PhilipsFMEAEnglish（英文版）

1、1.1Philips FMEA Failure Failure Mode and Effect Mode and Effect AnalysisAnalysis1.2Content 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、redStructured groupgroup of of activitiesactivities whichwhich. . 1.6FMEA PurposeFailuresTimeC R(Productionstart)FMEA1.7vRate severity of failure modesvIdentify actions to reduce occurencevTest adequacy of controlsFMEA PurposeFMEAsFMEAs are are intended tointended to . . 1.8FMEA Types OpticalProduct

4、-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 onchosenArchitecture1.10Be

5、nefits 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 potenti

6、al 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 prep

7、ares?1.13Managing FMEAs vModification to a product or process is plannedvComponent is to be used in new environmentvCustomer rejectionsFMEAsFMEAs are living are living documentsdocuments and are and are updatedupdated . .1.14FMEA Team ApproachCore-teamSupport-team1.15Product-FMEA ContentvDefine FMEA

8、-team vDefine scopevDescribe functions Brainstorming Function Trees1.16Product-FMEA TeamDesign-EnginieerProduction/ process-enginieerCore-team Representitives from: development production quality purchase testdept. .SupportteamFacilitator1.17Product-FMEA ScopevCreate BlockdiagramvIdentify the bounde

9、ry for AnalysisvConfirm composition of support team.Once coreteam is established .1.18BlockdiagramComponent/AssemblyPart XPart YPart ZServiceOther systemsAssemblyUserScrewWeldAdhesive1.19Example blockdiagram (Settop Wildfire)FrontKlickedDisplay PCBPSUSmartcard PCBFrameCoverKlickedKlickedScrewedScrew

10、ed1.20Determine FunctionsvDescribes the 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?1.21VerbIndicates action, occurrence, beingGenerateControlDisplayNounIndicates what the action relates toD

11、escribe Functionlightspeedinformation1.22Describe FunctionsThought starters .vSatisfy uservAttract uservGuarantee durabilityvEasy to reparevSafety requirements1.23Brainstorming1.24Functiontree vProvides an organized approach to identify the essential features of a productvDefines all spoken and unsp

12、oken requirementsvProvides the team with a clear overview of all the functions of the product.1.25FirstlevelSecondLevelConstructing FunctiontreesThirdLevelHOW?WHY ?1.26DisplayInformationFunctiontree Frontbutton (Settop) HOW?Must be printable and resistance te wear.PQR-Cleantest. Tekst clearly visibl

13、eafter x-times cleaning.WHY?1.27GuidelinesvBrainstorm 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?”1.28Product-FMEA Funct

14、ionsDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible afterPQR-testMCMLP1.29Potential failure ModesNo functionPartial functionFailure Mode TypeExampleNot operationalNot all of function operating1.30Failure Modes: FrontbuttonNo fu

15、nction No tekst availablePartial function Tekst partial availableFunction: Tekst clear visible after 100 x cleaning.Failure Mode Type Example1.31Product-FMEA Modes of failureDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after

16、 PQR-testTekst unread-ableMCMLP1.32Effects failureWhat are the effects of the failure relating to:- another part- the complete assembly- the customer- the enduser- the governmental regulations1.33Product-FMEA Tabel of effectsFailureModeTekstunread-ableFrontbuttonCompleteAssemblyDifficultto saleCusto

17、merDissatisfiedEnduserDissatisfiedGovernmental regulationNoneAnotherpartNone1.34Product-FMEA Effects of failureDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCus

18、tomerdissatisfied1.35Severity (Weightfactor)What is the severity of the effects?1.36Criteria: Severity of effectClassEffectAccepted failureDNoneSafety failureSUnacceptable riskNon-conforming with safetyCorrection is nescessary ARelative big riskCorrectie is recommendedBrisicoCorrectie is nuttigCRati

19、ngcriteria voor Severity (Weightfactor)Minimum riskCorrectie is usefullC1.37Frontbutton/Tekst readable after PQR-testFailureModeTekst unreadableEffects Assembly: unsaleable (A)Customer: Dissatisfied(A)Gov.Reg.: None (D)ARating of Weightfactor exampleSev.PartFunction1.38Product-FMEA WeightfactorDescr

20、iptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedA1.39Potential Cause of Failure A weakness in the design with a failure mode as effect.1.40Manufact

21、uring misbuilds Due to design Deficiencies+-+-1.41Manufacturing misbuildsRobust Design+-+-1.42Cause of failureTekst unreadableInkt of poor qualityTekst on wrong location1.43Cause of failure “Why”-ladderDesignrequirementWHY?level 1WHY?level 2WHY?level 3Inkt doesnt stickSurface roughness not ok. 1.44S

22、entencing TechniqueFailure ModeCould result inEffectDue toCause1.45Sentencing Technique - Example TekstunreadableCould result inDissatisfiedcustomerDue toSurfaceroughness(designreq.)1.46Product-FMEA CauseDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontB

23、uttonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location1.47Product-FMEA Occurrence What is the possibility thatthe failure occurrs?1.48Possible Failure RatesRankingProbability of failure 1 of 20Very highModerate 1 of 400 1

24、 of 15000Low 1 of 1500045321 1 of 31.49Product-FMEA OccurrenceDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location51.50Prod

25、ukt-FMEA Action/SolutionWhat are possible actions to:- eliminate the failure- reduce effect - reduce occurrence.1.51Product-FMEA Action/SolutionDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCML

26、PAssembly not possible to saleCustomerdissatisfiedATekston wrong location5No tekst on buttonsJD1.52Define Evolutionfactor vCause not known4vSolution not known3vSolution not evaluated2vSolution not implemented1vSolution implemented01.53Product-FMEA EvolutionfactorDescriptionLevel 1DescriptionLevel 2F

27、unctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location5No tekst on buttonsJD11.54Risk evaluationvSeverity (Weightfactor) vOccurrence vEvolutionfactorvRisk maturit

28、y - grid1.55Maturity Grid Weight FactorEvolution FactorEvolution FactorSABCD012340123437 5451231.56Product-FMEA Electrical (Example)DescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.PFront endTunerPut-through selected signal (SD12XX)Tuner gets disturbed by noi

29、se generated by 14-18V generationTuner gives bad signal throughALow frequent noise is not filtered5MLMCAdd bead in LNBA line, right next to tunerGD21.57Proces - FMEA ContentvFMEA-team vDefine scopevDescribe functions1.58Proces-FMEA TeamProduction/- process-engineerDesign-engineerCore-team Representa

30、tives of :ProductdevelopmentProcess-developmentProductionQualityPurchaseOwner of the next process .Support-teamFacilitator or application engineer1.59Process-FMEA ScopevCreate flow-diagram vDefine scopevDefine support-team.1.60Process-FMEA (Example)DescriptionLevel 1DescriptionLevel 2FunctionMode of

31、 FailureEffectCauseAction/SolutionResp.PGlueGlue with cyano-acrylateJoin partsCyanoacrylate not well curedLifetime problemsAGlue volume to high5MLMCUse activatorJD21.61FMEA Tasks Tasks & & ResponsibilitiesResponsibilities. .1.62FMEA TeamleadervPreparation of the FMEA - sessiondistribution of

32、 the product to the participants 1 or 2 weeks before the meeting to gather all the relevant information. Prepare (fill-in) FMEA-worksheet as good as possible (functions, failure modes, . )Tasks Tasks of the teamleader:of the teamleader:1.63FMEA TeamleadervPreparation of the FMEA - session:Distribute

33、/display important information: agenda, FMEA-methodDefine tasks of the team-members: Who is the teamleader, facilitator, timekeeper, secretary?Tasks Tasks of the teamleader:of the teamleader:1.64FMEA FacilitatorvHelps preparing the FMEA - sessionvSupports the teamleadervTakes care that FMEA-metholod

34、gy is correctly usedvTakes care of the team - process.Tasks Tasks of the of the facilitatorfacilitator: :1.65FMEA FacilitatorvPreparation of the FMEA - sessionpreparation together with the team-leaderdefine agenda for the meetingproduct-FMEA : create blockdiagramprocess-FMEA: create flowdiagramdefin

35、e participants (6-8 persons).Tasks Tasks of the of the facilitatorfacilitator: :1.66FMEA 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

36、 preparation of the meeting and during the FMEA-session.Tasks Tasks of the of the facilitatorfacilitator: :1.67FMEA 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 corr

37、ect? (no confusion between causes and effects).Tasks Tasks of the of the facilitatorfacilitator: :1.68FMEA 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)?TasksTasks of the of the fac