飞利浦失效模式与效应分析

PhilipsFMEA

FailureModeandEffectAnalysis第一页，共七十四页。ContentofthecourseIntroductionProduct-FMEABlockdiagram,functiontreeProcess-FMEAProcess-flowdiagram(macro-level),micro-levelFacilitatorskills第二页，共七十四页。FMEA–IntroductionWhyFMEA’s?Definition,Purpose,Types,BenefitsTeamApproachFMEA-PhilipsIntroduction第三页，共七十四页。WhyFMEA’s?Appropriaterecommendedactionsmaynothavebeentaken.Savingsinengineeringtime.Reductionofchangesimmediatelybeforeproductionstart(CommercialRelease).第四页，共七十四页。FMEA–DefinitionIdentifypotentialfailuremodesPrioritizeactionsDocumenttheprocess.Structuredgroupofactivitieswhich...第五页，共七十四页。FMEA–PurposeFailuresTimeCR(Productionstart)FMEA第六页，共七十四页。RateseverityoffailuremodesIdentifyactionstoreduceoccurenceTestadequacyofcontrolsFMEA–PurposeFMEA’sareintendedto...

第七页，共七十四页。FMEA–Types

OpticalProduct-FMEA

MechanicalProcess-FMEA

ElectricalMechanicalElectricalOptical第八页，共七十四页。FMEASessionsFMEAonEVTModelFMEAonFirstMechanicalWorkingModelFMEAonPartFilesFMEAonL1Board(ftboL2)FMEAonL0Board(ftboL1)FMEAonL0Schematics(ftboL0)FMEAonArchitecturesMechanicalElectricalFMEAonchosenArchitecture第九页，共七十四页。Benefits–Product-FMEA’sAssessfailuremodeeffectsonallcustomers.AidsinevaluatingtestspecificationsEvaluationofdesignrelatingto DFM DFA DFTIncreasesthepossibilitytodetectpossiblefailuremodes.ProcesProduct第十页，共七十四页。Voordelen–Proces-FMEA’sAssesseffectsonallcustomersIdentifiespotentialmanufacturingandassemblycausestofocuscontrolsonreducingoccurrenceorincreasingdetection.DesignProces第十一页，共七十四页。GeneratingFMEA’sFMEAsWhoinitiates?FailureModeandEffectAnalysisWhoupdates?WhoisFMEA-customer?Startingdate/

revisiondate?Whencompleted?Howdocu-mented?Whentodiscard?Whoprepares?第十二页，共七十四页。ManagingFMEA’sModificationtoaproductorprocessisplannedComponentistobeusedinnewenvironmentCustomerrejectionsFMEA’sarelivingdocumentsandareupdated...第十三页，共七十四页。FMEA–TeamApproachCore-

teamSupport-

team第十四页，共七十四页。Product-FMEA–ContentDefineFMEA-teamDefinescopeDescribefunctionsBrainstormingFunctionTreesPhilipsProduct-FMEAContent第十五页，共七十四页。Product-FMEA–TeamDesign-

EnginieerProduction/

process-enginieerCore-

team

Representitivesfrom:developmentproductionqualitypurchasetestdept....Support

teamFacilitator第十六页，共七十四页。Product-FMEA–ScopeCreateBlockdiagramIdentifythebounderyforAnalysisConfirmcompositionofsupportteam.Oncecoreteamisestablished...第十七页，共七十四页。BlockdiagramComponent/

AssemblyPartXPartYPartZServiceOthersystemsAssemblyUserScrewWeldAdhesive第十八页，共七十四页。Exampleblockdiagram(SettopWildfire)FrontKlickedDisplayPCBPSUSmartcardPCBFrameCoverKlickedKlickedScrewedScrewed第十九页，共七十四页。DetermineFunctionsDescribestheintentofthedesignMustbemeasurebleorsetatanactionablelevelRepresentsallwants,bothspokenandunspoken.Whatarethefunctionsofthedesign?第二十页，共七十四页。VerbIndicatesaction,occurrence,being

Generate Control Display NounIndicateswhattheactionrelatestoDescribeFunctionlightspeedinformation 第二十一页，共七十四页。DescribeFunctionsThoughtstarters...SatisfyuserAttractuserGuaranteedurabilityEasytorepareSafetyrequirements第二十二页，共七十四页。Brainstorming第二十三页，共七十四页。FunctiontreeProvidesanorganizedapproachtoidentifytheessentialfeaturesofaproductDefinesallspokenandunspokenrequirementsProvidestheteamwithaclearoverviewofallthefunctionsoftheproduct.第二十四页，共七十四页。FirstlevelSecondLevelConstructingFunctiontreesThirdLevelHOW?WHY?第二十五页，共七十四页。DisplayInformationFunctiontree–Frontbutton(Settop)HOW?Mustbeprintableandresistancetewear.PQR-Cleantest.Tekstclearlyvisibleafterx-timescleaning.WHY?第二十六页，共七十四页。GuidelinesBrainstormallfunctions(VERB-NOUN)Documentindividualfunctionsbyasking “Howisthisfunctionachieved?”Repeatlefttoright,untilactionablelevelWorkrighttoleftandcheckstructurebyasking“Whyisthisfunctionincluded?”第二十七页，共七十四页。Product-FMEA–FunctionsDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testMCMLP第二十八页，共七十四页。PotentialfailureModesNofunctionPartialfunction

FailureModeType ExampleNotoperationalNotalloffunctionoperating

第二十九页，共七十四页。FailureModes:FrontbuttonNofunction NotekstavailablePartialfunction TekstpartialavailableFunction:Tekstclearvisibleafter100xcleaning.FailureModeType

Example第三十页，共七十四页。Product-FMEA–ModesoffailureDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLP第三十一页，共七十四页。EffectsfailureWhataretheeffectsofthefailurerelatingto:-anotherpart-thecompleteassembly-thecustomer-theenduser-thegovernmentalregulations第三十二页，共七十四页。Product-FMEA–TabelofeffectsFailureModeTekstunread-ableFrontbuttonCompleteAssemblyDifficulttosaleCustomerDissatisfiedEnduserDissatisfiedGovernmentalregulationNoneAnotherpartNone第三十三页，共七十四页。Product-FMEA–EffectsoffailureDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfied第三十四页，共七十四页。Severity(Weightfactor)Whatistheseverityoftheeffects?第三十五页，共七十四页。Criteria:SeverityofeffectClassEffectAcceptedfailureDNoneSafetyfailureSUnacceptableriskNon-conformingwithsafetyCorrectionisnescessaryARelativebigriskCorrectieisrecommendedBrisicoCorrectieisnuttigCRatingcriteriavoorSeverity(Weightfactor)MinimumriskCorrectieisusefullC第三十六页，共七十四页。

Frontbutton/TekstreadableafterPQR-testFailureMode

TekstunreadableEffects

Assembly:unsaleable (A)Customer:Dissatisfied (A)Gov.Reg.:None (D)ARatingofWeightfactor–exampleSev.PartFunction第三十七页，共七十四页。Product-FMEA–WeightfactorDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedA第三十八页，共七十四页。PotentialCauseofFailure

Aweaknessinthedesignwithafailuremodeaseffect.第三十九页，共七十四页。ManufacturingmisbuildsDuetodesignDeficiencies+-+-第四十页，共七十四页。ManufacturingmisbuildsRobustDesign+-+-第四十一页，共七十四页。UseFishboneDiagramCauseoffailureTekstunreadableInktofpoorqualityTekstonwronglocation第四十二页，共七十四页。Causeoffailure–“Why”-ladderDesignrequirementWHY?level1TekstunreadableWHY?level2WHY?level3Inktdoesn’tstickSurfaceroughnessnotok.第四十三页，共七十四页。SentencingTechniqueFailureModeCouldresultinEffectDuetoCause第四十四页，共七十四页。SentencingTechnique-ExampleTekstunreadableCouldresultinDissatisfiedcustomerDuetoSurfaceroughness(designreq.)第四十五页，共七十四页。Product-FMEA–CauseDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation第四十六页，共七十四页。Product-FMEA–OccurrenceWhatisthepossibilitythatthefailureoccurrs?第四十七页，共七十四页。PossibleFailureRatesRankingProbabilityoffailure>1of20VeryhighModerate>1of400>1of15000Low<1of1500045321Ratingcriteriaoccurrence³1of3第四十八页，共七十四页。Product-FMEA–OccurrenceDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5第四十九页，共七十四页。Produkt-FMEA–Action/SolutionWhatarepossibleactionsto: -eliminatethefailure -reduceeffect -reduceoccurrence.第五十页，共七十四页。Product-FMEA–Action/SolutionDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5NotekstonbuttonsJD第五十一页，共七十四页。DefineEvolutionfactorCausenotknown 4Solutionnotknown 3Solutionnotevaluated 2Solutionnotimplemented 1Solutionimplemented 0第五十二页，共七十四页。Product-FMEA–EvolutionfactorDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5NotekstonbuttonsJD1第五十三页，共七十四页。RiskevaluationSeverity(Weightfactor)OccurrenceEvolutionfactorRiskmaturity-grid

第五十四页，共七十四页。MaturityGridWeightFactorEvolutionFactorEvolutionFactorSABCD012340123437545123第五十五页，共七十四页。Product-FMEA–Electrical(Example)DescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.PFrontendTunerPut-throughselectedsignal(SD12XX)Tunergetsdisturbedbynoisegeneratedby14-18VgenerationTunergivesbadsignalthroughALowfrequentnoiseisnotfiltered5MLMCAddbeadinLNBAline,rightnexttotunerGD2第五十六页，共七十四页。Proces-FMEA–ContentFMEA-teamDefinescopeDescribefunctionsPhilipsProces-FMEAContent第五十七页，共七十四页。Proces-FMEA–TeamProduction/-

process-engineerDesign-engineerCore-

team

Representativesof:ProductdevelopmentProcess-developmentProductionQualityPurchaseOwnerofthenextprocess….Support-

teamFacilitatororapplicationengineer第五十八页，共七十四页。Process-FMEA–ScopeCreateflow-diagramDefinescopeDefinesupport-team.第五十九页，共七十四页。Process-FMEA–(Example)DescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.PGlueGluewithcyano-acrylateJoinpartsCyanoacrylatenotwellcuredLifetimeproblemsAGluevolumetohigh5MLMCUseactivatorJD2第六十页，共七十四页。FMEA

Tasks&Responsibilities.第六十一页，共七十四页。FMEA–TeamleaderPreparationoftheFMEA-sessiondistributionoftheproducttotheparticipants1or2weeksbeforethemeetingtogatheralltherelevantinformation.Prepare(fill-in)FMEA-worksheetasgoodaspossible(functions,failuremodes,...)Tasksoftheteamleader:第六十二页，共七十四页。FMEA–TeamleaderPreparationoftheFMEA-session:Distribute/displayimportantinformation:agenda,FMEA-methodDefinetasksoftheteam-members:Whoistheteamleader,facilitator,timekeeper,secretary?Tasksoftheteamleader:第六十三页，共七十四页。FMEA–FacilitatorHelpspreparingtheFMEA-sessionSupportstheteamleaderTakescarethatFMEA-metholodgyiscorrectlyusedTakescareoftheteam-process.Tasksofthefacilitator:第六十四页，共七十四页。FMEA–FacilitatorPreparationoftheFMEA-sessionpreparationtogetherwiththeteam-leaderdefineagendaforthemeetingproduct-FMEA:createblockdiagramprocess-FMEA:createflowdiagramdefineparticipants(6-8persons).Tasksofthefacilitator:第六十五页，共七十四页。FMEA–FacilitatorSupportingtheteamleader:theteamleaderisfocussedontheproject(timing,technicalsollutions,…).ThefacilitatortakescareforcorrectapplyingoftheFMEA-proces.SupportstheteamleaderwiththepreparationofthemeetingandduringtheFMEA-session.Tasksofthefacilitator:第六十六页，共七十四页。FMEA–FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:arefunktionscorrectwrittendown(verb/noun)?areallfailuremodesmentioned,listed?areeffectsofthefailuremodescorrect?(noconfusionbetweencausesandeffects).Tasksofthefacilitator:第六十七页，共七十四页。FMEA–FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:Isforeacheffectaweigthfactormentioned,foreachcausetheprobabilityandforeachsollutiontheevolutionfactordefinedIstheFMEA-worksheetcompletelyfilled-in(actions,responsibleperson,date)?Tasksofthefacilitator:第六十八页，共七十四页。FMEA–FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:don’tloosetimewithlongdiscussionsaboutseverityan