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1、Systems EngineeringFundamentals系統(tǒng)工程基本原理系統(tǒng)工程基本原理Parameter Design參數(shù)設(shè)計參數(shù)設(shè)計ToleranceDesign公差設(shè)計公差設(shè)計Global 8D全球全球8DFMEA失效模式后果與分析失效模式后果與分析ExperimentalDesign實驗設(shè)計實驗設(shè)計Reliability可靠性可靠性Applied Consumer Focus應(yīng)用顧客的關(guān)注應(yīng)用顧客的關(guān)注DV&PV設(shè)計驗證設(shè)計驗證&生產(chǎn)確認(rèn)生產(chǎn)確認(rèn)Statistical Engineering統(tǒng)計工程學(xué)統(tǒng)計工程學(xué)Course Structure課程結(jié)構(gòu)Introduction to

2、 DV&PV對設(shè)計驗證及生產(chǎn)確認(rèn)的介紹Tools for DV&PV設(shè)計驗證及生產(chǎn)確認(rèn)的工具Vehicle Level DV整車級別的設(shè)計驗證System/Sub-System Level DV系統(tǒng)/子系統(tǒng)級別的設(shè)計驗證Component Level DV零部件級別的設(shè)計驗證System/Sub-System Level PV系統(tǒng)/子系統(tǒng)級別的生產(chǎn)確認(rèn)Component Level PV零部件級別的生產(chǎn)確認(rèn)Summary總結(jié)Design Verification and Production Validation設(shè)計驗證和生產(chǎn)確認(rèn)Benefit to Ford Motor Company對福特

3、汽車公司的益處Design Verification and Production Validation設(shè)計驗證和生產(chǎn)確認(rèn)Design Verification:設(shè)計驗證as designed,a product will function in the manner that the customer expects.根據(jù)設(shè)計狀態(tài)，一個產(chǎn)品的功能要符合顧客所期望的方式。Production Validation:生產(chǎn)確認(rèn)as manufactured,a product functions in the manner that the customer expects and can be

4、manufactured at required volumes.根據(jù)制造狀態(tài)，一個產(chǎn)品的功能要符合顧客所期望的方式，而且能以所要求的產(chǎn)量進(jìn)行生產(chǎn)。DV&PV Within Systems Engineering系統(tǒng)工程內(nèi)的DV&PVVerification and Systemic Thinking驗證和系統(tǒng)思想Customer Wants顧客的需要顧客的需要Engineering Targets工程目標(biāo)工程目標(biāo)Design Verification設(shè)計驗證設(shè)計驗證Requirements Cascade需求逐級傳遞Working in a Systems Engineering conte

5、xt supports systemic thinking.系統(tǒng)工程中的工作支持系統(tǒng)的考慮 Opposite of Traditional approach to engineering.與傳統(tǒng)的工程方法相反Systems“V”Model系統(tǒng)V模型DV&PV is a requirements driven processDV和PV 是一個需求驅(qū)動的過程DV&PV is best conducted in a systems engineering context through the systems V.DV和PV在貫穿系統(tǒng)V模型的系統(tǒng)工程中得到最好的實施。VehicleSystemSub

6、-SystemComponentDefining Requirements定義需求The requirements cascade down the left side.需求的逐級傳遞如左側(cè)The cascade is an iterative process.該逐級傳遞是一反復(fù)的過程 VehicleSystemSub-SystemComponentITERATIVE PLANNINGTop Down由上到下由上到下Verification Bottom-up驗證自下至上Verification testing is implemented as a bottom-up sequential

7、process.驗證試驗是按照自下至上的順序過程執(zhí)行的Verification may include a combination of Analytical and physical tests.驗證可能包括分析試驗和物理試驗的組合。VehicleSystemSub-SystemComponentITERATIVE PLANNINGTop Down自上至下自上至下Bottom Up自下至上自下至上SEQUENTIAL DOING反復(fù)計劃工作順序DV&PV and PDSAPlanPlanPlan Plan計劃計劃 Do,Study,Act 做，研究，行動做，研究，行動 Do,Study,Ac

8、tDo,Study,ActDo,Study,ActVehicle整車整車System系統(tǒng)系統(tǒng)Sub-System子系統(tǒng)子系統(tǒng)Component零部件零部件Lower Level Interactions較低級別的相互作用Systems Approach to Manufacturing進(jìn)行制造的系統(tǒng)方法VehicleSystemSub-SystemComponentPlantAssemblyOperationMachineVehicle整車整車System系統(tǒng)系統(tǒng)Sub-System子系統(tǒng)子系統(tǒng)Component零部件零部件ManufacturingDesignPlant 工廠工廠Assemb

9、ly 裝配裝配Operation 操作操作Machine機器機器設(shè)計設(shè)計制制 造造Note-S5/P5 TimingFPDS TimingFPDS時間Vehicle level,System level&Sub-sys level1DVP Created生成整車，系統(tǒng)&子系統(tǒng)的DVPSub-sys level 2&ComponentDVP Created生成子系統(tǒng)級別2&零部件DVPFull DVP CreatedReqts&Targets Frozen生成完整的生成完整的DVP需求需求&目標(biāo)凍結(jié)目標(biāo)凍結(jié)Component testing complete零部件試驗完成Sub-system a

10、nd System testing complete子系統(tǒng)和系統(tǒng)試驗完成Vehicle testing mostly complete:Prelim Eng Sign Off整車試驗大部分完成：工程預(yù)簽發(fā)Vehicle testing complete:Final Eng Sign Off整車試驗完成：最整車試驗完成：最終工程簽發(fā)終工程簽發(fā)DVP completeDVP完成完成Design“V”and FPDS TimingDV&PV設(shè)計V形圖及FPDS時間的DV&PVLow低低High高高ActivityLevel活動級別活動級別Time時間時間=Design Verification設(shè)計驗

11、證設(shè)計驗證=Production&Process Validation生產(chǎn)生產(chǎn)&過程確認(rèn)過程確認(rèn)SISCPAPRCPLRJ1DV&PV and FPDSDV&PV are key requirements for sign off of a vehicle programDV和PV對于汽車項目的簽發(fā)來說是關(guān)鍵的需求Key Sign off milestones are:關(guān)鍵簽發(fā)節(jié)點是：(CC)DV(LR)PV(LS)PVInputs Used in the Verification and Validation Processes在驗證和確認(rèn)過程中使用的輸入DV Plan設(shè)計驗證設(shè)計驗證計劃計

12、劃SDS RequirementsSDS的需求的需求LegalRequirements法規(guī)要求法規(guī)要求EngineeringSpecifications工程技術(shù)規(guī)范工程技術(shù)規(guī)范Concept and Design FMEAs概念和設(shè)計概念和設(shè)計FMEAReal World Usage Profile真正的顧客使用狀況真正的顧客使用狀況P-DiagramP圖圖Existing DVPs現(xiàn)有的現(xiàn)有的DVPGeneric DVMs一般一般DVMHistorical 8Ds歷史上歷史上8DKey Life Tests關(guān)鍵壽命試驗關(guān)鍵壽命試驗DV&PV as Part of the Product Cr

13、eation Process DV 和PV作為產(chǎn)品創(chuàng)造過程的部分DV and PV confirm that Components and system robustly meet customer requirementsDV和PV確認(rèn)零部件和系統(tǒng)殷實可靠地符合顧客的需求。DV&PV testing is not exploratoryDV和PV試驗不是探險Testing should be against expected results not to find out“what happens if”試驗應(yīng)該是針對所預(yù)測的結(jié)果而不是去發(fā)現(xiàn)“如果會怎樣”DV&PV comes after

14、the design phase not during the design phaseDV 和PV 要在設(shè)計以后而不是在設(shè)計階段中進(jìn)行Introduction of the FEAD ExampleFEAD舉例介紹FEAD ExampleFEAD范例A single system the FEAD(Front End Accessory Drive)will be used to demonstrate DV&PV使用一個單獨的系統(tǒng)FEAD（前端附件驅(qū)動）來示范DV&PVThe Front End Accessory Drive(FEAD)How It WorksFEAD-它如何工作The

15、source of power in the vehicle is the engine.汽車內(nèi)動力的來源是發(fā)動機Part of the rotational power output from the engine needs to be transmitted to the FEAD accessories.來自發(fā)動機轉(zhuǎn)動動力輸出的一部分需要被傳輸?shù)紽EAD附件上。The FEAD transmits this energyFEAD傳輸該能量Design Verification at All Levels所有級別上的設(shè)計驗證Design Verification should occur

16、 at all levels with the emphasis being at the lower levels.設(shè)計驗證應(yīng)該重點放在較低級別的情況下在所有級別上進(jìn)行。Production Validation生產(chǎn)確認(rèn)It is important to verify the design 驗證設(shè)計是重要的It is equally important to validate that the production process used to manufacture the belt is able to produce belts to the design specificatio

17、n.確認(rèn)制造皮帶所使用的生產(chǎn)過程能夠生產(chǎn)出符合設(shè)計規(guī)范的皮帶同等地重要。For example,the belt as manufactured must be able to transmit the required amount of torque.例如，所制造的皮帶必須能轉(zhuǎn)送所要求大小的扭矩。Confirming Robust and Reliable Design Robustness確認(rèn)殷實及可靠的設(shè)計-殷實可靠性Methods Used in Efficient and Effective Verification在有效且高效的驗證中使用的方法Some of the import

18、ant methods used in efficient and effective verification and validation processes are 在有效且高效的驗證和確認(rèn)過程中所使用的一些重要方法是Robust Engineering Design Philosophy(RED)殷實的工程設(shè)計基本定律Ford Design Verification System(FDVS)福特設(shè)計驗證體系Testing Methodologies,試驗方法學(xué)Real World Usage Profiles and Duty Cycles真正全球顧客使用的概況和工況Accelerat

19、ed Tests,加速試驗Key Life Tests(KLT),關(guān)鍵壽命試驗Computer Aided Engineering(CAE)計算機輔助工程Design of Experiment(DoE).實驗設(shè)計Robust Engineering Design(RED)殷實的工程設(shè)計Robust Test Plans殷實可靠的試驗計劃Robust test plans in DV&PV incorporate Noise factors and their effects in order to ensure that the product will meet its design in

20、tent under all conditions.Noise factors can be grouped into five categories:為了確保該產(chǎn)品在所有條件下都符合其設(shè)計意圖，DV和PV中殷實的試驗計劃合并了干擾因素及其他們的影響。干擾因素可以分成5類：Piece-to-Piece Variation 件與件間的變差Changes Over Time 隨著時間過去的變化Customer Usage 顧客的使用External Environment 外部環(huán)境System Interactions 系統(tǒng)間的交互作用Noise Factor Management干擾因素的管理T

21、est/TechnologyChange試驗/技術(shù)更改Robust Designby ParameterDesign通過參數(shù)設(shè)計的牢靠設(shè)計Robust Designby IncreasedStrength通過增加強度的牢靠的設(shè)計Remove orReduce Noise去除或減小干擾CompensationDevice補償裝置Disguise theProblem隱蔽問題InternalEnvironment(SystemInteractions)內(nèi)部環(huán)境（系統(tǒng)交互作YesYesYesSystemFMEAYesSystemFMEAExternalEnvironment(Climate/Road

22、Conditions)外部環(huán)境（氣候/路況）YesYesYesNoPiece to PieceVariation件與件間的差異YesYesYesSPCChanges Over Time(Wear Out)隨著時間產(chǎn)生的變化（磨損）YesYesMaterialsEngineeringYesSystemFMEACustomer Usage顧客使用YesYesYesNoRobust Engineering Design殷實可靠的工程設(shè)計Robust Engineering Design(RED)is primarily a design tool殷實的工程設(shè)計主要是一種設(shè)計工具RED must be

23、 considered in DV&PV as RED will drive the type of DV&PV tests that need to be undertaken 在DV和PV中必須考慮到RED，因為RED將決定需要采取的DV&PV試驗的類型。RED focuses on identification and management of noise factorsRED著重于干擾因素的識別和管理Robust Engineering Design殷實可靠的工程設(shè)計RED is inherent in the systems V and runs through all phase

24、s of the VRED是系統(tǒng)V內(nèi)固有的，并且貫穿系統(tǒng)V的所有階段RED is a team based processRED是以小組為基礎(chǔ)的過程RED applies throughout Ford(Design and Manufacturing)and at suppliersRED應(yīng)用于整個福特（設(shè)計和制造）以及供應(yīng)商。Applying RED應(yīng)用REDRED allows testing at the lowest possible levelRED允許在最低可能性級別進(jìn)行測試Caution must be used必須使用警示Red Applied to Vehicle Leve

25、l Testing Red應(yīng)用于整車級別的測試RED Applied at Sub-System LevelRED應(yīng)用于子系統(tǒng)級別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.當(dāng)開發(fā)系統(tǒng)

26、/子系統(tǒng)或零部件級別的設(shè)計驗證方法時，重要的是確保要包括整個汽車環(huán)境中出現(xiàn)的系統(tǒng)交互作用干擾因素的影響。RED Applied at Component LevelRED應(yīng)用于零部件級別At the component level testing is most efficent but interactions with other components are lost零部件級別的試驗是最有效的，但失去了與其他零件的交互作用Test plans must compensate for this loss by reproducing the key stresses from the in

27、teractions試驗計劃必須通過再制造來自交互作用的關(guān)鍵應(yīng)力彌補這一損失Much component testing may be done at suppliers.許多零部件試驗可能在供應(yīng)商處進(jìn)行。Suppliers must apply the same RED methodolgies供應(yīng)商必須應(yīng)用相同的RED方法To support this,Ford engineers need to cascade noise factors to the supplier為了支持這個，福特工程師需要逐層傳遞干擾因素直到供應(yīng)商RED in the Design Process設(shè)計過程中的RE

28、D Noise Factors干擾因素Piece to Piece件與件件與件Aging/Wear老化老化/磨損磨損Customer Usage顧客使用顧客使用Environment環(huán)境環(huán)境Subsystem Interaction子系統(tǒng)交互作用子系統(tǒng)交互作用Sources that disrupt idealfunction that can not be controlled(e.g.column friction)不可控制的，破壞理想功能的來源（例如.轉(zhuǎn)向柱磨擦）P-DiagramReliability Checklist 可靠性檢查清單Reliability/RobustnessDem

29、onstration Matrix 可靠性/殷實可靠性實證矩陣圖Signal信號Energy put intothe systems tomake it work(e.g.Steeringwheel angle)能量進(jìn)入系統(tǒng)使其工作（例如.方向盤轉(zhuǎn)角）Control FactorsFeatures of the designthat can be controlled(e.g.Torsion bar rate)控制因素可以控制的設(shè)計特性（例如.扭桿比率）ErrorStates異常狀態(tài)Undesirable outputor Failure Modes(e.g.Tire slip)不需要的輸出或

30、失效模式（例如.輪胎打滑）Error States異常狀態(tài) NoiseFactors干擾因素 AvailableTests有用的試驗DVP&RTest試驗CriticalNoiseFactors關(guān)鍵干擾因素Failure mode totest traceability失效模式試驗可追查性 Noise FactorsManagement StrategySystem(Steering System)系統(tǒng)（轉(zhuǎn)向系統(tǒng)）IdealFunction理想功能Primary intendedfunction of the design設(shè)計的主要意圖功能(e.g.Lateral accelerationof

31、 vehicle)（例如.車輛的橫向加速度）FMEASDSWCRDOE(if necessary如果有必要)KLTWCRFailureMode失效模式DemonstratedResult論證的結(jié)果In scope范圍內(nèi)FDVSFDVSPrevention of Mistake Reoccurrence錯誤再次發(fā)生的預(yù)防Campaign Prevent 防召回Lessons Learned 吸取的教訓(xùn)Vigilance 警惕.干擾因素管理策略Ford Design Verification System福特設(shè)計驗證系統(tǒng)Ford Design Verification System FDVS福特設(shè)

32、計驗證系統(tǒng)-FDVSFDVS is a computer based system to create and manage requirements driven DV plans.FDVS是一計算機為基礎(chǔ)的系統(tǒng)，生成并管理驅(qū)動DV計劃的需求。FDVS includes a number of generic requirements and Design Verification Methods(DVMs)FDVS包括許多一般需求和設(shè)計驗證方面（DVM）安全法規(guī)安全法規(guī)法人的要求法人的要求技術(shù)規(guī)范技術(shù)規(guī)范設(shè)計驗證方法設(shè)計驗證方法整車要求整車要求（項目專有）（項目專有）項目專有的設(shè)項目專有的

33、設(shè)計驗證計劃計驗證計劃系統(tǒng)要求系統(tǒng)要求（項目專有）（項目專有）DVM（項目專有）項目專有）Design Verification Method設(shè)計驗證方法Within FDVS requirements are verified using Design Verification Methods(DVMs)在FDVS內(nèi)，使用設(shè)計驗證方法（DVM）驗證需求DVMs contain all the information required to conduct testing and record resultsDVM包括所有要求試驗和記錄結(jié)果的信息Existing and Generic DVM

34、s can be used as a starting point to develop program DMVs,but they must be reviewed現(xiàn)有的和一般的DVM能作為一個開始點用以開發(fā)項目的DMV，但是它們必須進(jìn)行審核Testing Methodologies試驗方法學(xué)Types of Test試驗的類型There are three general types of testing that can be implemented for either Design Verification or Production Validation:有三種可以在設(shè)計驗證或生產(chǎn)

35、確認(rèn)中實施的一般試驗類型Testing to Bogey 標(biāo)準(zhǔn)測試Testing to Failure 測試至失效Testing Functional Degradation 測試功能退化Test to BogeyMinimum Acceptable Function最小可接受功能最小可接受功能Function功能功能Time/Cycles/Miles時間時間/循環(huán)循環(huán)/里程里程Bogey失效柱狀圖失效柱狀圖Test to Failure測試至失效Failure Time DistributionMinimum Acceptable Function最小可接受功能最小可接受功能Function

36、功能功能Time/Cycles/Miles時間時間/循環(huán)循環(huán)/里程里程失效時間分布圖失效時間分布圖Degradation Testing退化測試Minimum Acceptable Function最小可接受功能最小可接受功能Function功能功能Time/Cycles/Miles時間時間/循環(huán)循環(huán)/里程里程BogeyComplete DegradationHistoryExample:Functional Degradation of Three Design Alternatives范例：三種設(shè)計方案的功能退化CBATest Level Comparison測試水平比較Bogey標(biāo)準(zhǔn)Fa

37、ilure 失效Information Quality信息質(zhì)量信息質(zhì)量Cost成本成本Higher較高較高Lower較低較低Higher較高較高Lower較低較低Degradation 退化Test Precision測試精度失效概率失效概率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.對于特定的可靠性預(yù)測，統(tǒng)計可信度是一種

38、總體真實可靠性等于或大于預(yù)測情況的概率Large Sample大樣本大樣本Reduced Sample減少的樣本減少的樣本Min:1 sample/failure mode最?。?個樣本/失效模式Severity/Acceleration of key noises in tests試驗中關(guān)鍵干擾的嚴(yán)重度試驗中關(guān)鍵干擾的嚴(yán)重度/加速加速Knowledge of prior perform-ance under similar conditions相似條件下優(yōu)先性相似條件下優(yōu)先性能的知識能的知識Normal通常通常High高高High高高Low低低FailureSeverity&Occurren

39、ce失效嚴(yán)重度失效嚴(yán)重度&發(fā)生發(fā)生Test Level測試水平測試水平BogeyFailureDegradationReal World Usage Profiles真正顧客使用概況Types of Customer Usage顧客使用的類型Normal use一般使用Misuse誤用Abuse?濫用？濫用？Normal Use一般使用Misuse誤用Abuse濫用Data Sources數(shù)據(jù)來源Yourself自身自身Instrumentation儀器儀器Existing Data現(xiàn)有數(shù)據(jù)現(xiàn)有數(shù)據(jù)Observation觀察觀察Actual Customer Usage真正顧客使用5%Tota

40、l95th Percentile use95th 百分點使用 Core Target Customer(Marketing)核心目標(biāo)顧客（市場）Stress受力狀態(tài)受力狀態(tài)Europe歐洲歐洲Usage Profile and Customer Duty Cycle使用概況及顧客工況Usage Profile使用概況使用概況Duty Cycle工況工況How often the customer opens a window顧客開啟窗戶的頻次如何Number of switch activations or motor running times for the window motor 開關(guān)

41、的次數(shù)或窗戶電機運轉(zhuǎn)次數(shù)Climate or outside temperature ranges in which the vehicle operates車輛運轉(zhuǎn)時的氣候或外界溫度的范圍Air conditioning system frequency of operation and load空調(diào)系統(tǒng)的運轉(zhuǎn)頻次和負(fù)荷Duty Cycle Example工況范例同步齒形帶發(fā)動機工況同步齒形帶發(fā)動機工況綠線：一般顧客綠線：一般顧客紅線：苛刻顧客紅線：苛刻顧客注：皮帶負(fù)荷在低轉(zhuǎn)注：皮帶負(fù)荷在低轉(zhuǎn) 速時更苛刻速時更苛刻Accelerated Testing加速測試Accelerated Test

42、ing加速測試Purpose:目的:Accumulate product stress history in a short period of time 在短時間內(nèi)累積產(chǎn)品應(yīng)力史Shorten verification time&reduce development costs縮短驗證時間&減少開發(fā)成本Accelerated Testing Methods加速測試方法Load Frequency over a Specified Test Procedure 在指定的試驗規(guī)程上加大加載頻次在指定的試驗規(guī)程上加大加載頻次010020030040030%60%100%Percent Freque

43、ncy of Occurrence發(fā)生頻次的百分比發(fā)生頻次的百分比Load載荷載荷Normal Load正常負(fù)載正常負(fù)載Increased Load加大負(fù)載加大負(fù)載Define Accelerated Test based on this portion of procedure with increased loads50 mph Freeway 50 mph高速公路高速公路Climbing hill in 1st gear一檔爬山一檔爬山以加大的載荷在這部分試驗規(guī)程的基礎(chǔ)上定以加大的載荷在這部分試驗規(guī)程的基礎(chǔ)上定義加速測試義加速測試Accelerated Testing Cautions加

44、速測試警示Correlate acceleration to real world deterioration使其加速形式與真正顧客使用的退化情況相關(guān)聯(lián)Prevent unrepresentative failure modes預(yù)防不具備代表性的失效模式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關(guān)鍵壽命試驗Key Life Tests關(guān)鍵壽命試驗Key Life Tests focus on the key stress(es)which drive loss of function and/or

45、failure mechanisms associated with real world usage.關(guān)鍵壽命試驗著重于會促使真正顧客使用相關(guān)的功能損失關(guān)鍵壽命試驗著重于會促使真正顧客使用相關(guān)的功能損失和和/或失效機理的關(guān)鍵應(yīng)力或失效機理的關(guān)鍵應(yīng)力Key Life Tests關(guān)鍵壽命試驗A Key Life Test:一個關(guān)鍵壽命試驗Is based on the RWUP 是以RWUP為基礎(chǔ)的Provides a tool to evaluate product reliability 提供了一個工具以評估產(chǎn)品的可靠性Allows comparison of designs with be

46、nchmarked competitive products so that the best design can be identified 使其與競爭產(chǎn)品進(jìn)行設(shè)計的比較，從而可以確定最佳設(shè)計Validates models and assumptions in the design process 在設(shè)計過程中確認(rèn)模型和設(shè)想Validates the design 確認(rèn)設(shè)計Key Life Tests關(guān)鍵壽命試驗IS是是IS Not否否Reliability and Robustness Demonstration Matrix可靠性和殷實可靠性實證矩陣圖Reliability and

47、Robustness Demonstration Matrix可靠性和殷實可靠性實證矩陣圖Reliability and Robustness Demonstration Matrix(RRDM)captures and displays the key verification methods and all Critical Noise factors.RRDM吸取并顯示了關(guān)鍵驗證方法以及所有的關(guān)鍵干擾因素。Self Assessment自我評估Vehicle Level DV&PV整車級別的DV&PVVerification and Validation of Vehicle level

48、 requirements整車級別的驗證和確認(rèn)的要求Illustrated with an example around a real world problem Transit FEAD穿插了一個真實問題的范例Transit FEADProblem問題Customers were experiencing problems after washing their vehicles or driving through water顧客在洗車或開車涉水后出現(xiàn)問題Global 8D全球8DA Global 8D was conducted on the van jet spray washing

49、problem that was looked at earlier and the root cause was identified as belt slip.采取了全球8D方式來處理剛才看到的噴霧式洗車的問題，確定根本原因為皮帶打滑。Applying RED應(yīng)用REDHaving developed a fix for the problem the team needed to verify the change針對問題制定出解決方案，該小組需要驗證其更改Verification is a key part of the 8D process,just as it is for the

50、 PDP驗證是8D過程中的一個關(guān)鍵部分，就象其相對于PDP一樣。To do this they need to apply RED principles to the verification為了進(jìn)行該工作，他們需要把RED的原理應(yīng)用到驗證上。Verifying Robustness驗證殷實可靠性Existing verification methods used as a starting point使用現(xiàn)有的驗證方法作為起點From studying the data,the team new that the existing DVMs were insufficient通過研究該數(shù)據(jù)，

51、小組發(fā)現(xiàn)現(xiàn)有的DVM還不充分New DVMs must include RED considerations新的DVM必須包括RED需要考慮的事項Revised DVM修正的DVMThe DVMs were then modified.于是對DVM進(jìn)行修改FEAD子系統(tǒng)設(shè)計驗證方法子系統(tǒng)設(shè)計驗證方法目標(biāo)：目標(biāo)：驗證驗證FEAD系統(tǒng)存有水時性能的殷實可靠性系統(tǒng)存有水時性能的殷實可靠性試驗描述：在試驗描述：在10kph至至50kph之間每次增加之間每次增加5kph的車速，開車通過的車速，開車通過25，50，75以及以及100mm深的水洼深的水洼可測量的可測量的/觀察：曲軸皮帶輪和附件皮帶輪之觀察：

52、曲軸皮帶輪和附件皮帶輪之間的差速間的差速驗收標(biāo)準(zhǔn)：差速小于驗收標(biāo)準(zhǔn)：差速小于5%需要的資源及試驗設(shè)備：水洼，在已知的曲軸需要的資源及試驗設(shè)備：水洼，在已知的曲軸/發(fā)動機轉(zhuǎn)速下對附件皮帶輪轉(zhuǎn)速的整車評估發(fā)動機轉(zhuǎn)速下對附件皮帶輪轉(zhuǎn)速的整車評估Planning and Implementing Verification and Validation計劃并實施驗證和確認(rèn)Planning occurs down the V plan the vehicle level first沿著V形方式向下作計劃首先計劃整車級別Verification and Validation occurs up the V

53、Verify and Validate the vehicle last沿著V形方式向上進(jìn)行驗證和確認(rèn)最后驗證和確認(rèn)整車Global 8D and DV&PV全球8D和DV&PVGlobal 8D studies on previous similar products or processes help identify potential error states對以前相似產(chǎn)品或過程的全球8D研究幫助識別潛在的異常狀態(tài)This is an important input to the design of verification methods for a new product or m

54、anufacturing process.對于一個新產(chǎn)品或制造過程，這是驗證方法設(shè)計中的一個重要的輸入Verification methods must demonstrate that these error states do not recur in the new product or process.驗證方法必須證明這些異常狀態(tài)不會在新的產(chǎn)品和過程中再次發(fā)生。Self Assessment自 評FEAD Sub-SystemFEAD子系統(tǒng)A FEAD system is to be developed for a new vehicle program 為一新車項目開發(fā)一個FEAD系

55、統(tǒng)Sub-System Level Design Verification子系統(tǒng)級別設(shè)計驗證Form a cross functional team:組成一個交叉功能的小組Design設(shè)計Testing試驗Manufacturing制造Supplier供應(yīng)商CAEQuality質(zhì)量Reliability可靠性Aim to verify at the lowest possible level on the V瞄準(zhǔn)V模形最低可能級別上進(jìn)行驗證FEAD Design Verification PlanFEAD設(shè)計驗證計劃DV PlanDV計劃計劃SDS RequirementsSDS要求要求Leg

56、alRequirements法規(guī)要求法規(guī)要求EngineeringSpecifications工程技術(shù)規(guī)范工程技術(shù)規(guī)范Concept and Design FMEAs概念和設(shè)計概念和設(shè)計FMEAReal World Usage Profile真實顧客使用概況真實顧客使用概況P-DiagramP 圖圖Existing DVPs現(xiàn)有現(xiàn)有DVPGeneric DVMs一般一般DVMHistorical 8Ds歷史上的歷史上的8DKey Life Tests關(guān)鍵壽命試驗關(guān)鍵壽命試驗FEAD Function and OperationFEAD功能和運行Ideal function of the FEA

57、D is to transfer torque to the accessoriesFEAD的理想功能是把扭矩傳遞給附件Irregularity in rotation is a key noise旋轉(zhuǎn)不規(guī)則是一個關(guān)鍵的干擾The tensioner compensates for the noise張緊輪對該干擾進(jìn)行補償The correct functioning of the tensioner is a priority for the FEAD team張緊輪的正確機能對于前端驅(qū)動附件組是最首要的。Customer Requirements顧客需求FEAD SDS Requireme

58、nt FEAD SDS 要求Belt span vibration does not exceed 10%of belt span and meets system clearance requirements to other components.Maximum tensioner amplitude leaves 10%of total travel clear to end stop in both directions.相帶寬度振動不超過相帶寬度的10%，要符合與其它零部件間的系統(tǒng)間隙要求。最大張緊輪振幅要與兩端止點留有總行程10%的間隙余量。A DVM is required to

59、 verify this requirement 需要DVM來驗證這一要求Existing DV Test現(xiàn)有的DV試驗There is an existing DVM for the requirement對該要求有一現(xiàn)有的DVMThe team need to assess if this DVM is appropriate小組需要評估該DVM是否合適RED in Sub-System DV子系統(tǒng)DV中的REDSystem and Sub-System level DVMs must include consideration of noises系統(tǒng)和子系統(tǒng)級別的DVM必須包括干擾需要考

60、慮的事項In the FEAD example excessive belt vibration was identified as a critical error state.在FEAD的范例中，過多的皮帶振動被認(rèn)為是一個關(guān)鍵的異常狀態(tài)The DVM was assessed to be inadequate for this failure mode in the presence of noise評定該DVM在有干擾存在時對這個失效模式來說是不充分的FEAD Acceptance CriteriaFEAD驗收標(biāo)準(zhǔn)The acceptance criteria was assessed

61、by the team and found to cover the SDS requirement,but needed minor improvement.小組評估該驗收標(biāo)準(zhǔn)，發(fā)現(xiàn)涵蓋了SDS的要求，但仍需要小的改進(jìn)。Application of REDRED的應(yīng)用The team needs to consider all key noise factors小組需要考慮所有關(guān)鍵干擾因素The key noise factors were identified as:確認(rèn)關(guān)鍵噪聲為：Carryover tensioner in a new environment在新的環(huán)境中借用張緊輪裝置A

62、ccessory loading附加載荷These Noise factors were not taken into account in the previous DVM.在以前的DVM中沒有考慮這些干擾因素Previous Robustness Studies之前的殷實可靠性研究Previous robustness studies are a key source of information之前的殷實可靠性研究是信息的關(guān)鍵來源The team can use this information for their design and testing小組可以把這一信息用于設(shè)計和測試Th

63、is type of information can come from similar or different vehicles這種類型的信息可以來自相似或不同的車輛These strategies were incorporated into the new design.這些策略可以并入新的設(shè)計中Check of DVM ObjectiveDVM目標(biāo)的檢查The design team did not think that the objective in the existing DVM covered robustness設(shè)計小組不認(rèn)為現(xiàn)有DVM中的目標(biāo)涵蓋了殷實可靠性DVM Ob

64、jective revised to include robustness修正DVM目標(biāo)，使其包括殷實可靠性DVM Test MethodDVM試驗方法The team then turned its attention to the test method 然后小組把注意力轉(zhuǎn)向試驗方法This method had been used on previous programs but these programs had experienced failures 這個方法在原來的項目中曾被使用過，但是這些項目已經(jīng)出現(xiàn)過失效Applying RED應(yīng)用REDA RED approach,was

65、 used to modify the DVM.采用RED的方法修改DVMA G8D study had been conducted to resolve the belt squeal problem on the previous vehicle.采用了全球8D的研究來解決原來車輛上皮帶尖叫的問題The G8D is key information for RED全球8D對于RED是關(guān)鍵的信息Global 8D Summary Report全球8D總結(jié)報告Global 8D Summary Findings全球8D總結(jié)調(diào)查結(jié)果5：選擇永久糾正措施：采用參數(shù)設(shè)計實驗以增加在附加載荷的干擾因

66、素存在時FEAD系統(tǒng)的殷實可靠性驗證：從產(chǎn)品開發(fā)實驗的確認(rèn)來確定FEAD的殷實可靠性增加了%效果100%Confirming Robustness確定殷實可靠性The successful improvement of the FEAD robustness to different accessory loading conditions meant that one of the teams priorities was to ensure that this robustness would be confirmed by the revised DVM.對不同附加載荷的條件下FEAD殷實可靠性的成功改進(jìn)意味著小組優(yōu)先考慮的事項之一是確保該殷實可靠性會通過修正的DVM來確認(rèn)。Design FMEA Review計劃FMEA評審項目功能潛在失效模式潛在失效后果潛在原因/失效機理保持皮帶張緊力張緊力降低過多的相帶寬度振動。指定阻尼帶的不適當(dāng)?shù)牟牧咸匦?。阻尼帶材料特性的退化P-Diagram as Source of InformationP圖作為信息來源輸入信號輸入信號理想功能理想功