PHILIPS-FMEA.ppt

PhilipsFMEA FailureModeandEffectAnalysis Contentofthecourse IntroductionProduct FMEABlockdiagram functiontreeProcess FMEAProcess flowdiagram macro level micro levelFacilitatorskills FMEA Introduction WhyFMEA s Definition Purpose Types BenefitsTeamApproach WhyFMEA s Appropriaterecommendedactionsmaynothavebeentaken Savingsinengineeringtime Reductionofchangesimmediatelybeforeproductionstart CommercialRelease FMEA Definition IdentifypotentialfailuremodesPrioritizeactionsDocumenttheprocess Structuredgroupofactivitieswhich FMEA Purpose Failures Time RateseverityoffailuremodesIdentifyactionstoreduceoccurenceTestadequacyofcontrols FMEA Purpose FMEA sareintendedto FMEA Types Optical Product FMEA Mechanical Process FMEA Electrical Mechanical Electrical Optical FMEASessions Benefits Product FMEA s Assessfailuremodeeffectsonallcustomers AidsinevaluatingtestspecificationsEvaluationofdesignrelatingtoDFMDFADFTIncreasesthepossibilitytodetectpossiblefailuremodes Proces Product Voordelen Proces FMEA s AssesseffectsonallcustomersIdentifiespotentialmanufacturingandassemblycausestofocuscontrolsonreducingoccurrenceorincreasingdetection Design Proces GeneratingFMEA s FMEAs Whoinitiates FailureModeandEffectAnalysis Whoupdates WhoisFMEA customer Startingdate revisiondate Whencompleted Howdocu mented Whentodiscard Whoprepares ManagingFMEA s ModificationtoaproductorprocessisplannedComponentistobeusedinnewenvironmentCustomerrejections FMEA sarelivingdocumentsandareupdated FMEA TeamApproach Support team Product FMEA Content DefineFMEA teamDefinescopeDescribefunctionsBrainstormingFunctionTrees Product FMEA Team Product FMEA Scope CreateBlockdiagramIdentifythebounderyforAnalysisConfirmcompositionofsupportteam Oncecoreteamisestablished Blockdiagram Component Assembly Screw Weld Adhesive Exampleblockdiagram SettopWildfire Front Klicked DisplayPCB PSU SmartcardPCB Frame Cover Klicked Klicked Screwed Screwed DetermineFunctions DescribestheintentofthedesignMustbemeasurebleorsetatanactionablelevelRepresentsallwants bothspokenandunspoken Whatarethefunctionsofthedesign GenerateControlDisplay DescribeFunction lightspeedinformation DescribeFunctions Thoughtstarters SatisfyuserAttractuserGuaranteedurabilityEasytorepareSafetyrequirements Brainstorming Functiontree ProvidesanorganizedapproachtoidentifytheessentialfeaturesofaproductDefinesallspokenandunspokenrequirementsProvidestheteamwithaclearoverviewofallthefunctionsoftheproduct ConstructingFunctiontrees DisplayInformation Functiontree Frontbutton Settop Guidelines Brainstormallfunctions VERB NOUN Documentindividualfunctionsbyasking Howisthisfunctionachieved Repeatlefttoright untilactionablelevelWorkrighttoleftandcheckstructurebyasking Whyisthisfunctionincluded Product FMEA Functions DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test MC ML P PotentialfailureModes NofunctionPartialfunction FailureModeTypeExample NotoperationalNotalloffunctionoperating FailureModes Frontbutton NofunctionNotekstavailablePartialfunctionTekstpartialavailable Function Tekstclearvisibleafter100 xcleaning FailureModeTypeExample Product FMEA Modesoffailure DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P Effectsfailure Whataretheeffectsofthefailurerelatingto anotherpart thecompleteassembly thecustomer theenduser thegovernmentalregulations Product FMEA Tabelofeffects FailureModeTekstunread able Frontbutton CompleteAssemblyDifficulttosale CustomerDissatisfied EnduserDissatisfied GovernmentalregulationNone AnotherpartNone Product FMEA Effectsoffailure DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P AssemblynotpossibletosaleCustomerdissatisfied Severity Weightfactor Whatistheseverityoftheeffects Criteria Severityofeffect Class Effect Acceptedfailure D None Safetyfailure S Unacceptablerisk Non conformingwithsafety Correctionisnescessary A Relativebigrisk Correctieisrecommended B risico Correctieisnuttig C RatingcriteriavoorSeverity Weightfactor Minimumrisk Correctieisusefull C Frontbutton TekstreadableafterPQR test FailureModeTekstunreadable EffectsAssembly unsaleable A Customer Dissatisfied A Gov Reg None D A RatingofWeightfactor example Sev Part Function Product FMEA Weightfactor DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P AssemblynotpossibletosaleCustomerdissatisfied A PotentialCauseofFailure Aweaknessinthedesignwithafailuremodeaseffect Manufacturingmisbuilds DuetodesignDeficiencies Manufacturingmisbuilds RobustDesign UseFishboneDiagram Causeoffailure Tekstunreadable Inktofpoorquality Tekstonwronglocation Causeoffailure Why ladder Designrequirement WHY level1 Tekstunreadable WHY level2 WHY level3 Inktdoesn tstick Surfaceroughnessnotok SentencingTechnique FailureMode SentencingTechnique Example Tekstunreadable Product FMEA Cause DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P AssemblynotpossibletosaleCustomerdissatisfied A Tekstonwronglocation Product FMEA Occurrence Whatisthepossibilitythatthefailureoccurrs PossibleFailureRates Ranking Probabilityoffailure 1of20 Veryhigh Moderate 1of400 1of15000 Low 1of15000 4 5 3 2 1 Ratingcriteriaoccurrence 1of3 Product FMEA Occurrence DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P AssemblynotpossibletosaleCustomerdissatisfied A Tekstonwronglocation 5 Produkt FMEA Action Solution Whatarepossibleactionsto eliminatethefailure reduceeffect reduceoccurrence Product FMEA Action Solution DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P AssemblynotpossibletosaleCustomerdissatisfied A Tekstonwronglocation 5 Notekstonbuttons JD DefineEvolutionfactor Causenotknown4Solutionnotknown3Solutionnotevaluated2Solutionnotimplemented1Solutionimplemented0 Product FMEA Evolutionfactor DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp Front Button TekstclearvisibleafterPQR test Tekstunread able MC ML P AssemblynotpossibletosaleCustomerdissatisfied A Tekstonwronglocation 5 Notekstonbuttons JD 1 Riskevaluation Severity Weightfactor OccurrenceEvolutionfactorRiskmaturity grid MaturityGrid WeightFactor EvolutionFactor EvolutionFactor S A B C D 0 1 2 3 4 0 1 2 3 4 3 7 5 4 5 1 2 3 Product FMEA Electrical Example DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp P Frontend Tuner Put throughselectedsignal SD12XX Tunergetsdisturbedbynoisegeneratedby14 18Vgeneration Tunergivesbadsignalthrough A Lowfrequentnoiseisnotfiltered 5 ML MC AddbeadinLNBAline rightnexttotuner GD 2 Proces FMEA Content FMEA teamDefinescopeDescribefunctions Proces FMEA Team Process FMEA Scope Createflow diagramDefinescopeDefinesupport team Process FMEA Example DescriptionLevel1 DescriptionLevel2 Function ModeofFailure Effect Cause Action Solution Resp P Glue Gluewithcyano acrylate Joinparts Cyanoacrylatenotwellcured Lifetimeproblems A Gluevolumetohigh 5 ML MC Useactivator JD 2 FMEA Tasks Responsibilities FMEA Teamleader PreparationoftheFMEA sessiondistributionoftheproducttotheparticipants1or2weeksbeforethemeetingtogatheralltherelevantinformation Prepare fill in FMEA worksheetasgoodaspossible functions failuremodes Tasksoftheteamleader FMEA Teamleader PreparationoftheFMEA session Distribute displayimportantinformation agenda FMEA methodDefinetasksoftheteam members Whoistheteamleader facilitator timekeeper secretary Tasksoftheteamleader FMEA Facilitator HelpspreparingtheFMEA sessionSupportstheteamleaderTakescarethatFMEA metholodgyiscorrectlyusedTakescareoftheteam process Tasksofthefacilitator FMEA Facilitator PreparationoftheFMEA sessionpreparationtogetherwiththeteam leaderdefineagendaforthemeetingproduct FMEA createblockdiagramprocess FMEA createflowdiagramdefineparticipants 6 8persons Tasksofthefacilitator FMEA Facilitator Supportingtheteamleader theteamleaderisfocussedontheproject timing technicalsollutions ThefacilitatortakescareforcorrectapplyingoftheFMEA proces SupportstheteamleaderwiththepreparationofthemeetingandduringtheFMEA session Tasksofthefacilitator FMEA Facilitator TakingcareforcorrectapplyingFMEA metholodgy arefunktionscorrectwrittendown verb noun areallfailuremodesmentioned listed areeffectsofthefailuremodescorrect noconfusionbetweencausesandeffects