Research On PFMEA Technology Of Multi-varieties And Small-batch Customization Mode

Process failure mode and effects analysis(PFMEA) is a systematic and procedural technique analysis activity, which commits to identify potential process failure in the production process, and evaluates the possible failure mode and its effect on the subsequent process. Then effective measures are formulated and implemented to prevent and control the failure occurred. This method has been widely used in the prevention and control of process defects of industrial mass production mode. However,under the model of multi-varieties and small-batch production, the high uncertainty of the potential process failure mode and lack of historical data and experience for reference make it hard to identify potential process failure modes and evaluate the possible risks based on past experience, which restricts the application of PFMEA technology.In terms of the key problems of PFMEA application in small-batch production, the paper has systematically carried out the related research work on the basis of the full analysis of the characteristics of multi-varieties and small-batch production mode.First, the model of process elements is established by the application of process principle and method of quality management. The relationship between process failure and the elements of the process is studied to reveal that the process failure originated is from the defects of the components of the process. The general decision criteria and decision process of process failure are given at the same time.Second, the effect of risk factors to the evaluation results is analyzed with the applying of the principle of feedback control. By referring to the concept of probability of natural disasters occurrence and the process control method of long-term accumulation in enterprises, the evaluation of the three risk factors, severity, occurrence and detection, are studied. Thus a multidimensional evaluation model of risk factors with universal application value is established.Third, according to the aircraft assembly process of application enterprise and its management practice, the informatization of the CAPfmea technology management information system is realized by using oracle as its underlying database and adopting B/S model, based on the research results. These realized the automatization of risk assessment and the informatization of document management, and made the processfailure mode identification programmatically.Finally, the research results are applied to the process failure analysis of 9 specific assembly process such as engine installation of a certain type of aircraft to validate the applicability and effectiveness of the PFMEA technique in multi-varieties and small-batch production mode.The application of the CAPfmea system could not only guarantee the standardization of the application of PFMEA technology, but also improve the effectiveness and efficiency of defect prevention and control in process design.