. It clarifies what content is obtained or transmitted from each system. Standard 1 obtains product characteristics (e.g., "weld strength"), technical requirements (e.g., "≥500Mpa"), and characteristic levels (e.g., S-value) from DFMEA. Standard 2 obtains process paths (e.g., "stamping-welding-inspection"), process characteristics (e.g., "welding current: 500A±10A"), and technical requirements from BOP. Standard 3 transmits PFMEA optimization measures to PR (Problem Management System) for progress management and returns the final completion status to PFMEA. Standard 4 transmits product characteristics, technical requirements, and control methods from CP (Control Plan) to QMS for process quality control. Standard 5 transmits lessons learned from customer complaints or process defect improvements in QMS to PFMEA for horizontal integration.

[0051] In some feasible implementations, combined with Figure 3 As shown, step S3, which involves automatically obtaining a product characteristic list from the project DFMEA in the FMS system using the project number and product number, including product characteristics, technical requirements, and characteristic levels, includes, for example, the PFMEA analysis of the automotive headlight production process. After creating the "Automotive Headlight Assembly" project PFMEA, the system automatically associates the project DFMEA with the project number to obtain key product characteristics: lamp cover appearance (technical requirements: no scratches, shrinkage, or cracks); assembly positioning dimensions (technical requirements: ±0.5mm); luminous flux (characteristic level: high, technical requirements ≥2000lm).

[0052] In some feasible implementations, combined with Figure 4 As shown, step S2, during the data freezing phase, retrieves the process path from the BOP system in the TC system using the project number, and automatically generates a structure tree composed of process steps. This includes: the process item being the automatically mapped process path transmitted by the BOP system; the process step being the process step data obtained after decomposing the process path; and the work element being obtained through associating process characteristics. Specifically, process path import: the BOP system transmits the process path "lamp cover injection molding → surface spraying → lamp body assembly → electrical performance testing" to the project PFMEA using the project number, automatically generating a structure tree process step: injection molding / spraying / assembly / testing).

[0053] In some feasible implementations, step S4 includes: step S401, assigning a unique number to the product characteristic; step S402, selecting the required part or interface product characteristic at the process step level; step S403, comparing the product characteristic data of the project DFMEA with that of the project PFMEA using the unique number; step S404, displaying identical product characteristics on the same line, and confirming whether replacement is needed by the engineer based on the technical requirements and characteristic level; step S405, displaying different product characteristics on different lines, and the engineer provides feedback to the library administrator to add the different product characteristics to the basic PFMEA library. Specifically, the preferred unique numbering rule is: project number (PRJ-001) + characteristic type (P-product / C-process) + serial number (001) → PRJ-001-P-001. The system compares unique numbers, displaying identical characteristics (such as "luminous flux") on the same line, and the engineer directly uses them after confirming that the technical requirements match the project; different characteristics (such as "sealing performance") are displayed on different lines, and feedback is provided to the library administrator to add them to the basic PFMEA. The process of matching features avoids duplicate data entry.

[0054] In some feasible implementations, step S5 includes: step S501, obtaining a risk priority number composed of three key parameters—severity, frequency of occurrence, and detectability—included in the PFMEA output results; step S502, engineers construct optimization measures for projects with high risk priority values, including assigning them clear responsibilities and task completion dates.

[0055] In some feasible implementations, combined with Figure 5 As shown, step S7 includes: step S701, assigning a project issue list to the corresponding engineer through the PR system and setting a completion deadline; step S702, the engineer implementing measures based on the project issue list and updating the work order status; step S703, the PR system synchronously transmitting the work order status back to the project PFMEA in real time. Preferably, the optimization measures in the project PFMEA are transmitted to the issue management module in the TC system through the project number, generating a project issue list. The TC performs closed-loop management of the optimization measures. After the issue is closed, the TC will transmit the issue status and actual completion date back to the PFMEA optimization measures module. Specifically, the project PFMEA analysis found the "lamp cover collapse" failure mode (cause: insufficient injection molding holding pressure). The engineer formulated the optimization measure "extend the holding pressure time to 18s". The system automatically transmits it to the PR issue management module through the project number, generating an issue list (responsible person: injection molding process engineer, target date: 2024-06-30). Status feedback: After the process engineer completes the verification, the PR will send the status "Verification passed on 2024-06-28" and the date back to the project PFMEA, automatically updating the closed-loop status of the measures. This ensures that the measures are implemented and forms a feedback loop.

[0056] In some feasible implementations, step S8 further includes: before mass production, the project PFMEA actively acquires process parameter items from the BOP system and incorporates them into the control plan in the form of an appendix. Preferably, at T0 (before mass production), the PFMEA actively acquires process parameter items from the BOP and incorporates them into the control plan in the form of an appendix. Specifically, at the T0 stage (before mass production), the project PFMEA retrieves process parameters from the BOP system and integrates them into the control plan, including: injection molding process: melt temperature 220±10℃, holding time 15±2s; spraying process: gun distance 300±20mm, drying temperature 80±5℃.

[0057] In some feasible implementations, combined with Figure 6As shown, step S8 includes: step S801, extracting the characteristic description, control method, and sampling frequency fields from the control plan; step S802, converting the characteristic description, control method, and sampling frequency fields into the inspection items, inspection methods, and inspection frequency fields required by the QMS system according to preset mapping rules. After the structured inspection specification is transmitted to the QMS system, a specific inspection task is generated and associated with the MOM system. The operator enters the inspection results through the SN barcode, and the system automatically determines acceptance or rejection, returning the data to the QMS experience database. The summary in the experience database confirms whether the basic PFMEA needs to be updated. Specifically, the "lamp cover appearance inspection" requirement in the control plan output by the project PFMEA generates an inspection specification in the TC system (e.g., "sampling 10 pieces per hour to check for scratches / shrinkage / cracks"). QMS execution: After the inspection specification is transmitted to the QMS, a specific inspection task is generated and associated with the MOM (Manufacturing Operations System). The operator enters the inspection results through the SN barcode, and the system automatically determines Ac (acceptance) / Re (rejection). The data is fed back to the QMS experience database in real time for subsequent updates to the basic PFMEA.

[0058] In some feasible implementations, combined with Figure 7 As shown, step S10 includes: step S1001, parsing the failure mode, root cause, and preventive action fields in the structured experience data; step S1002, automatically matching the knowledge base corresponding to the basic PFMEA; and step S1003, automatically notifying the project engineer to update the current project PFMEA when the basic PFMEA is updated to avoid the recurrence of similar problems. Preferably, the requirements for filling in the QMS improvement experience base module are structured. After the experience information is approved, it is automatically triggered to be transmitted to the corresponding knowledge base of the PFMEA system. For example, the preventive action for improvement is transmitted to the PFMEA preventive action base and the database administrator is notified via Feishu. After receiving the information, the database administrator confirms the content in the knowledge base and adds the content to the basic PFMEA of the corresponding process. After the basic PFMEA is published, the system notifies the corresponding engineer to update the project PFMEA. Specifically, after the 8D improvement report (root cause: spray gun angle deviation) for "color difference in headlight painting" in QMS is approved, the system automatically transmits the preventive action of "fixing the spray gun angle to 45°" to the PFMEA knowledge base and notifies the database administrator via Feishu. After the library administrator confirms, the measures will be added to the basic PFMEA of the "lamp cover spraying" process. The system will then notify the project engineer to update the current project PFMEA to prevent similar problems from recurring.

[0059] In some feasible implementations, combined with Figure 8The diagram illustrates the complete workflow for creating a project PFMEA. Engineers begin by accepting the project task assigned from the main schedule, creating the project PFMEA, retrieving relevant data from various systems, and finally submitting four deliverables (PFMEA, process flowchart, process characteristic list, and control plan) back to the TC system for approval. The process for updating the PFMEA is also illustrated using customer complaint improvement experience as an example; the workflow for other input sources triggering PFMEA updates is the same. Specifically, it includes two phases: Phase 1 is the data freezing phase (process design completed), and Phase 2 is the development phase (trial production preparation). Phase 1 includes: 1. Creating the project PFMEA: Starting from "accepting the task," a project PFMEA is created and associated with the TC project folder, serving as the starting point of the workflow. 2. Building the process and operation hierarchy: The process and operation hierarchy are obtained from the BOP. 3. Importing the basic PFMEA: A basic PFMEA is selected; if unique, it is used directly; otherwise, it is selected and synthesized. 4. Review Special Tag Content: Filter special tags, check if they are suitable for the project. If suitable, keep them and hide the tags; otherwise, delete them and restore the structure to ensure the accuracy of the analysis object. 5. Confirm Product Characteristics Transmitted by DFMEA: Synchronize DFMEA product characteristics. If inconsistent, either replace the technical requirements or report to the administrator to update the basic PFMEA to ensure accurate characteristic transmission from design to process. 6. Check for Isolated Content: Determine if there is any isolated content (information unrelated to the overall logic). If so, delete it, restore the structure, and avoid redundant interference. 7. Fill in Optimization Measures: Determine the optimization content, mark and filter it, select measures to edit, and transmit it to the PR closed loop for continuous improvement of PFMEA. 8. Return Deliverables: After completing the optimization, return the process flowchart, PFMEA, characteristic list, CP (Control Plan), etc., to the TC (Target Recipient, such as the Technical Center) according to the approval status, outputting the phase results. Development Phase: 9. Obtain Process Parameters: Obtain BOP process parameters from the BOP to provide actual production data support for subsequent analysis. 10. Return Deliverables: Return the feature list and CP to TC. After approval and confirmation, final delivery is completed, connecting to subsequent production / technology application stages. In short, it uses PFMEA as the core, covering the entire "analysis-improvement-output" process from project creation, data adaptation, feature alignment, optimization iteration, to final delivery to TC, ensuring controllable project process risks and accurate transfer of design and process features.

[0060] In the above implementation, PFMEA is used as the core analysis tool. By integrating the FMEA system with the front-end and back-end systems, data transfer is achieved, the end-to-end business flow of the system is opened up, and the data chain of requirements-planning-execution-feedback is connected; data consistency is ensured; and writing efficiency is improved simultaneously.

[0061] Example 2 Please see Figure 9This embodiment provides a schematic diagram of a multi-system integrated PFMEA analysis system structure.

[0062] As an example, the analysis system is implemented using the multi-system integrated PFMEA analysis method described in Example 1. The multi-systems include a TC system, an FMS system, and a QMS system. The analysis system includes: Initialization module 900 is suitable for responding to project tasks and generating project numbers and product numbers.

[0063] The PFMEA structure tree automatic generation module 910 is suitable for automatically obtaining process paths from the BOP system in the TC system by project number during the data freeze phase and generating a structure tree composed of process steps.

[0064] Product Feature List Acquisition Module 920 is suitable for automatically acquiring product feature lists from the project DFMEA in the FMS system using project number and product number, including product features, technical requirements and feature levels.

[0065] The feature data alignment module 930 is suitable for comparing the product feature data of the project DFMEA in the FMS system with the product feature data of the project PFMEA in the FMS system using a pre-coded unique number. When the features are the same, the alignment is automatic. When the features are different, a new feature is added and the basic PFMEA is updated.

[0066] The optimization measure generation module 940 is applicable to the project PFMEA for identifying potential failure modes, combining the product characteristic list transmitted by the project DFMEA with the failure causes and measures in the basic PFMEA to identify high-risk items, and assigning optimization measures to the project corresponding to the high-risk items.

[0067] The project issue list generation module 950 is suitable for generating a project issue list by transmitting the optimization measures to the issue management module of the TC system through the project number.

[0068] The closed-loop control module 960 is suitable for closed-loop management of optimization measures for the project issue list through the TC system. After the issue is closed, the TC system will send the issue status and the actual completion date back to the project PFMEA.

[0069] The Quality Control Module 970 is suitable for control plans based on project PFMEA outputs. It generates inspection specifications and component inspection methods in the TC system using project number, OP number, and process name. The component inspection methods or inspection specifications are then transferred to the QMS system to generate specific inspection items, which are directly used for quality inspection in the production process.

[0070] The knowledge feedback module 980 is suitable for receiving customer complaints after mass production; the QMS system analyzes the customer complaints to obtain structured experience data, transmits it to the basic PFMEA, and triggers the project PFMEA to be updated synchronously.

[0071] It is not difficult to see that this embodiment is a system implementation corresponding to the first embodiment, and this embodiment can be implemented in conjunction with the first embodiment. The relevant technical details mentioned in the first embodiment are still valid in this embodiment, and will not be repeated here to reduce repetition. Accordingly, the relevant technical details mentioned in this embodiment can also be applied to the first embodiment.

[0072] It is worth mentioning that all modules involved in this embodiment are logical units. In practical applications, a logical unit can be a physical unit, a part of a physical unit, or a combination of multiple physical units. Furthermore, to highlight the innovative aspects of this invention, this embodiment does not introduce units that are not closely related to solving the technical problem proposed by this invention; however, this does not mean that other units are absent from this embodiment.

[0073] Example 3 Please see Figure 10 The present invention also provides an electronic device, including: a memory and a processor; the memory stores at least one program instruction; the processor loads and executes the at least one program instruction to implement the multi-system integrated PFMEA analysis method provided in Embodiment 1.

[0074] The memory 702 and processor 701 are connected via a bus, which may include any number of interconnecting buses and bridges, connecting various circuits of one or more processors 701 and memory 702 together. The bus may also connect various other circuits, such as peripheral devices, voltage regulators, and power management circuits, which are well known in the art and therefore will not be described further herein. A bus interface provides an interface between the bus and the transceiver. The transceiver may be a single element or multiple elements, such as multiple receivers and transmitters, providing a unit for communicating with various other devices over a transmission medium. Data processed by processor 701 is transmitted over a wireless medium via an antenna, which further receives data and transmits it to processor 701.

[0075] Processor 701 is responsible for managing the bus and general processing, and can also provide various functions, including timing, peripheral interfaces, voltage regulation, power management, and other control functions. Memory 702 can be used to store data used by processor 701 during operation.

[0076] Example 4 This invention also proposes a storage medium storing a multi-system integrated PFMEA analysis method. When the multi-system integrated PFMEA analysis program is executed by a processor, it implements the steps of the multi-system integrated PFMEA analysis method as described above. Since this storage medium employs all the technical solutions of the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon further here.

[0077] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, based on the guidance provided in this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A PFMEA analysis method for multi-system integration, characterized in that, The analytical method includes: Step S1: Respond to the project task and generate the project number and product number; Step S2: During the data freezing phase, obtain the process path from the BOP system in the TC system by project number and automatically generate a structure tree consisting of process steps. Step S3: Automatically obtain the product characteristic list from the project DFMEA in the FMS system using the project number and product number, including product characteristics, technical requirements and characteristic levels; Step S4: Compare the product characteristics of the project DFMEA in the FMS system with the product characteristics of the project PFMEA in the FMS system using the pre-coded unique number. When the characteristics are the same, they are automatically aligned. When the characteristics are different, a new characteristic is added and the basic PFMEA is updated. Step S5: The project PFMEA identifies potential failure modes, combines the product feature list transmitted by the project DFMEA with the failure causes and measures in the basic PFMEA to identify high-risk items, and assigns optimization measures to the projects corresponding to the high-risk items. Step S6: Transfer the optimization measures to the problem management module of the TC system through the project number to generate a project problem list; Step S7: Implement closed-loop management of optimization measures for the project issue list through the TC system. After an issue is closed, the TC system will send the issue status and actual completion date back to the project PFMEA. Step S8: Based on the control plan output by the project PFMEA, generate inspection specifications and component inspection methods in the TC system through the project number, OP number and process name, and transfer the component inspection methods or inspection specifications to the QMS system to generate specific inspection items, which can be directly used for quality inspection in the production process. Step S9: Receive customer feedback on issues after mass production; Step S10: The QMS system analyzes the customer complaint to obtain structured experience data, transmits it to the basic PFMEA, and triggers the project PFMEA to update synchronously.

2. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S2 includes: The process steps are process step data obtained by decomposing the process path, including process level and operation level.

3. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S4 includes: Step S401: Uniquely number the product characteristics; Step S402: At the process step level, select the product characteristics of the required parts or interfaces; Step S403: Compare the product characteristics of the project DFMEA with the product characteristic data of the project PFMEA using the unique identification number; Step S404: Display products with the same characteristics in the same row, and confirm whether replacement is needed by having an engineer confirm the technical requirements and characteristic levels. Step S405: Different product characteristics are displayed in staggered rows. The engineer reports this to the library administrator so that the different product characteristics can be added to the basic PFMEA library.

4. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S5 includes: Step S501: Obtain the risk priority number, which is composed of the three key parameters, severity, frequency of occurrence and detectability, contained in the PFMEA output results; Step S502: For projects with high risk priority values, engineers develop optimization measures, including assigning clear responsibilities and task completion dates.

5. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S7 includes: Step S701: Assign a project issue list to the corresponding engineer through the PR system and set a completion deadline; Step S702: The engineer implements measures based on the project issue list and updates the work order status; Step S703: The PR system will synchronize the work order status back to the project PFMEA in real time.

6. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S8 further includes: before mass production, the project PFMEA actively obtains process parameter items in the BOP system and reflects them in the control plan in the form of an appendix.

7. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S8 includes: Step S801: Extract the characteristic description, control method, and sampling frequency fields from the control plan; Step S802: Convert the characteristic description, control method and sampling frequency field into the inspection items, inspection methods and inspection frequency fields required by the QMS system according to the preset mapping rules.

8. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S8 further includes: After the structured inspection specifications are transmitted to the QMS system, specific inspection tasks are generated and associated with the MOM system. Operators enter the inspection results through the SN barcode, and the system automatically determines whether to accept or reject the results and returns the data to the QMS experience database. The summary in the experience database confirms whether the basic PFMEA needs to be updated.

9. The PFMEA analysis method for multi-system integration according to claim 1, characterized in that, Step S10 includes: Step S1001: Parse the failure mode, root cause and preventive measures fields in the structured experience data; Step S1002: Automatically match the knowledge base corresponding to the basic PFMEA; Step S1003: When the base PFMEA is updated, the project engineer is automatically notified to update the current project PFMEA to avoid the recurrence of similar problems.

10. A multi-system integrated PFMEA analysis system, wherein the analysis system is implemented using the multi-system integrated PFMEA analysis method according to any one of claims 1-9, characterized in that, The multi-systems include a TC system, an FMS system, and a QMS system, and the analysis system includes: The initialization module is suitable for responding to project tasks and generating project and product numbers. The PFMEA structure tree automatic generation module is suitable for automatically obtaining process paths from the BOP system in the TC system by project number during the data freeze phase and generating a structure tree composed of process steps. The Product Feature List Acquisition Module is suitable for automatically retrieving the product feature list from the project DFMEA in the FMS system using the project number and product number. The product feature list includes product features, technical requirements, and feature levels. The feature data alignment module is suitable for comparing the product feature data of the project DFMEA in the FMS system with the product feature data of the project PFMEA in the FMS system using a pre-coded unique number. When the features are the same, it automatically aligns them; when the features are different, it adds new features and triggers the basic PFMEA update. The optimization measure generation module is applicable to the project PFMEA for identifying potential failure modes, combining the product characteristic list transmitted by the project DFMEA with the failure causes and measures in the basic PFMEA to identify high-risk items, and assigning optimization measures to the projects corresponding to the high-risk items; the project problem list generation module is applicable to the project problem list generated by transmitting the optimization measures to the problem management module of the TC system through the project number. The closed-loop control module is suitable for closed-loop management of optimization measures for the project issue list through the TC system. After the issue is closed, the TC system will send the issue status and the actual completion date back to the project PFMEA. The quality control module is suitable for control plans based on project PFMEA outputs. It generates inspection specifications and component inspection methods in the TC system using project number, OP number, and process name. The component inspection methods or inspection specifications are then transferred to the QMS system to generate specific inspection items, which are directly used for quality inspection in the production process. The knowledge feedback module is suitable for receiving customer complaints after mass production. The QMS system analyzes the customer complaints to obtain structured experience data, which is then transmitted to the basic PFMEA and triggers the project PFMEA to be updated synchronously.

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