philips fmea english
TRANSCRIPT
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1.1
Philips FMEA
Failure Mode and Effect Analysis
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1.2
Content of the course
Introduction Product - FMEA
Blockdiagram , functiontree Process - FMEA
Process-flowdiagram (macro-level) , micro-level Facilitatorskills
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1.3
FMEA – Introduction
Why FMEA’s? Definition, Purpose,
Types, Benefits Team Approach
FMEA-FMEA-Philips
PhilipsIntroductionIntroduction
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1.4
Why FMEA’s?
Appropriate recommended actions may not have been taken.
Savings in engineering time. Reduction of changes
immediately before productionstart (Commercial Release).
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1.5
FMEA – Definition
Identify potential failure modes
Prioritize actions
Document the process.
Structured group of activities which...
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1.6
FMEA – PurposeFa
ilure
s
TimeC R(Productionstart)
FMEA
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1.7
Rate severity of failure modes Identify actions to reduce occurence Test adequacy of controls
FMEA – Purpose
FMEA’s are intended to ...
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1.8
FMEA – Types
Optical
Product-FMEA
Product-FMEA
Mechanical
Process-FMEA
Process-FMEA
Electrical
Mechanical
Electrical
Optical
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1.9
FMEA Sessions FMEA on
EVT ModelFMEA onFirst MechanicalWorking ModelFMEA on
Part Files
FMEA onL1 Board(ftbo L2)
FMEA onL0 Board(ftbo L1)
FMEA onL0 Schematics
(ftbo L0)
FMEA onArchitectures
Mechanical
Electrical
FMEA onchosen
Architecture
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1.10
Benefits – Product-FMEA’s Assess failure mode effects on all
customers. Aids in evaluating testspecifications Evaluation of design relating to
DFM DFA
DFT Increases the possibility to detect
possible failure modes.
Proces
ProductProduct
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1.11
Voordelen – Proces-FMEA’s
Assess effects on all customers
Identifies potential manufacturing and assembly causes to focus controls on reducing occurrence or increasing detection.
Design
ProcesProces
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1.12
Generating FMEA’s
FMEAs
Who initiates?
Failure Mode and
Effect Analysis
Failure Mode and
Effect Analysis
Who updates?
Who is FMEA-customer?
Startingdate/revisiondate?
When completed?
How docu-mented?
When to discard?
Who prepares?
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1.13
Managing FMEA’s
Modification to a product or process is planned
Component is to be used in new environment
Customer rejections
FMEA’s are living documents and are updated ...
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1.14
FMEA – Team Approach
Core-team
Support-team
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1.15
Product-FMEA – Content
Define FMEA-team
Define scope
Describe functions
» Brainstorming
» Function Trees
PhilipsPhilips
Product-FMEA Product-FMEA ContentContent
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1.16
Product-FMEA – Team
Design-Enginieer
Production/ process-enginieer
Core-team
Representitives from:
• development
• production
• quality
• purchase
• testdept.
• ...
Supportteam
Facilitator
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1.17
Product-FMEA – Scope
Create Blockdiagram Identify the boundery for Analysis Confirm composition of support
team.
Once coreteam is established ...
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1.18
Blockdiagram
Component/Assembly
Part X
Part Y
Part Z
Service
Other systems
Assembly
User
Screw Weld
Adhesive
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1.19
Example blockdiagram (Settop Wildfire)
FrontKlicked Display PCB
PSU
Smartcard PCB
FrameCover
Klicked
Klicked
ScrewedScrewed
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1.20
Determine Functions
Describes the intent of the design Must be measureble or set at an
actionable level Represents all wants, both spoken
and unspoken.
What are the functions of the design?
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1.21
VerbVerb
Indicates action, occurrence, being
GenerateControlDisplay
NounNoun
Indicates what the action relates to
Describe Function
lightspeedinformation
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1.22
Describe Functions
Thought starters ... Satisfy user Attract user Guarantee durability Easy to repare Safety requirements
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1.23
Brainstorming
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1.24
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.
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1.25
Firstlevel
SecondLevel
Constructing Functiontrees
ThirdLevel
HOW? WHY ?
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1.26
DisplayInformation
Functiontree – Frontbutton (Settop)
HOW?
Must be printable and resistance te wear.
PQR-Cleantest. Tekst clearly visible
after x-times cleaning.
WHY?
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1.27
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?”
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1.28
Product-FMEA – Functions
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after
PQR-test
MC
ML
P
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1.29
Potential failure Modes
No function
Partial function
Failure Mode Type Example
Not operational
Not all of function operating
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1.30
Failure Modes: Frontbutton
No function No tekst available
Partial function Tekst partial available
Function: Tekst clear visible after 100x cleaning.
Failure Mode Type Example
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1.31
Product-FMEA – Modes of failure
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-
able
MC
ML
P
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1.32
Effects failure
What are the effects of the failure relating to:
- another part
- the complete assembly
- the customer
- the enduser
- the governmental regulations
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1.33
Product-FMEA – Tabel of effects
Failure
Mode
Tekst
unread-
able
Frontbutton
Complete
Assembly
Difficult
to sale
Customer
Dissatisfied
Enduser
Dissatisfied
Governmental regulation
None
Another
part
None
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1.34
Product-FMEA – Effects of failure
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-
able
MC
ML
P
Assembly not
possible to sale
Customerdissatisfied
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1.35
Severity (Weightfactor)
What is the severity of the effects?
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1.36
Criteria: Severity of effect ClassEffect
Accepted failure DNone
Safety failureS
Unacceptable risk
Non-conforming with safety
Correction is nescessary A
Relative big risk
Correctie is recommendedB
risico Correctie is nuttigC
Ratingcriteria voor Severity (Weightfactor)
Minimum risk Correctie is usefull C
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1.37
Frontbutton/
Tekst readable
after PQR-
test
Failure
Mode
Tekst unreadable
Effects
Assembly: unsaleable (A)
Customer: Dissatisfied (A)
Gov.Reg.: None (D)
A
Rating of Weightfactor– example
Sev.
Part
Function
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1.38
Product-FMEA – Weightfactor
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-
able
MC
ML
P
Assembly not
possible to sale
Customerdissatisfied
A
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1.39
Potential Cause of Failure
A weakness in the design with a failure mode as effect.
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1.40
Manufacturing misbuilds
Due to design Deficiencies
+-
+-
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1.41
Manufacturing misbuilds
Robust Design
+-
+-
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1.42
Use Fishbone DiagramUse Fishbone Diagram
Cause of failure
Tekst unreadable
Inkt of poor quality
Tekst on wrong location
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1.43
Cause of failure – “Why”-ladder
Designrequirement
WHY?level 1
Tekst unreadableTekst unreadable
WHY?level 2
WHY?level 3
Inkt doesn’t stickSurface roughness
not ok.
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1.44
Sentencing Technique
Failure Mode
Could result in Effect
Due to
Cause
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1.45
Sentencing Technique - Example
Tekstunreadable
Could result inDissatisfied
customer
Due to Surfaceroughness
(designreq.)
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1.46
Product-FMEA – Cause
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-able
MC
ML
P
Assembly not
possible to sale
Customerdissatisfied
ATekst
on wrong
location
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1.47
Product-FMEA – Occurrence
What is the possibility that
the failure occurrs?
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1.48
Possible Failure Rates RankingProbability of failure
> 1 of 20
Very high
Moderate > 1 of 400
> 1 of 15000
Low < 1 of 15000
4
5
3
2
1
Ratingcriteria Ratingcriteria occurrenceoccurrence
1 of 3
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1.49
Product-FMEA – Occurrence
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-able
MC
ML
P
Assembly not
possible to sale
Customerdissatisfied
ATekst
on wrong
location
5
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1.50
Produkt-FMEA – Action/Solution
What are possible actions to:
- eliminate the failure
- reduce effect
- reduce occurrence.
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1.51
Product-FMEA – Action/Solution
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-able
MC
ML
P
Assembly not
possible to sale
Customerdissatisfied
ATekst
on wrong
location
5No tekst on
buttons
JD
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1.52
Define Evolutionfactor
Cause not known 4 Solution not known
3 Solution not evaluated 2 Solution not implemented
1 Solution implemented 0
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1.53
Product-FMEA – Evolutionfactor
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp.
Front Button Tekst clear
visible after PQR-test
Tekst unread-able
MC
ML
P
Assembly not
possible to sale
Customerdissatisfied
ATekst
on wrong
location
5No tekst on
buttons
JD 1
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1.54
Risk evaluation
Severity (Weightfactor)
Occurrence
Evolutionfactor
Risk maturity - grid
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1.55
Maturity Grid
Weight Factor
Evolution Factor Evolution Factor
S A B C D
0
1
2
3
4
0
1
2
3
4
3
7
5
4
5 1 2
3
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1.56
Product-FMEA – Electrical (Example)
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp. P
Front end
Tuner Put-through selected signal
(SD12XX)
Tuner gets disturbed by
noise generated by 14-18V generation
Tuner gives bad signal through
ALow frequent noise is not
filtered
5
ML
MC
Add bead in LNBA line, right
next to tuner
GD 2
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1.57
Proces - FMEA – Content
FMEA-team
Define scope
Describe functions
PhilipsPhilips
Proces - FMEA Proces - FMEA ContentContent
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1.58
Proces-FMEA – Team
Production/- process-engineer
Design-engineer
Core-team
Representatives of :
• Productdevelopment
• Process-development
• Production
• Quality
• Purchase
• Owner of the next process
• … .
Support-
team
Facilitator or application engineer
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1.59
Process-FMEA – Scope
Create flow-diagram Define scope Define support-team.
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1.60
Process-FMEA – (Example)
Description
Level 1
Description
Level 2Function Mode of
FailureEffect Cause Action/
Solution
Resp. P
Glue Glue with cyano-
acrylate
Join parts
Cyanoacrylate not well cured
Lifetime problems
AGlue volume to high
5
ML
MC
Use activator
JD 2
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1.61
FMEA
Tasks & Responsibilities.
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1.62
FMEA – 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, ... )
Tasks of the teamleader:
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1.63
FMEA – 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?
Tasks of the teamleader:
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1.64
FMEA – Facilitator
Helps preparing the FMEA - session
Supports the teamleader
Takes care that FMEA-metholodgy is
correctly used
Takes care of the team - process.
Tasks of the facilitator:
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1.65
FMEA – 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).
Tasks of the facilitator:
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1.66
FMEA – 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.
Tasks of the facilitator:
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1.67
FMEA – 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).
Tasks of the facilitator:
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1.68
FMEA – 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)?
Tasks of the facilitator:
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FMEA – 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’.
Tasks of the facilitator:
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FMEA – Facilitator
Taking care for the TEAM-process:» Are the different teamroles defined by the
teamleader. Who is the» Teamleader?
» Facilitator?
» Timekeeper?
» Secretary?
Tasks of the facilitator:
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FMEA – 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,…)
Tasks of the facilitator:
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FMEA
Software - tools at
Philips
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FMEA Library
DesignerConsult the Library
Search for solutions
Consult
FMEATool
FMEA Reports
Follow-up actions
FMEA Session
ConsultFill in
FMEA Facilitator
FMEA Maintenance
team
Maintain the FMEA Library
Filter the remarks
"POOL"of remarks
QualityEngineering Development
PurchasingOrg. and Eff. Proc. Impr.
Team
New Remarks
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FMEA
THE END