失效模式[001].ppt

FMEAFailureModeandEffectsAnalysis失效模式與效應分析,1of33,FMEA意義說明,FMEA是不良預防的工具,是一種有條理程序可藉由一張包含所有的失效模式的表,並以數據來表示風險的大小和預先採取預防改善措施。,2of33,導入FMEA的優點,Teamwork方式提高部門或Function間連繫溝通,共同預防改善問題腦力激盪方式,讓每一成員在同一議題上發揮想像力,經由有系統整合提出有效之預防改善對策徹底了解產品功能架構圖或產品製造組合流程圖以魚骨圖分析方式列出失效模式每一種可能因子以失效樹分析(FTA)方法了解產品失效模式各種組合型式把失效模式量化針對TopFailureMode優先採取對策預防確保所有想像得到失效模式和影響,在正常操作情況之下均被考慮到藉由過去的資料給未來參考,協助分析失效的範圍和影響性提供設計產品或製程管制預防採取對策時使用,3of33,Coreteam:列出與FMEAteam相關人員名字,部門與職責Failuremode:失效模式種類Effect:失效後對產品產生影響Cause:造成失效模式之原因Severity:失效模式發生之嚴重程度等級(110)Occurrence:失效模式之發生頻度等級(110)Detection:失效模式發生可被偵測程度等級(110)RPN:RiskPriorityNumber指評估風險及優先處理指數是Severity*Occurrence*Detection之乘積FTA:Faulttreeanalysis是失效樹分析是導果為因由頂端事件利用邏輯(OR或AND)持續分析第1.2層直至真正Rootcause將這些原因謀求徹底改善,FMEA相關名詞解說,4of33,QFD:QualityFunctionDeploymentDOE:DesignofExperimentsVOC:VoiceofCustomerVOE:VoiceofEngineeringSOP:StandardOperationProcedureSIP:StandardInspectionProcedureFRACAS:FailureReportAnalysisandCorrectiveActionSystemSPC:StatisticProcessControlTQM:TotalQualityManagementDVT:DesignValuationTestMTBF:MeanTimeBetweenFailure,FMEA書籍相關名詞解說,5of33,FMEA型式,SYSTEMSFMEADesignDFMEA*Component*Unit*ModuleProcessPFMEAMachineMFMEAEquipmentEFMEAServiceSFMEA,6of33,組成FMEA團隊,設計FMEA流程(DFMEA),蒐集資料,完成FMEA執行方案,系統特性,系統功能,硬品架構,分析失效模式,分析設計管制方法,分析失效原因,分析失效效應,分析嚴重度,計算關鍵指數,分析發生率,分析難檢度,建議改正行動,決定關鍵性失效模式,設計審查評估資料,設計改善參考資料,可靠度分析參考資料,標準檢驗程序資料,教育訓練參考資料,失效報告。分析與改正作業系統(FRACAS),設計改善,撰寫報告,維護度分析參考資料,7of33,組成FMEA團隊,製程FMEA流程(PFMEA),蒐集資料,完成FMEA執行方案,定義製造流程,分析產品特性,分析製程特性,分析失效模式,分析現行管制方法,分析失效原因,分析失效效應,分析嚴重度,計算關鍵指數,分析發生率,分析難檢度,建議改正行動,決定關鍵性失效模式,設計審查評估資料,設計改善參考資料,新製程設計參考資料,標準檢驗程序資料,教育訓練參考資料,失效報告。分析與改正作業系統(FRACAS),製程改善,檢驗程序改善,撰寫報告,8of33,FMEA實施步驟,1.決定FMEA對象2.成立&組成FMEAteammembers3.收集&準備相似產品之歷史資料4.列出產品方塊圖或製程流程圖5.列出Failuremode各種可能情況6.列出Failuremode對產品/機器之影響(Effect)7.魚骨圖分析造成此Failuremode之可能原因(Cause)8.根據相關產品之歷史資料定義出Severity/OccurrenceDetection之等級9.根據S/O/D的定義定出每個Failuremode之S/O/D值10.列出相似Model目前採行之Action,11.計算出RPN=S*O*D值12.取RPN值100(值大小需定義)orTop20%優先採取對策13.針對RPN值超出上述定之項目提出Action再改善14.定出Actionitem之owner及完成日期15.Action切入後檢視其效果及切入時間點16.重新計算Action後之RPN值17.若RPN值未達定義要求RPN100orTop20%回覆到item13重提Action18.若RPN達到要求完成FMEA表格,9of33,FMEATeamMembers,DFMEA(Design)Chairperson*ProgramManager(PM)*ElectronicEngineer(EE)*MechanicalEngineer(ME)*QualityEngineer(QE)*QualityEngineer(QA)*Manufacturing(MES)SupportTeam*Purchasing(Buyer)ifNeed,PFMEA(Process)Chairperson*ProgramManager(PM)*QualityEngineer(QA)*IndustryEngineer(IE)*MechanicalEngineer(MFGME)*TestEngineer(TE)*ManufactureSupervisor(MFG)*ElectronicEngineer(EE)ifNeed*MechanicalEngineer(ME)ifNeed,10of33,FailureModeFishboneAnalysis,Hi-Pot不良FailureMode(Defect),錫面,組立,加工不良,第一層分析Workmanship,第二層分析,第三層分析,第四層分析,正面裝插,零件插歪斜,零件面有異物,無線尾,零件變形,零件碰case,零件相碰,第一層分析Material,變壓器不良,PCB不良,Y電容不良,PowerCable破,EMI不良,Case不良,第二層分析,第三層分析,絕緣tape破,引腳超出base,焊點過大造成tape破,儀器設備,儀器設定,Layout安規距離不夠,Arcing規定過嚴,零件間安規距離不足,第一層分析Design,第一層分析Test,第二層分析,第三層分析,第二層分析,第三層分析,鎖螺絲過長,套管短,零件本体大Layout面積小,測試條件設錯,O/I寫錯,測試線接錯,11of33,Hi-PotFailureAnalysis,FaultTreeAnalysisForHi-PotFailure,5.板邊零件傾斜踫Case,造成安規距離不夠,b.Socket上Y電容線腳靠近馬口鐵,a.SocketFG線漏焊,Process,4.錫面,3.正面裝插,2.組立,1.加工不良,d.錫面短路錫珠,錫渣,c.線腳過長,b.漏焊Y電容,a.異物,c.零件插歪斜,零件變形,碰Case,碰T1,碰H/S,相互碰撞,b.零件面有異物,a.無線尾,h.鎖絲未鎖緊或漏鎖,g.掉金屬物進產品,f.絕緣片放置不當或漏裝,d.PCB沒有卡到位,c.組立時,B+B-線壓傷壓破,b.絕緣片膠布破,a.FG線有無Touch任何零件,c.膠布沒貼到位,Design,2.元件之間安規距離不夠,3.Arcing規格過嚴,c.鎖螺絲過長,b.套管短,a.原件本体大Layout面積小,4.板邊零件與Case安規距離不夠,1.Layout安規距離不夠,Material,9.變壓器PFC電感,8.膠雜質過多,7.Y電容不良,6.線材PowerCable破,5.PCB,4.EMISocket,3.Case,2.接地小黃豆電容耐壓不夠,c.有毛刺,b.耳掛有凸起,a.碎屑,b.本身耐壓不夠,a.FG線氧化不吃錫,b.Trace近似短路或開路,a.PCB受潮,e.絕緣Tape破,d.零件本体歪斜,c.焊點過大,造成錫間賜破絕緣層,b.引線腳超出base,a.絕緣膠布位置不恰當,1.光藕合器不良,e.O/I寫錯誤,Test,2.儀器設定,1.儀器,c.測試條件設置錯誤,b.O/I寫錯誤,a.測試線接錯,b.儀器本身電壓頻率誤差大,a.接觸不良,f.本身繞線造成Arcing過大,其他,2.接地銅箔被燒斷,3.接地跳線斷,4.未依O/I作業,1.SocketY電容線腳斷,5.油墨,黑色Mark筆,在初級側導電,12of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Thiscolumnisusedtolistthepartnameandfunction.Listallthefunctionsforthefunctionalblock,FMEA格式逐項解說,1.,2.,10.,4.,3.,5.,6.,8.,7.,9.,12.,11.,15.,14.,13.,13of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,2.,Inthefailuremodecolumn,listeachofthefailuremodesforthefunction.,FMEA格式逐項解說,1.,10.,4.,3.,5.,6.,8.,7.,9.,12.,11.,15.,14.,13.,14of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Detection,Detection,RPN,RPN,Occurrence,3.,Listtheeffectsoffailureforeachofthefailuremodes.,FMEA格式逐項解說,1.,10.,4.,2.,5.,6.,8.,7.,9.,12.,11.,15.,14.,13.,15of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Foreachoneoftheeffects,listtheseverity(scalefrom1to10),4.,FMEA格式逐項解說,1.,10.,3.,2.,5.,6.,8.,7.,9.,12.,11.,15.,14.,13.,16of33,符合需求,17of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,TheClasscolumnisoptional.Itistypicallyusediftheseverityis9or10.,5.,FMEA格式逐項解說,1.,10.,3.,2.,4.,6.,8.,7.,9.,12.,11.,15.,14.,13.,18of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,IntheCausecolumn,listthecausesforeachfailuremode,6.,FMEA格式逐項解說,1.,10.,3.,2.,4.,5.,8.,7.,9.,12.,11.,15.,14.,13.,19of33,FMEAModel,LinkingFailureModetoCauseandEffect,Cause,FailureMode(Defect),Effect,20of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Estimatethelikelihoodofthe“causes”happeningona“1to10”scale.Thehigherthenumberthemorelikelythe“causes”willoccur.,7.,FMEA格式逐項解說,1.,10.,3.,2.,4.,5.,8.,6.,9.,12.,11.,15.,14.,13.,21of33,22of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Listtheprevention,designvalidation/verification,orotheractivitieswhichwillassurethedesignadequacyforthefailuremodeand/orcause/mechanismunderconsideration.TestsDesignreviews,Mathematicalstudies,Fail/safe(Example:redundantpowersupplies),8.,FMEA格式逐項解說,1.,10.,3.,2.,5.,4.,6.,7.,9.,12.,11.,15.,14.,13.,23of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Estimatethelikelihoodofthedetectionona“1to10”scale.Thelowerthenumberthemorelikelythecausewillbedetected.,9.,FMEA格式逐項解說,1.,10.,3.,2.,5.,4.,8.,7.,6.,12.,11.,15.,14.,13.,24of33,25of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,RPN(RiskPriorityNumber)istheproductofSeverity,Occurrence,andDetection.Thehigherthenumber,thehighertherisk.,10.,FMEA格式逐項解說,1.,2.,4.,3.,5.,6.,8.,7.,9.,12.,11.,15.,14.,13.,26of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,WhatactionsneedtobetakentopreventtheFailureMode?Ifnoactionistaken,record“none”,11.,FMEA格式逐項解說,1.,10.,4.,3.,5.,6.,8.,7.,9.,12.,2.,15.,14.,13.,27of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Assignappropriateindividual,area,functionorteam.SetarealistictargetforcompletionTargetdatecouldbeestablishedbydevelopmentprogram,12.,FMEA格式逐項解說,1.,10.,4.,3.,5.,6.,8.,7.,9.,2.,11.,15.,14.,13.,28of33,PartFailureModeEffect(s)Cause(s)CurrentorAction(s)toAreaorAction(s)Name*Control(s)betakenIndividualtakenFunctionresponsibleEnergyManagementCannotCustomerSoftwareMonitordissatisfactionFailureMonitorBatteryBatteryalertBatteryuserofstatusconnectionsspec.wrongIncorrectbatteryusedCannotCustomerSoftwareaccuratelydissatisfactionfailureIDstatusBatteryConnectionsdamagespec.wrongUnabletodetectbatteryFaults,Severity,Severity,Occurrence,Occurrence,Detection,Detection,RPN,RPN,Listtheresultsoftheactionstaken.Alwaysenterareferencesuchasdataortestreports.,13.,FMEA格式逐項解說,1.,10.,4.,3.,5.,6