设计验证和生产确认[福特FORD].ppt

,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,*,Welcome,Design Verification and,Production Validation,设计验证和生产确认,F,ord,T,echnical,E,ducation,P,rogram,福特技术培训项目,Systems Engineering,Fundamentals,系统工程基本原理,Parameter Design,参数设计,ToleranceDesign,公差设计,Global 8D,全球8,D,FMEA,失效模式后果与分析,ExperimentalDesign,实验设计,FTEP,福特技术培训项目,Reliability,可靠性,Applied Consumer Focus,应用顾客的关注,DV&PV,设计验证&生产确认,Statistical Engineering,统计工程学,Course Structure,课程结构,Introduction to DV&PV,对设计验证及生产确认的介绍,Tools for DV&PV,设计验证及生产确认的工具,Vehicle Level DV,整车级别的设计验证,System/Sub-System Level DV,系统/子系统级别的设计验证,Component Level DV,零部件级别的设计验证,System/Sub-System Level PV,系统/子系统级别的生产确认,Component Level PV,零部件级别的生产确认,Summary,总结,Design Verification and Production Validation,设计验证和生产确认,Design Verification and Production Validation,设计验证和生产确认,Benefit to Ford Motor Company,对福特汽车公司的益处,Design Verification and Production Validation,设计验证和生产确认,Design Verification:,设计验证,as designed,a product will function in the manner that the customer expects.,根据设计状态，一个产品的功能要符合顾客所期望的方式。,Production Validation:,生产确认,as manufactured,a product functions in the manner that the customer expects and can be manufactured at required volumes.,根据制造状态，一个产品的功能要符合顾客所期望的方式，而且能以所要求的产量进行生产。,DV&PV Within Systems Engineering,系统工程内的,DV&PV,Verification and Systemic Thinking,验证和系统思想,Customer Wants,顾客的需要,Engineering Targets,工程目标,Design Verification,设计验证,Requirements Cascade,需求逐级传递,Working in a Systems Engineering context supports systemic thinking.,系统工程中的工作支持系统的考虑,O,pposite of,T,raditional approach to engineering.,与传统的工程方法相反,Systems“V”Model,系统,V,模型,DV&PV is a requirements driven process,DV,和,PV,是一个需求驱动的过程,DV&PV is best conducted in a systems engineering context,through the systems V,.,DV,和,PV,在贯穿系统,V,模型的系统工程中得到最好的实施。,Vehicle,System,Sub-System,Component,Defining Requirements,定义需求,The requirements cascade down the left side.,需求的逐级传递如左侧,T,he cascade is an iterative process.,该逐级传递是一反复的过程,Vehicle,System,Sub-System,Component,I,T,E,R,A,T,I,V,E,P,L,A,N,N,I,N,G,Top Down,由上到下,Verification Bottom-up,验证自下至上,Verification testing is implemented as a bottom-up sequential process.,验证试验是按照自下至上的顺序过程执行的,Verification may include a combination of Analytical and physical tests,.,验证可能包括分析试验和物理试验的组合。,Vehicle,System,Sub-System,Component,I,T,E,R,A,T,I,V,E,P,L,A,N,N,I,N,G,Top Down,自上至下,Bottom Up,自下至上,S,E,Q,U,E,N,T,I,A,L,D,O,I,N,G,反复计划,工作顺序,DV&PV and PDSA,Plan,Plan,Plan,Plan,计划,Do,Study,Act,做，研究，行动,Do,Study,Act,Do,Study,Act,Do,Study,Act,Vehicle,整车,System,系统,Sub-System,子系统,Component,零部件,Lower Level Interactions,较低级别的相互作用,Systems Approach to Manufacturing,进行制造的系统方法,Vehicle,System,Sub,-,System,Component,Plant,Assembly,Operation,Machine,Vehicle,整车,System,系统,Sub,-,System,子系统,Component,零部件,Manufacturing,Design,Plant,工厂,Assembly,装配,Operation,操作,Machine,机器,设计,制 造,Note-S5/P5 Timing,FPDS TimingFPDS,时间,Vehicle level,System level,&Sub-sys level1,DVP Created,生成整车，系统&子系统的,DVP,Sub-sys level 2,&Component,DVP Created,生成子系统级别2,&零部件,DVP,Full DVP Created,Reqts&Targets Frozen,生成完整的,DVP,需求&目标冻结,Component testing complete,零部件试验完成,Sub-system and System testing complete,子系统和系统试验完成,Vehicle testing mostly complete:,Prelim Eng Sign Off,整车试验大部分完成：工程预签发,Vehicle testing complete:,Final Eng Sign Off,整车试验完成：最终工程签发,DVP complete,DVP,完成,Design“V”and FPDS Timing,DV&PV,设计,V,形图及,FPDS,时间的,DV&PV,Low,低,High,高,Activity,Level,活动级别,Time,时间,=Design Verification,设计验证,=Production&Process Validation,生产&过程确认,SI,SC,PA,PR,CP,LR,J1,DV&PV and FPDS,DV&PV are key requirements for sign off of a vehicle program,DV,和,PV,对于汽车项目的签发来说是关键的需求,Key Sign off milestones are:,关键签发节点是：,(CC)DV,(LR)PV,(LS)PV,Inputs Used in the Verification and Validation Processes,在验证和确认过程中使用的输入,DV,Plan,设计验证,计划,SDS,Requirements,SDS,的需求,Legal,Requirements,法规要求,Engineering,Specifications,工程技术规范,Concept and,Design FMEAs,概念和设计,FMEA,Real World,Usage Profile,真正的顾客使用状况,P-Diagram,P,图,Existing DVPs,现有的,DVP,Generic DVMs,一般,DVM,Historical 8Ds,历史上8,D,Key Life Tests,关键寿命试验,DV&PV as Part of the,Product Creation Process DV,和,PV,作为产品创造过程的部分,DV and PV confirm that Components and system robustly meet customer requirements,DV,和,PV,确认零部件和系统殷实可靠地符合顾客的需求。,DV&PV testing,is not,exploratory,DV,和,PV,试验不是探险,Testing should be against expected results,not,to find out“what happens if”,试验应该是针对所预测的结果而不是去发现“如果会怎样”,DV&PV comes after the design phase,not,during the design phase,DV,和,PV,要在设计以后而不是在设计阶段中进行,Introduction of the FEAD Example,FEAD,举例介绍,FEAD ExampleFEAD,范例,A single system the FEAD(Front End Accessory Drive)will be used to demonstrate DV&PV,使用一个单独的系统,FEAD（,前端附件驱动）来示范,DV&PV,The Front End Accessory Drive(FEAD),How It WorksFEAD-,它如何工作,The source of power in the vehicle is the engine.,汽车内动力的来源是发动机,Part of the rotational power output from the engine needs to be transmitted to the FEAD accessories.,来自发动机转动动力输出的一部分需要被传输到,FEAD,附件上。,The FEAD transmits this energy,FEAD,传输该能量,Design Verification at All Levels,所有级别上的设计验证,Design Verification should occur at all levels with the emphasis being at the lower levels.,设计验证应该重点放在较低级别的情况下在所有级别上进行。,Production Validation,生产确认,It is important to verify the design,验证设计是重要的,It is equally important to validate that the production process used to manufacture the belt is able to produce belts to the design specification.,确认制造皮带所使用的生产过程能够生产出符合设计规范的皮带同等地重要。,For example,the belt as manufactured must be able to transmit the required amount of torque.,例如，所制造的皮带必须能转送所要求大小的扭矩。,Confirming Robust and Reliable Design Robustness,确认殷实及可靠的设计-殷实可靠性,Tools For DV&PVDV&PV,的工具,Methods Used in Efficient and Effective Verification,在有效且高效的验证中使用的方法,Some of the important methods used in efficient and effective verification and validation processes are,在有效且高效的验证和确认过程中所使用的一些重要方法是,Robust Engineering Design Philosophy(RED),殷实的工程设计基本定律,Ford Design Verification System(FDVS),福特设计验证体系,Testing Methodologies,试验方法学,Real World Usage Profiles and Duty Cycles,真正全球顾客使用的概况和工况,Accelerated Tests,加速试验,Key Life Tests(KLT),关键寿命试验,Computer Aided Engineering(CAE),计算机辅助工程,Design of Experiment(DoE).,实验设计,Robust Engineering Design(RED),殷实的工程设计,Robust Test Plans,殷实可靠的试验计划,Robust test plans in DV&PV incorporate Noise factors and their effects in order to ensure that the product will meet its design intent under all conditions.Noise factors can be grouped into five categories:,为了确保该产品在所有条件下都符合其设计意图，,DV,和,PV,中殷实的试验计划合并了干扰因素及其他们的影响。干扰因素可以分成5类：,Piece-to-Piece Variation,件与件间的变差,Changes Over Time,随着时间过去的变化,Customer Usage,顾客的使用,External Environment,外部环境,System Interactions,系统间的交互作用,Noise Factor Management,干扰因素的管理,Robust Engineering Design,殷实可靠的工程设计,Robust Engineering Design(RED)is primarily a design tool,殷实的工程设计主要是一种设计工具,RED must be considered in DV&PV as RED will drive the type of DV&PV tests that need to be undertaken,在,DV,和,PV,中必须考虑到,RED，,因为,RED,将决定需要采取的,DV&PV,试验的类型。,RED focuses on identification and management of noise factors,RED,着重于干扰因素的识别和管理,Robust Engineering Design,殷实可靠的工程设计,RED is inherent in the systems V and runs through all phases of the V,RED,是系统,V,内固有的，并且贯穿系统,V,的所有阶段,RED is a team based process,RED,是以小组为基础的过程,RED applies throughout Ford(Design and Manufacturing)and at suppliers,RED,应用于整个福特（设计和制造）以及供应商。,Applying RED,应用,RED,RED allows testing at the lowest possible level,RED,允许在最低可能性级别进行测试,Caution must be used,必须使用警示,Red Applied to Vehicle Level Testing Red,应用于整车级别的测试,RED Applied at Sub-System LevelRED,应用于子系统级别,When developing Design Verification Methods at the system/sub-system or component level,it is important to ensure that the effects of System Interaction Noise factors that are present in the total vehicle environment are included.,当开发系统/子系统或零部件级别的设计验证方法时，重要的是确保要包括整个汽车环境中出现的系统交互作用干扰因素的影响。,RED Applied at Component LevelRED,应用于零部件级别,At the component level testing is most efficent but interactions with other components are lost,零部件级别的试验是最有效的，但失去了与其他零件的交互作用,Test plans must compensate for this loss by reproducing the key stresses from the interactions,试验计划必须通过再制造来自交互作用的关键应力弥补这一损失,Much component testing may be done at suppliers.,许多零部件试验可能在供应商处进行。,Suppliers must apply the same RED methodolgies,供应商必须应用相同的,RED,方法,To support this,Ford engineers need to cascade noise factors to the supplier,为了支持这个，福特工程师需要逐层传递干扰因素直到供应商,RED in the Design Process,设计过程中的,RED,Noise Factors,干扰因素,Piece to Piece,件与件,Aging/Wear,老化/磨损,Customer Usage,顾客使用,Environment,环境,Subsystem Interaction,子系统交互作用,Sources that disrupt ideal,function that can not be,controlled,(e.g.column friction),不可控制的，破坏理想功能的来源,（例如.转向柱磨擦）,P-Diagram,Reliability,Checklist,可靠性检查清单,Reliability/Robustness,Demonstration Matrix,可靠性/殷实可靠性实证矩阵图,Signal,信号,Energy put into,the systems to,make it work,(,e.g.Steering,wheel angle),能量进入系统,使其工作,（例如.方向盘转角）,Control Factors,Features of the design,that can be controlled,(e.g.Torsion bar rate),控制因素,可以控制的设计特性,（例如.扭杆比率）,Error,States,异常状态,Undesirable output,or Failure Modes,(e.g.Tire slip),不需要的输出或失效模式,（例如.轮胎打滑）,Error States,异常状态,Noise,Factors,干扰因素,Available,Tests,有用的试验,DVP&R,Test,试验,Critical,Noise,Factors,关键干扰因素,Failure mode to,test traceability,失效模式试验可追查性,Noise Factors,Management Strategy,System,(Steering System),系统（转向系统）,Ideal,Function,理想功能,Primary intended,function of the design,设计的主要意图功能,(e.g.Lateral acceleration,of vehicle,),（,例如.车辆的横向加速度）,FMEA,SDS,WCR,DOE,(if necessary,如果有必要),KLT,WCR,Failure,Mode,失效模式,Demonstrated,Result,论证的结果,In scope,范围内,FDVS,FDVS,Prevention of,Mistake Reoccurrence,错误再次发生的预防,Campaign Prevent,防召回,Lessons Learned,吸取的教训,Vigilance,警惕,.,.,.,.,.,.,干扰因素管理策略,Ford Design Verification System,福特设计验证系统,Ford Design Verification System FDVS,福特设计验证系统-,FDVS,FDVS is a computer based system to create and manage requirements driven DV plans.,FDVS,是一计算机为基础的系统，生成并管理驱动,DV,计划的需求。,FDVS includes a number of generic requirements and Design Verification Methods(DVMs),FDVS,包括许多一般需求和设计验证方面（,DVM）,安全法规,法人的要求,技术规范,设计验证方法,整车要求,（项目专有）,项目专有的设计验证计划,系统要求,（项目专有）,DVM,（,项目专有）,Design Verification Method,设计验证方法,Within FDVS requirements are verified using Design Verification Methods(DVMs),在,FDVS,内，使用设计验证方法（,DVM）,验证需求,DVMs contain all the information required to conduct testing and record results,DVM,包括所有要求试验和记录结果的信息,Existing and Generic DVMs can be used as a starting point to develop program DMVs,but they must be reviewed,现有的和一般的,DVM,能作为一个开始点用以开发项目的,DMV，,但是它们必须进行审核,Testing Methodologies,试验方法学,Types of Test,试验的类型,There are three general types of testing that can be implemented for either Design Verification or Production Validation:,有三种可以在设计验证或生产确认中实施的一般试验类型,Testing to Bogey,标准测试,Testing to Failure,测试至失效,Testing Functional Degradation,测试功能退化,Test to Bogey,Minimum Acceptable,Function,最小可接受功能,Function,功能,Time/Cycles/Miles,时间/循环/里程,Bogey,失效柱状图,Test to Failure,测试至失效,Minimum Acceptable,Function,最小可接受功能,Function,功能,Time/Cycles/Miles,时间/循环/里程,失效时间分布图,Degradation Testing,退化测试,Minimum Acceptable,Function,最小可接受功能,Function,功能,Time/Cycles/Miles,时间/循环/里程,Bogey,Complete Degradation,History,Example:Functional Degradation of Three Design Alternatives,范例：三种设计方案的功能退化,C,B,A,Test Level Comparison,测试水平比较,Bogey,标准,Failure,失效,Information,Quality,信息质量,Cost,成本,Higher,较高,Lower,较低,Higher,较高,Lower,较低,Degradation,退化,Test Precision,测试精度,失效概率,Statistical Confidence,统计可信度,Statistical confidence for a given reliability estimate is the probability that the true reliability of the population is equal to or greater than the estimate.,对于特定的可靠性预测，统计可信度是一种总体真实可靠性等于或大于预测情况的概率,Engineering Confidence Reduces Sample Size,工程可信度减小样本量,Large,Sample,大样本,Reduced Sample,减少的样本,Min:1 sample/failure mode,最小：1个样本/失效模式,Severity/Acceleration of,key noises in tests,试验中关键干扰的严重度/加速,Knowledge of prior perform-,ance under similar conditions,相似条件下优先性能的知识,Normal,通常,High,高,High,高,Low,低,Failure,Severity&Occurrence,失效严重度&发生,Test Level,测试水平,Bogey,Failure,Degradation,Real World Usage Profiles,真正顾客使用概况,Types of Customer Usage,顾客使用的类型,Normal use,一般使用,Misuse,误用,Abuse,?,滥用？,Normal Use,一般使用,Misuse,误用,Abuse,滥用,Data Sources,数据来源,Yourself,自身,Instrumentation,仪器,Existing Data,现有数据,Observation,观察,Percentiles,百分点,Actual Customer Usage,真正顾客使用,5,%,Total,95,th,Percentile use,95,th,百分点使用,Core Target Customer,(Marketing),核心目标顾客,（市场）,Example:Cooling Fan,范例：冷却风扇,Stress,受力状态,Europe,欧洲,Southern,European,Cities,南欧城市,Northern,European,Cities,北欧城市,Usage Profile and Customer Duty Cycle,使用概况及顾客工况,Usage Profile,使用概况,Duty Cycle,工况,How often the customer opens a window,顾客开启窗户的频次如何,Number of switch activations or motor running times for the window motor,开关的次数或窗户电机运转次数,Climate or outside temperature ranges in which the vehicle operates,车辆运转时的气候或外界温度的范围,Air conditioning system frequency of operation and load,空调系统的运转频次和负荷,Duty Cycle Example,工况范例,同步齿形带发动机工况,绿线：一般顾客,红线：苛刻顾客,注：皮带负荷在低转,速时更苛刻,Accelerated Testing,加速测试,Accelerated Testing,加速测试,Purpose:,目的:,Accumulate product stress history in a short period of time,在短时间内累积产品应力史,Shorten verification time&reduce development costs,缩短验证时间&减少开发成本,Accelerated Testing Methods,加速测试方法,Load Frequency over a Specified Test Procedure,在指定的试验规程上加大加载频次,0,100,200,300,400,30%,60%,100%,Percent Frequency of Occurrence,发生频次的百分比,Load,载荷,Normal Load,正常负载,Increased Load,加大负载,Define Accelerated Test based on this,portion of procedure with increased loads,50,mph Freeway,50,mph,高速公路,Climbing hill,in 1st gear,一档爬山,以加大的载荷在这部分试验规程的基础上定义加速测试,Accelerated Testing Cautions,加速测试警示,Correlate acceleration to real world deterioration,使其加速形式与真正顾客使用的退化情况相关联,Prevent unrepresentative failure modes,预防不具备代表性的失效模式,Not all failure modes can be accelerated,不是所有的失效模式都可以加速的,Key Life Tests,关键寿命试验,Key Life Tests,关键寿命试验,Key Life Tests focus on the key stress(es)which drive loss of function and/or failure mechanisms associated with real world usage.,关键寿命试验着重于会促使真正顾客使用相关的功能损失和/或失效机理的关键应力,Key Life Tests,关键寿命试验,A Key Life Test:,一个关键寿命试验,Is based on the RWUP,是以,RWUP,为基础的,Provides a tool to evaluate product reliability,提供了一个工具以评估产品的可靠性,Allows comparison of designs with benchmarked competitive products so that the best design can be identified,使其与竞争产品进行设计的比较，从而可以确定最佳设计,Validates models and assumptions in the design process,在设计过程中确认模型和设想,Validates the design,确认设计,Key Life Tests,关键寿命试验,IS,是,IS Not,否,Reliability and Robustness Demonstration Matrix,可靠性和殷实可靠性实证,矩阵图,Reliability and Robustness Demonstration Matrix,可靠性和殷实可靠性实证矩阵图,Reliability and Robustness Demonstration Matrix(RRDM),captures and displays the key verification methods and all Critical Noise factor,s.,RRDM,吸取并显示了关键验证方法以及所有的关键干扰因素。,Self Assessment,自我评估,Vehicle Level DV&PV,整车级别的,DV&PV,Vehicle Level DV&PV,整车级别的,DV&PV,Verification and Validation of Vehicle level requirements,整车级别的验证和确认的要求,Illustrated with an example around a real world problem Transit FEAD,穿插了一个真实问题的范例,Transit FEAD,Problem,问题,Customers were experiencing problems after washing their vehicles or driving through water,顾客在洗车或开车涉水后出现问题,Global 8D,全球8,D,A Global 8D was conducted on the van jet spray washing problem that was looked at earlier and the root cause was identified as belt slip.,采取了全球8,D,方式来处理刚才看到的喷雾式洗车的问题，确定根本原因为皮带打滑。,Applying RED,应用,RED,Having developed a fix for the problem the team needed to verify the change,针对问题制定出解决方案，该小组需要验证其更改,Verification is a key part of the 8D process,just as it is for the PDP,验证是8,D,过程中的一个关键部分，就象其相对于,PDP,一