Philips FMEA by 6pVau3

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									      Philips   FMEA
Failure Mode and Effect Analysis



                              1.1
          Content of the course
   Introduction
   Product - FMEA
       Blockdiagram , functiontree
   Process - FMEA
       Process-flowdiagram (macro-level) , micro-level
   Facilitatorskills


                                                    1.2
     FMEA – Introduction

                  Why FMEA‟s?
                  Definition, Purpose,
                   Types, Benefits
                  Team Approach
Introduction



                                          1.3
    Why FMEA’s?

   Appropriate recommended
    actions may not have been
    taken.
   Savings in engineering time.
   Reduction of changes
    immediately before
    productionstart (Commercial
    Release).                   1.4
           FMEA – Definition
Structured group of activities
which...
     Identify potential failure modes
     Prioritize actions
     Document the process.


                                         1.5
Failures
           FMEA – Purpose




              FMEA


                     C R                 Time   1.6
                     (Productionstart)
           FMEA – Purpose
    FMEA’s are intended to ...
   Rate severity of failure modes
   Identify actions to reduce occurence
   Test adequacy of controls




                                           1.7
FMEA – Types
           Mechanical
Product-
           Electrical
 FMEA
           Optical

           Mechanical
Process-
 FMEA      Electrical

           Optical



                        1.8
FMEA Sessions
                                                                 FMEA on
                                                 FMEA on        EVT Model
                                             First Mechanical
                                  FMEA on Working Model
                   FMEA on        Part Files
                    chosen
   FMEA on        Architecture
  Architectures

                    FMEA on
                  L0 Schematics   FMEA on
                    (ftbo L0)     L0 Board      FMEA on
                                  (ftbo L1)     L1 Board
                                                (ftbo L2)

                                                                            1.9
Benefits – Product-FMEA’s
Product      Assess failure mode effects on all
              customers.
Proces       Aids in evaluating testspecifications
             Evaluation of design relating to
                 DFM
                 DFA
                 DFT
             Increases the possibility to detect
              possible failure modes.

                                                 1.10
Voordelen – Proces-FMEA’s
Design
            Assess effects on all customers

Proces      Identifies potential manufacturing
             and assembly causes to focus
             controls on reducing occurrence or
             increasing detection.




                                                  1.11
           Generating FMEA’s
Who initiates?   Who prepares?   Who updates?

When to           Failure        Who is FMEA-
discard?                         customer?
                 Mode and
                  FMEAs
How docu-         Effect         Startingdate/
mented?          Analysis        revisiondate?

When
completed?
                                             1.12
         Managing FMEA’s
FMEA’s are living documents
and are updated ...

    Modification to a product or process
     is planned
    Component is to be used in new
     environment
    Customer rejections
                                            1.13
  FMEA – Team Approach

Core-
team

                  Support-
                    team
                         1.14
   Product-FMEA – Content

                  Define FMEA-team
                  Define scope
                  Describe functions
Product-FMEA
   Content
                   » Brainstorming
                   » Function Trees

                                        1.15
            Product-FMEA – Team
              Facilitator


                            Support     Representitive
                             team       s from:
                                      • development
Design-
Enginieer           Core-             • production
                    team              • quality
Production/
process-enginieer                     • purchase
                                      • testdept.    1.16

                                      • ...
     Product-FMEA – Scope
Once coreteam is established ...
   Create Blockdiagram
   Identify the boundery for Analysis
   Confirm composition of support
    team.


                                         1.17
                 Blockdiagram
                    Service              Assembly



  Part   Screw     Component/             Weld      Part
   X                Assembly                         Y


User
                  Other       Adhesive       Part
                 systems                      Z            1.18
 Example blockdiagram (Settop Wildfire)
                    Smartcard PCB


                  Klicked

                                              Klicked
                       Front                                  Display PCB


                              Klicked

        Screwed                         Screwed
Cover                       Frame                       PSU




                                                                            1.19
       Determine Functions
    What are the functions of the design?


   Describes the intent of the design
   Must be measureble or set at an
    actionable level
   Represents all wants, both spoken
    and unspoken.
                                            1.20
        Describe Function

         Verb          Noun
  Indicates action,   Indicates what the
 occurrence, being    action relates to

Generate              light
Control               speed
Display               information

                                           1.21
        Describe Functions

Thought starters ...
   Satisfy user
   Attract user
   Guarantee durability
   Easy to repare
   Safety requirements
                             1.22
Brainstorming




                1.23
            Functiontree

   Provides an organized approach to
    identify the essential features of a
    product
   Defines all spoken and unspoken
    requirements
   Provides the team with a clear overview
    of all the functions of the product.
                                        1.24
Constructing Functiontrees
HOW?                 WHY ?
            Second
             Level
 First                  Third
 level                  Level




                                1.25
  Functiontree – Frontbutton (Settop)
    HOW?                                          WHY?
              Must be printable and   PQR-Cleantest. Tekst clearly visible
              resistance te wear.     after x-times cleaning.




  Display
Information


                                                                       1.26
               Guidelines
   Brainstorm all functions (VERB-NOUN)
   Document individual functions by asking
      “How is this function achieved?”
   Repeat left to right, until actionable level
   Work right to left and check structure by
    asking “Why is this function included?”


                                               1.27
              Product-FMEA – Functions
Description   Description              Mode of
                            Function             Effect   Cause   Action/ Resp. M M    P
                                       Failure                                C   L
Level 1       Level 2                                             Solution



  Front       Button        Tekst
                             clear
                            visible
                             after
                            PQR-
                             test




                                                                                      1.28
       Potential failure Modes

Failure Mode Type        Example
No function         Not operational
Partial function    Not all of function operating




                                                1.29
      Failure Modes: Frontbutton
    Function: Tekst clear visible after 100x cleaning.


Failure Mode Type                 Example
No function                 No tekst available
Partial function            Tekst partial available




                                                         1.30
Product-FMEA – Modes of failure
Description   Description              Mode of
                            Function             Effect   Cause   Action/    Resp. M   M   P
                                       Failure                                    C    L
Level 1       Level 2                                             Solution



  Front       Button        Tekst       Tekst
                             clear     unread-
                            visible     able
                             after
                            PQR-
                              test




                                                                                       1.31
           Effects failure

What are the effects of
the failure relating to:

        - another part
        - the complete assembly
        - the customer
        - the enduser
        - the governmental regulations
                                         1.32
 Product-FMEA – Tabel of effects
                    Frontbutton

Failure   Another   Complete      Customer       Enduser       Governmental
                                                                regulation
 Mode      part     Assembly

 Tekst                                                            None
           None      Difficult   Dissatisfied   Dissatisfied

unread-              to sale

 able




                                                                              1.33
 Product-FMEA – Effects of failure
Description   Description              Mode of
                            Function               Effect       Cause   Action/    Resp. M   M   P
                                       Failure                                          C    L
Level 1       Level 2                                                   Solution



  Front       Button        Tekst       Tekst    Assembly
                             clear     unread-      not
                            visible     able     possible to
                             after                  sale
                            PQR-
                              test               Customer
                                                 dissatisfied




                                                                                             1.34
 Severity (Weightfactor)


What is the severity of the effects?




                                       1.35
Ratingcriteria voor Severity
(Weightfactor)
    Effect            Criteria: Severity of effect   Class
Non-conforming
                 Safety failure
with safety
                                                      S

Unacceptable     Correction is nescessary
risk                                                  A
                 Correctie is recommended
Relative big
risk
                                                      B

risico           Correctie is nuttig
                 Correctie is usefull
 Minimum risk                                         C
                                                      C
                                                          1.36

     None        Accepted failure                     D
  Rating of Weightfactor– example
                                                          S
 Part
              Failure                     Effects         ev
                                                          .
   Function   Mode
                         Assembly: unsaleable       (A)
Frontbutton   Tekst      Customer: Dissatisfied     (A)    A
     /      unreadable   Gov.Reg.: None             (D)

   Tekst
 readable
after PQR-
                                                          1.37
   test
          Product-FMEA – Weightfactor
Description   Description              Mode of
                            Function               Effect       Cause   Action/    Resp. M   M   P
                                       Failure                                          C    L
Level 1       Level 2                                                   Solution



  Front       Button        Tekst       Tekst    Assembly
                                                                                        A
                             clear     unread-      not
                            visible     able     possible to
                             after                  sale
                            PQR-
                              test               Customer
                                                 dissatisfied




                                                                                             1.38
Potential Cause of Failure

A weakness in the design with a
failure mode as effect.




                                  1.39
Manufacturing misbuilds
 Due to design Deficiencies



        +           +
         -          -

                              1.40
Manufacturing misbuilds
     Robust Design



       +             +
       -             -

                          1.41
 Cause of failure
Use Fishbone Diagram

          Tekst on wrong location


                                Tekst
                              unreadable




Inkt of poor quality                   1.42
Cause of failure – “Why”-ladder
                Tekst unreadable


Inkt doesn’t stick
                     Surface roughness
    level 1
    WHY?             not ok.
                        level 2
                                         Designrequirement
                       WHY?
                                            level 3     1.43
                                           WHY?
 Sentencing Technique

          Could result in   Effect

Failure
 Mode         Due to
                            Cause


                                     1.44
  Sentencing Technique -
        Example
                               Dissatisfied
             Could result in    customer
  Tekst
unreadable
             Due to                Surface
                                 roughness
                                (designreq.)



                                               1.45
                   Product-FMEA – Cause
Description   Description              Mode of
                            Function               Effect        Cause     Action/    Resp. M   M   P
                                       Failure                                             C    L
Level 1       Level 2                                                      Solution



  Front       Button        Tekst      Tekst     Assembly
                                                                 Tekst                     A
                             clear     unread-      not
                            visible    able      possible to    on wrong
                             after                  sale
                            PQR-                                location
                              test               Customer
                                                 dissatisfied




                                                                                                1.46
Product-FMEA – Occurrence


     What is the possibility that
        the failure occurrs?



                                    1.47
                          Ratingcriteria
                           occurrence


 Probability of failure      Possible Failure Rates   Ranking

Very high                           1 of 3            5
                                    > 1 of 20           4

Moderate                           > 1 of 400           3

                                  > 1 of 15000          2

Low                               < 1 of 15000          1

                                                            1.48
          Product-FMEA – Occurrence
Description   Description              Mode of
                            Function               Effect        Cause     Action/    Resp. M   M   P
                                       Failure                                             C    L
Level 1       Level 2                                                      Solution



  Front       Button        Tekst      Tekst     Assembly                                           5
                                                                 Tekst                     A
                             clear     unread-      not
                            visible    able      possible to    on wrong
                             after                  sale
                            PQR-                                location
                              test               Customer
                                                 dissatisfied




                                                                                                1.49
 Produkt-FMEA – Action/Solution

What are possible actions to:

       - eliminate the failure
       - reduce effect
       - reduce occurrence.


                                  1.50
 Product-FMEA – Action/Solution
Description   Description              Mode of
                            Function               Effect        Cause     Action/    Resp. M   M   P
                                       Failure                                             C    L
Level 1       Level 2                                                      Solution



  Front       Button        Tekst      Tekst     Assembly                             JD            5
                                                                 Tekst     No tekst        A
                             clear     unread-      not
                            visible    able      possible to                 on
                                                                on wrong
                             after                  sale                   buttons
                            PQR-                                location
                              test               Customer
                                                 dissatisfied




                                                                                                1.51
     Define Evolutionfactor

   Cause not known            4
   Solution not known         3
   Solution not evaluated     2
   Solution not implemented   1
   Solution implemented       0


                                   1.52
  Product-FMEA – Evolutionfactor
Description   Description              Mode of
                            Function               Effect        Cause     Action/    Resp. M   M   P
                                       Failure                                             C    L
Level 1       Level 2                                                      Solution



  Front       Button        Tekst      Tekst     Assembly                                           5
                             clear     unread-      not          Tekst     No tekst JD     A 1
                            visible    able      possible to                 on
                                                                on wrong
                             after                  sale                   buttons
                            PQR-                                location
                              test               Customer
                                                 dissatisfied




                                                                                                1.53
           Risk evaluation

   Severity (Weightfactor)

   Occurrence

   Evolutionfactor

   Risk maturity - grid

                              1.54
                   Maturity Grid
                       Weight Factor
                   S   A    B      C   D

           4                               4
           3            5    1    2        3
           2            3         5        2
           1                 7             1
            0          3          4        0
Evolution Factor                       Evolution Factor
                                                          1.55
 Product-FMEA – Electrical                                                                              (Example)

Description   Description                      Mode of
                              Function                          Effect          Cause        Action/     Resp. M M   P
                                               Failure
Level 1       Level 2                                                                                          C L
                                                                                             Solution



  Front        Tuner         Put-through      Tuner gets      Tuner gives   Low frequent Add bead        GD   A 2 5
   end                      selected signal disturbed by      bad signal     noise is not in LNBA
                                                               through                    line, right
                              (SD12XX)      noise generated                    filtered
                                                                                             next to
                                              by 14-18V                                       tuner
                                              generation




                                                                                                                1.56
    Proces - FMEA – Content

                   FMEA-team
                   Define scope
                   Describe functions
Proces - FMEA
   Content


                                         1.57
           Proces-FMEA – Team
  Facilitator or application engineer

                                                  Representatives
                                   Support-       of :
                                     team     •   Productdevelopment
                                              •   Process-development
Production/-                                  •   Production
process-engineer    Core-                     •   Quality
                    team                      •   Purchase
Design-engineer
                                              •   Owner of the next
                                                  process
                                              •   ….
                                                                 1.58
     Process-FMEA – Scope


   Create flow-diagram
   Define scope
   Define support-team.



                            1.59
                        Process-FMEA – (Example)
Description   Description                 Mode of
                            Function                     Effect    Cause     Action/    Resp. M M   P
                                          Failure
Level 1       Level 2                                                                         C L
                                                                             Solution



  Glue        Glue with      Join      Cyanoacrylate    Lifetime                            A 2 5
                                                                    Glue        Use    JD
               cyano-        parts     not well cured   problems
                                                                   volume    activator
              acrylate                                             to high




                                                                                               1.60
         FMEA

Tasks & Responsibilities.


                        1.61
          FMEA – Teamleader
Tasks of the teamleader:
     Preparation of the FMEA - session
      »   distribution of 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, ... )



                                                         1.62
          FMEA – Teamleader
Tasks of the teamleader:
     Preparation of the FMEA - session:
      »   Distribute/display important information:
          » agenda, FMEA-method

      »   Define tasks of the team-members:
          » Who is the teamleader, facilitator, timekeeper,
            secretary?




                                                              1.63
          FMEA – Facilitator
Tasks of the facilitator:
     Helps preparing the FMEA - session
     Supports the teamleader
     Takes care that FMEA-metholodgy is
      correctly used
     Takes care of the team - process.
                                           1.64
            FMEA – Facilitator
Tasks of the facilitator:
     Preparation of the FMEA - session
      »   preparation together with the team-leader
      »   define agenda for the meeting
      »   product-FMEA : create blockdiagram
      »   process-FMEA: create flowdiagram
      »   define participants (6-8 persons).


                                                      1.65
            FMEA – Facilitator
Tasks of the facilitator:
     Supporting 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
          preparation of the meeting and during the
          FMEA-session.
                                                           1.66
            FMEA – Facilitator
Tasks of the facilitator:
     Taking 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 correct? (no
          confusion between causes and effects).


                                                          1.67
            FMEA – Facilitator
Tasks of the facilitator:
     Taking care for correct applying
      FMEA-metholodgy:
      »   Is for each effect a weigthfactor mentioned,
          for each cause the probability and for each
          sollution the evolutionfactor defined
      »   Is the FMEA-worksheet completely filled-in
          (actions, responsible person, date)?

                                                         1.68
            FMEA – Facilitator
Tasks of the facilitator:
     Taking care for correct applying
      FMEA-metholodgy:
      »   don‟t loose time with long discussions
          about severity and probability. In case of
          doubt, take the „worst case‟.




                                                       1.69
            FMEA – Facilitator
Tasks of the facilitator:
     Taking care for the TEAM-process:
      »   Are the different teamroles defined by the
          teamleader. Who is the
          » Teamleader?
          » Facilitator?
          » Timekeeper?
          » Secretary?



                                                       1.70
            FMEA – Facilitator
Tasks of the facilitator:
     Taking care for the TEAM-process:
      »   Are all teammembers participating in
          discussions
      »   Avoid long discussions between 2 persons,
          don‟t look for sollutions.(discuss difficult
          items in a small group separately)
      »   An „open-climate‟ during the meeting is very
          important (don‟t look for „guilty persons‟, try
          to know te real problems,…)                       1.71
     FMEA

Software - tools
   at Philips

                   1.72
                                       Development
                        Engineering                  Purchasing
          Quality                                                     Org. and Eff.   Proc. Impr.
                                                                                        Team



                                         "POOL"
                                       of remarks


                                    FMEA      Maintain the FMEA Library
                                  Maintenance
  New                                         Filter the remarks
Remarks                              team



                                      FMEA Library
               FMEA        FMEA Reports                                      Consult the Library
                                                                  Designer
                Tool                                                         Search for solutions
                           Follow-up actions

                                                                             Consult
Fill in                     Consult


                    FMEA Facilitator
                                                                                                1.73

     FMEA Session
 FMEA

THE END


          1.74

								
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