1、1.1Philips FMEA Failure Mode and Effect AnalysisFailure Mode and Effect Analysis1.2Content of the coursevIntroductionvProduct - FMEAvBlockdiagram , functiontree vProcess - FMEAvProcess-flowdiagram (macro-level) , micro-levelvFacilitatorskills1.3FMEA IntroductionvWhy FMEAs?vDefinition, Purpose, Types

2、, BenefitsvTeam Approach1.4Why FMEAs?vAppropriate recommended actions may not have been taken.vSavings in engineering time.vReduction of changes immediately before productionstart (Commercial Release).1.5FMEA DefinitionvIdentify potential failure modesvPrioritize actionsvDocument the process.Structu

3、red group of activities which. Structured group of activities which. 1.6FMEA PurposeFailuresTimeC R(Productionstart)FMEA1.7vRate severity of failure modesvIdentify actions to reduce occurencevTest adequacy of controlsFMEA PurposeFMEAs are intended to .FMEAs are intended to . 1.8FMEA Types OpticalPro

4、duct-FMEA MechanicalProcess-FMEA Electrical MechanicalElectricalOptical1.9FMEA SessionsFMEA onEVT ModelFMEA onFirst MechanicalWorking ModelFMEA onPart FilesFMEA onL1 Board(ftbo L2)FMEA onL0 Board(ftbo L1)FMEA onL0 Schematics(ftbo L0)FMEA onArchitecturesMechanicalElectricalFMEA onchosenArchitecture1.

5、10Benefits Product-FMEAsvAssess failure mode effects on all customers.vAids in evaluating testspecificationsvEvaluation of design relating to DFM DFA DFT vIncreases the possibility to detect possible failure modes.ProcesProduct1.11Voordelen Proces-FMEAsvAssess effects on all customersvIdentifies pot

6、ential manufacturing and assembly causes to focus controls on reducing occurrence or increasing detection.DesignProces1.12Generating FMEAs FMEAsWho initiates?Failure Mode and Effect AnalysisWho updates?Who is FMEA-customer?Startingdate/revisiondate?When completed?How docu-mented?When to discard?Who

7、prepares?1.13Managing FMEAs vModification to a product or process is plannedvComponent is to be used in new environmentvCustomer rejectionsFMEAs are living documentsFMEAs are living documents and are updated . and are updated .1.14Product-FMEA ContentvDefine FMEA-team vDefine scopevDescribe function

8、s Brainstorming Function Trees1.15Product-FMEA TeamDesign-EnginieerProduction/ process-enginieerCore-team Representitives from: development production quality purchase testdept. .SupportteamFacilitator1.16Product-FMEA ScopevCreate BlockdiagramvIdentify the boundery for AnalysisvConfirm composition o

9、f support team.Once coreteam is established .1.17BlockdiagramComponent/AssemblyPart XPart YPart ZServiceOther systemsAssemblyUserScrewWeldAdhesive1.18Example blockdiagram (Settop Wildfire)FrontKlickedDisplay PCBPSUSmartcard PCBFrameCoverKlickedKlickedScrewedScrewed1.19Determine FunctionsvDescribes t

10、he intent of the designvMust be measureble or set at an actionable levelvRepresents all wants, both spoken and unspoken.What are the functions of the design?1.20VerbIndicates action, occurrence, beingGenerateControlDisplayNounIndicates what the action relates toDescribe Functionlightspeedinformation

11、1.21Describe FunctionsThought starters .vSatisfy uservAttract uservGuarantee durabilityvEasy to reparevSafety requirements1.22Brainstorming1.23Functiontree vProvides an organized approach to identify the essential features of a productvDefines all spoken and unspoken requirementsvProvides the team w

12、ith a clear overview of all the functions of the product.1.24FirstlevelSecondLevelConstructing FunctiontreesThirdLevelHOW?WHY ?1.25DisplayInformationFunctiontree Frontbutton (Settop) HOW?Must be printable and resistance te wear.PQR-Cleantest. Tekst clearly visibleafter x-times cleaning.WHY?1.26Guide

13、linesvBrainstorm all functions (VERB-NOUN)vDocument individual functions by asking“How is this function achieved?”vRepeat left to right, until actionable levelvWork right to left and check structure by asking “Why is this function included?”1.27Product-FMEA FunctionsDescriptionLevel 1DescriptionLeve

14、l 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible afterPQR-testMCMLP1.28Potential failure ModesNo functionPartial functionFailure Mode TypeExampleNot operationalNot all of function operating1.29Failure Modes: FrontbuttonNo function No tekst availablePartial func

15、tion Tekst partial availableFunction: Tekst clear visible after 100 x cleaning.Failure Mode Type Example1.30Product-FMEA Modes of failureDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLP1.31Ef

16、fects failureWhat are the effects of the failure relating to:- another part- the complete assembly- the customer- the enduser- the governmental regulations1.32Product-FMEA Tabel of effectsFailureModeTekstunread-ableFrontbuttonCompleteAssemblyDifficultto saleCustomerDissatisfiedEnduserDissatisfiedGov

17、ernmental regulationNoneAnotherpartNone1.33Product-FMEA Effects of failureDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfied1.34Severity (Weight

18、factor)What is the severity of the effects?1.35Criteria: Severity of effectClassEffectAccepted failureDNoneSafety failureSUnacceptable riskNon-conforming with safetyCorrection is nescessary ARelative big riskCorrectie is recommendedBrisicoCorrectie is nuttigCRatingcriteria voor Severity (Weightfacto

19、r)Minimum riskCorrectie is usefullC1.36Frontbutton/Tekst readable after PQR-testFailureModeTekst unreadableEffects Assembly: unsaleable (A)Customer: Dissatisfied(A)Gov.Reg.: None (D)ARating of Weightfactor exampleSev.PartFunction1.37Product-FMEA WeightfactorDescriptionLevel 1DescriptionLevel 2Functi

20、onMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedA1.38Potential Cause of Failure A weakness in the design with a failure mode as effect.1.39Manufacturing misbuilds Due to design Deficie

21、ncies+-+-1.40Manufacturing misbuildsRobust Design+-+-1.41Cause of failureTekst unreadableInkt of poor qualityTekst on wrong location1.42Cause of failure “Why”-ladderDesignrequirementWHY?level 1WHY?level 2WHY?level 3Inkt doesnt stickSurface roughness not ok. 1.43Sentencing TechniqueFailure ModeCould

22、result inEffectDue toCause1.44Sentencing Technique - Example TekstunreadableCould result inDissatisfiedcustomerDue toSurfaceroughness(designreq.)1.45Product-FMEA CauseDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-te

23、stTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location1.46Product-FMEA Occurrence What is the possibility thatthe failure occurrs?1.47Possible Failure RatesRankingProbability of failure 1 of 20Very highModerate 1 of 400 1 of 15000Low 1 of 1500045321 1 of 31.

24、48Product-FMEA OccurrenceDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location51.49Produkt-FMEA Action/SolutionWhat are poss

25、ible actions to:- eliminate the failure- reduce effect - reduce occurrence.1.50Product-FMEA Action/SolutionDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustome

26、rdissatisfiedATekston wrong location5No tekst on buttonsJD1.51Define Evolutionfactor vCause not known4vSolution not known3vSolution not evaluated2vSolution not implemented1vSolution implemented01.52Product-FMEA EvolutionfactorDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseActi

27、on/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location5No tekst on buttonsJD11.53Risk evaluationvSeverity (Weightfactor) vOccurrence vEvolutionfactorvRisk maturity - grid1.54Maturity Grid Weight Fact

28、orEvolution FactorEvolution FactorSABCD012340123437 5451231.55Product-FMEA Electrical (Example)DescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.PFront endTunerPut-through selected signal (SD12XX)Tuner gets disturbed by noise generated by 14-18V generationTune

29、r gives bad signal throughALow frequent noise is not filtered5MLMCAdd bead in LNBA line, right next to tunerGD21.56Proces - FMEA ContentvFMEA-team vDefine scopevDescribe functions1.57Proces-FMEA TeamProduction/- process-engineerDesign-engineerCore-team Representatives of :ProductdevelopmentProcess-d

30、evelopmentProductionQualityPurchaseOwner of the next process .Support-teamFacilitator or application engineer1.58Process-FMEA ScopevCreate flow-diagram vDefine scopevDefine support-team.1.59Process-FMEA (Example)DescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionRes

31、p.PGlueGlue with cyano-acrylateJoin partsCyanoacrylate not well curedLifetime problemsAGlue volume to high5MLMCUse activatorJD21.60FMEA Tasks & Responsibilities.Tasks & Responsibilities.1.61FMEA TeamleadervPreparation of the FMEA - sessiondistribution of the product to the participants 1 or

32、2 weeks before the meeting to gather all the relevant information. Prepare (fill-in) FMEA-worksheet as good as possible (functions, failure modes, . )Tasks of the teamleader:Tasks of the teamleader:1.62FMEA TeamleadervPreparation of the FMEA - session:Distribute/display important information: agenda

33、, FMEA-methodDefine tasks of the team-members: Who is the teamleader, facilitator, timekeeper, secretary?Tasks of the teamleader:Tasks of the teamleader:1.63FMEA FacilitatorvHelps preparing the FMEA - sessionvSupports the teamleadervTakes care that FMEA-metholodgy is correctly usedvTakes care of the

34、 team - process.Tasks of the facilitator:Tasks of the facilitator:1.64FMEA FacilitatorvPreparation of the FMEA - sessionpreparation together with the team-leaderdefine agenda for the meetingproduct-FMEA : create blockdiagramprocess-FMEA: create flowdiagramdefine participants (6-8 persons).Tasks of t

35、he facilitator:Tasks of the facilitator:1.65FMEA FacilitatorvSupporting the teamleader:the teamleader is focussed on the project (timing,technical sollutions,). The facilitator takes care for correct applying of the FMEA-proces.Supports the teamleader with the preparation of the meeting and during t

36、he FMEA-session.Tasks of the facilitator:Tasks of the facilitator:1.66FMEA FacilitatorvTaking care for correct applying FMEA-metholodgy:are funktions correct written down (verb/noun)?are all failure modes mentioned,listed?are effects of the failure modes correct? (no confusion between causes and eff

37、ects).Tasks of the facilitator:Tasks of the facilitator:1.67FMEA FacilitatorvTaking care for correct applying FMEA-metholodgy:Is for each effect a weigthfactor mentioned, for each cause the probability and for each sollution the evolutionfactor definedIs the FMEA-worksheet completely filled-in (actions, responsible person, date)?Tasks of the facilitator: Tas