PhilipsFMEA

FailureModeandEffectAnalysisContentofthecourseIntroductionProduct-FMEABlockdiagram,functiontreeProcess-FMEAProcess-flowdiagram(macro-level),micro-levelFacilitatorskillsFMEA–IntroductionWhyFMEA’s?Definition,Purpose,Types,BenefitsTeamApproachFMEA-PhilipsIntroductionWhyFMEA’s?Appropriaterecommendedactionsmaynothavebeentaken.Savingsinengineeringtime.Reductionofchangesimmediatelybeforeproductionstart(CommercialRelease).FMEA–DefinitionIdentifypotentialfailuremodesPrioritizeactionsDocumenttheprocess.Structuredgroupofactivitieswhich...FMEA–PurposeFailuresTimeCR(Productionstart)FMEARateseverityoffailuremodesIdentifyactionstoreduceoccurenceTestadequacyofcontrolsFMEA–PurposeFMEA’sareintendedto...

FMEA–Types

OpticalProduct-FMEA

MechanicalProcess-FMEA

ElectricalMechanicalElectricalOpticalFMEASessionsFMEAonEVTModelFMEAonFirstMechanicalWorkingModelFMEAonPartFilesFMEAonL1Board(ftboL2)FMEAonL0Board(ftboL1)FMEAonL0Schematics(ftboL0)FMEAonArchitecturesMechanicalElectricalFMEAonchosenArchitectureBenefits–Product-FMEA’sAssessfailuremodeeffectsonallcustomers.AidsinevaluatingtestspecificationsEvaluationofdesignrelatingto DFM DFA DFTIncreasesthepossibilitytodetectpossiblefailuremodes.ProcesProductVoordelen–Proces-FMEA’sAssesseffectsonallcustomersIdentifiespotentialmanufacturingandassemblycausestofocuscontrolsonreducingoccurrenceorincreasingdetection.DesignProcesGeneratingFMEA’sFMEAsWhoinitiates?FailureModeandEffectAnalysisWhoupdates?WhoisFMEA-customer?Startingdate/

revisiondate?Whencompleted?Howdocu-mented?Whentodiscard?Whoprepares?ManagingFMEA’sModificationtoaproductorprocessisplannedComponentistobeusedinnewenvironmentCustomerrejectionsFMEA’’sarelivingdocumentsandareupdated...FMEA––TeamApproachCore-

teamSupport-teamProduct-FMEA––ContentDefineFMEA-teamDefinescopeDescribefunctionsBrainstormingFunctionTreesPhilipsProduct-FMEAContentProduct-FMEA–TeamDesign-

EnginieerProduction/

process-enginieerCore-

team

Representitivesfrom:developmentproductionqualitypurchasetestdept....Support

teamFacilitatorProduct-FMEA–ScopeCreateBlockdiagramIdentifythebounderyforAnalysisConfirmcompositionofsupportteam.Oncecoreteamisestablished...BlockdiagramComponent/AssemblyPartXPartYPartZServiceOthersystemsAssemblyUserScrewWeldAdhesiveExampleblockdiagram(SettopWildfire)FrontKlickedDisplayPCBPSUSmartcardPCBFrameCoverKlickedKlickedScrewedScrewedDetermineFunctionsDescribestheintentofthedesignMustbemeasurebleorsetatanactionablelevelRepresentsallwants,bothspokenandunspoken.Whatarethefunctionsofthedesign?VerbIndicatesaction,occurrence,beingGenerateControlDisplayNounIndicateswhattheactionrelatestoDescribeFunctionlightspeedinformationDescribeFunctionsThoughtstarters...SatisfyuserAttractuserGuaranteedurabilityEasytorepareSafetyrequirementsBrainstormingFunctiontreeProvidesanorganizedapproachtoidentifytheessentialfeaturesofaproductDefinesallspokenandunspokenrequirementsProvidestheteamwithaclearoverviewofallthefunctionsoftheproduct.FirstlevelSecondLevelConstructingFunctiontreesThirdLevelHOW?WHY?DisplayInformationFunctiontree–Frontbutton(Settop)HOW?Mustbeprintableandresistancetewear.PQR-Cleantest.Tekstclearlyvisibleafterx-timescleaning.WHY?GuidelinesBrainstormallfunctions(VERB-NOUN)Documentindividualfunctionsbyasking““Howisthisfunctionachieved?”Repeatlefttoright,untilactionablelevelWorkrighttoleftandcheckstructurebyasking“Whyisthisfunctionincluded?””Product-FMEA–FunctionsDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testMCMLPPotentialfailureModesNofunctionPartialfunctionFailureModeType ExampleNotoperationalNotalloffunctionoperatingFailureModes:FrontbuttonNofunctionNotekstavailablePartialfunctionTekstpartialavailableFunction:Tekstclearvisibleafter100xcleaning.FailureModeTypeExampleProduct-FMEA–ModesoffailureDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPEffectsfailureWhataretheeffectsofthefailurerelatingto:-anotherpart-thecompleteassembly-thecustomer-theenduser-thegovernmentalregulationsProduct-FMEA–TabelofeffectsFailureModeTekstunread-ableFrontbuttonCompleteAssemblyDifficulttosaleCustomerDissatisfiedEnduserDissatisfiedGovernmentalregulationNoneAnotherpartNoneProduct-FMEA–EffectsoffailureDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedSeverity(Weightfactor)Whatistheseverityoftheeffects?Criteria:SeverityofeffectClassEffectAcceptedfailureDNoneSafetyfailureSUnacceptableriskNon-conformingwithsafetyCorrectionisnescessaryARelativebigriskCorrectieisrecommendedBrisicoCorrectieisnuttigCRatingcriteriavoorSeverity(Weightfactor)MinimumriskCorrectieisusefullCFrontbutton/TekstreadableafterPQR-testFailureModeTekstunreadableEffectsAssembly:unsaleable(A)Customer:Dissatisfied(A)Gov.Reg.:None(D)ARatingofWeightfactor––exampleSev.PartFunctionProduct-FMEA––WeightfactorDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedAPotentialCauseofFailureAweaknessinthedesignwithafailuremodeaseffect.ManufacturingmisbuildsDuetodesignDeficiencies+-+-ManufacturingmisbuildsRobustDesign+-+-UseFishboneDiagramCauseoffailureTekstunreadableInktofpoorqualityTekstonwronglocationCauseoffailure–“Why””-ladderDesignrequirementWHY?level1TekstunreadableWHY?level2WHY?level3Inktdoesn’tstickSurfaceroughnessnotok.SentencingTechniqueFailureModeCouldresultinEffectDuetoCauseSentencingTechnique-ExampleTekstunreadableCouldresultinDissatisfiedcustomerDuetoSurfaceroughness(designreq.)Product-FMEA––CauseDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocationProduct-FMEA––OccurrenceWhatisthepossibilitythatthefailureoccurrs?PossibleFailureRatesRankingProbabilityoffailure>1of20VeryhighModerate>1of400>1of15000Low<1of1500045321Ratingcriteriaoccurrence31of3Product-FMEA––OccurrenceDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5Produkt-FMEA––Action/SolutionWhatarepossibleactionsto:-eliminatethefailure-reduceeffect-reduceoccurrence.Product-FMEA––Action/SolutionDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5NotekstonbuttonsJDDefineEvolutionfactorCausenotknown4Solutionnotknown3Solutionnotevaluated2Solutionnotimplemented1Solutionimplemented0Product-FMEA––EvolutionfactorDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5NotekstonbuttonsJD1RiskevaluationSeverity(Weightfactor)OccurrenceEvolutionfactorRiskmaturity-gridMaturityGridWeightFactorEvolutionFactorEvolutionFactorSABCD012340123437545123Product-FMEA––Electrical(Example)DescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.PFrontendTunerPut-throughselectedsignal(SD12XX)Tunergetsdisturbedbynoisegeneratedby14-18VgenerationTunergivesbadsignalthroughALowfrequentnoiseisnotfiltered5MLMCAddbeadinLNBAline,rightnexttotunerGD2Proces-FMEA–ContentFMEA-teamDefinescopeDescribefunctionsPhilipsProces-FMEAContentProces-FMEA––TeamProduction/-

process-engineerDesign-engineerCore-

team

Representativesof:ProductdevelopmentProcess-developmentProductionQualityPurchaseOwnerofthenextprocess….Support-

teamFacilitatororapplicationengineerProcess-FMEA––ScopeCreateflow-diagramDefinescopeDefinesupport-team.Process-FMEA––(Example)DescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.PGlueGluewithcyano-acrylateJoinpartsCyanoacrylatenotwellcuredLifetimeproblemsAGluevolumetohigh5MLMCUseactivatorJD2FMEATasks&Responsibilities.FMEA––TeamleaderPreparationoftheFMEA-sessiondistributionoftheproducttotheparticipants1or2weeksbeforethemeetingtogatheralltherelevantinformation.Prepare(fill-in)FMEA-worksheetasgoodaspossible(functions,failuremodes,...)Tasksoftheteamleader:FMEA––TeamleaderPreparationoftheFMEA-session:Distribute/displayimportantinformation:agenda,FMEA-methodDefinetasksoftheteam-members:Whoistheteamleader,facilitator,timekeeper,secretary?Tasksoftheteamleader:FMEA––FacilitatorHelpspreparingtheFMEA-sessionSupportstheteamleaderTakescarethatFMEA-metholodgyiscorrectlyusedTakescareoftheteam-process.Tasksofthefacilitator:FMEA––FacilitatorPreparationoftheFMEA-sessionpreparationtogetherwiththeteam-leaderdefineagendaforthemeetingproduct-FMEA:createblockdiagramprocess-FMEA:createflowdiagramdefineparticipants(6-8persons).Tasksofthefacilitator:FMEA––FacilitatorSupportingtheteamleader:theteamleaderisfocussedontheproject(timing,technicalsollutions,…).ThefacilitatortakescareforcorrectapplyingoftheFMEA-proces.SupportstheteamleaderwiththepreparationofthemeetingandduringtheFMEA-session.Tasksofthefacilitator:FMEA––FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:arefunktionscorrectwrittendown(verb/noun)?areallfailuremodesmentioned,listed?areeffectsofthefailuremodescorrect?(noconfusionbetweencausesandeffects).Tasksofthefacilitator:FMEA––FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:Isforeacheffectaweigthfactormentioned,foreachcausetheprobabilityandforeachsollutiontheevolutionfactordefinedIstheFMEA-worksheetcompletelyfilled-in(actions,responsibleperson,date)?Tasksofthefacilitator:FM