飛利浦失效模式與效應(yīng)分析

PhilipsFMEA

FailureModeandEffectAnalysis第一頁(yè)，共七十四頁(yè)。ContentofthecourseIntroductionProduct-FMEABlockdiagram,functiontreeProcess-FMEAProcess-flowdiagram(macro-level),micro-levelFacilitatorskills第二頁(yè)，共七十四頁(yè)。FMEA–IntroductionWhyFMEA’s?Definition,Purpose,Types,BenefitsTeamApproachFMEA-PhilipsIntroduction第三頁(yè)，共七十四頁(yè)。WhyFMEA’s?Appropriaterecommendedactionsmaynothavebeentaken.Savingsinengineeringtime.Reductionofchangesimmediatelybeforeproductionstart(CommercialRelease).第四頁(yè)，共七十四頁(yè)。FMEA–DefinitionIdentifypotentialfailuremodesPrioritizeactionsDocumenttheprocess.Structuredgroupofactivitieswhich...第五頁(yè)，共七十四頁(yè)。FMEA–PurposeFailuresTimeCR(Productionstart)FMEA第六頁(yè)，共七十四頁(yè)。RateseverityoffailuremodesIdentifyactionstoreduceoccurenceTestadequacyofcontrolsFMEA–PurposeFMEA’sareintendedto...

第七頁(yè)，共七十四頁(yè)。FMEA–Types

OpticalProduct-FMEA

MechanicalProcess-FMEA

ElectricalMechanicalElectricalOptical第八頁(yè)，共七十四頁(yè)。FMEASessionsFMEAonEVTModelFMEAonFirstMechanicalWorkingModelFMEAonPartFilesFMEAonL1Board(ftboL2)FMEAonL0Board(ftboL1)FMEAonL0Schematics(ftboL0)FMEAonArchitecturesMechanicalElectricalFMEAonchosenArchitecture第九頁(yè)，共七十四頁(yè)。Benefits–Product-FMEA’sAssessfailuremodeeffectsonallcustomers.AidsinevaluatingtestspecificationsEvaluationofdesignrelatingto DFM DFA DFTIncreasesthepossibilitytodetectpossiblefailuremodes.ProcesProduct第十頁(yè)，共七十四頁(yè)。Voordelen–Proces-FMEA’sAssesseffectsonallcustomersIdentifiespotentialmanufacturingandassemblycausestofocuscontrolsonreducingoccurrenceorincreasingdetection.DesignProces第十一頁(yè)，共七十四頁(yè)。GeneratingFMEA’sFMEAsWhoinitiates?FailureModeandEffectAnalysisWhoupdates?WhoisFMEA-customer?Startingdate/

revisiondate?Whencompleted?Howdocu-mented?Whentodiscard?Whoprepares?第十二頁(yè)，共七十四頁(yè)。ManagingFMEA’sModificationtoaproductorprocessisplannedComponentistobeusedinnewenvironmentCustomerrejectionsFMEA’sarelivingdocumentsandareupdated...第十三頁(yè)，共七十四頁(yè)。FMEA–TeamApproachCore-

teamSupport-

team第十四頁(yè)，共七十四頁(yè)。Product-FMEA–ContentDefineFMEA-teamDefinescopeDescribefunctionsBrainstormingFunctionTreesPhilipsProduct-FMEAContent第十五頁(yè)，共七十四頁(yè)。Product-FMEA–TeamDesign-

EnginieerProduction/

process-enginieerCore-

team

Representitivesfrom:developmentproductionqualitypurchasetestdept....Support

teamFacilitator第十六頁(yè)，共七十四頁(yè)。Product-FMEA–ScopeCreateBlockdiagramIdentifythebounderyforAnalysisConfirmcompositionofsupportteam.Oncecoreteamisestablished...第十七頁(yè)，共七十四頁(yè)。BlockdiagramComponent/

AssemblyPartXPartYPartZServiceOthersystemsAssemblyUserScrewWeldAdhesive第十八頁(yè)，共七十四頁(yè)。Exampleblockdiagram(SettopWildfire)FrontKlickedDisplayPCBPSUSmartcardPCBFrameCoverKlickedKlickedScrewedScrewed第十九頁(yè)，共七十四頁(yè)。DetermineFunctionsDescribestheintentofthedesignMustbemeasurebleorsetatanactionablelevelRepresentsallwants,bothspokenandunspoken.Whatarethefunctionsofthedesign?第二十頁(yè)，共七十四頁(yè)。VerbIndicatesaction,occurrence,being

Generate Control Display NounIndicateswhattheactionrelatestoDescribeFunctionlightspeedinformation 第二十一頁(yè)，共七十四頁(yè)。DescribeFunctionsThoughtstarters...SatisfyuserAttractuserGuaranteedurabilityEasytorepareSafetyrequirements第二十二頁(yè)，共七十四頁(yè)。Brainstorming第二十三頁(yè)，共七十四頁(yè)。FunctiontreeProvidesanorganizedapproachtoidentifytheessentialfeaturesofaproductDefinesallspokenandunspokenrequirementsProvidestheteamwithaclearoverviewofallthefunctionsoftheproduct.第二十四頁(yè)，共七十四頁(yè)。FirstlevelSecondLevelConstructingFunctiontreesThirdLevelHOW?WHY?第二十五頁(yè)，共七十四頁(yè)。DisplayInformationFunctiontree–Frontbutton(Settop)HOW?Mustbeprintableandresistancetewear.PQR-Cleantest.Tekstclearlyvisibleafterx-timescleaning.WHY?第二十六頁(yè)，共七十四頁(yè)。GuidelinesBrainstormallfunctions(VERB-NOUN)Documentindividualfunctionsbyasking “Howisthisfunctionachieved?”Repeatlefttoright,untilactionablelevelWorkrighttoleftandcheckstructurebyasking“Whyisthisfunctionincluded?”第二十七頁(yè)，共七十四頁(yè)。Product-FMEA–FunctionsDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testMCMLP第二十八頁(yè)，共七十四頁(yè)。PotentialfailureModesNofunctionPartialfunction

FailureModeType ExampleNotoperationalNotalloffunctionoperating

第二十九頁(yè)，共七十四頁(yè)。FailureModes:FrontbuttonNofunction NotekstavailablePartialfunction TekstpartialavailableFunction:Tekstclearvisibleafter100xcleaning.FailureModeType

Example第三十頁(yè)，共七十四頁(yè)。Product-FMEA–ModesoffailureDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLP第三十一頁(yè)，共七十四頁(yè)。EffectsfailureWhataretheeffectsofthefailurerelatingto:-anotherpart-thecompleteassembly-thecustomer-theenduser-thegovernmentalregulations第三十二頁(yè)，共七十四頁(yè)。Product-FMEA–TabelofeffectsFailureModeTekstunread-ableFrontbuttonCompleteAssemblyDifficulttosaleCustomerDissatisfiedEnduserDissatisfiedGovernmentalregulationNoneAnotherpartNone第三十三頁(yè)，共七十四頁(yè)。Product-FMEA–EffectsoffailureDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfied第三十四頁(yè)，共七十四頁(yè)。Severity(Weightfactor)Whatistheseverityoftheeffects?第三十五頁(yè)，共七十四頁(yè)。Criteria:SeverityofeffectClassEffectAcceptedfailureDNoneSafetyfailureSUnacceptableriskNon-conformingwithsafetyCorrectionisnescessaryARelativebigriskCorrectieisrecommendedBrisicoCorrectieisnuttigCRatingcriteriavoorSeverity(Weightfactor)MinimumriskCorrectieisusefullC第三十六頁(yè)，共七十四頁(yè)。

Frontbutton/TekstreadableafterPQR-testFailureMode

TekstunreadableEffects

Assembly:unsaleable (A)Customer:Dissatisfied (A)Gov.Reg.:None (D)ARatingofWeightfactor–exampleSev.PartFunction第三十七頁(yè)，共七十四頁(yè)。Product-FMEA–WeightfactorDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedA第三十八頁(yè)，共七十四頁(yè)。PotentialCauseofFailure

Aweaknessinthedesignwithafailuremodeaseffect.第三十九頁(yè)，共七十四頁(yè)。ManufacturingmisbuildsDuetodesignDeficiencies+-+-第四十頁(yè)，共七十四頁(yè)。ManufacturingmisbuildsRobustDesign+-+-第四十一頁(yè)，共七十四頁(yè)。UseFishboneDiagramCauseoffailureTekstunreadableInktofpoorqualityTekstonwronglocation第四十二頁(yè)，共七十四頁(yè)。Causeoffailure–“Why”-ladderDesignrequirementWHY?level1TekstunreadableWHY?level2WHY?level3Inktdoesn’tstickSurfaceroughnessnotok.第四十三頁(yè)，共七十四頁(yè)。SentencingTechniqueFailureModeCouldresultinEffectDuetoCause第四十四頁(yè)，共七十四頁(yè)。SentencingTechnique-ExampleTekstunreadableCouldresultinDissatisfiedcustomerDuetoSurfaceroughness(designreq.)第四十五頁(yè)，共七十四頁(yè)。Product-FMEA–CauseDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation第四十六頁(yè)，共七十四頁(yè)。Product-FMEA–OccurrenceWhatisthepossibilitythatthefailureoccurrs?第四十七頁(yè)，共七十四頁(yè)。PossibleFailureRatesRankingProbabilityoffailure>1of20VeryhighModerate>1of400>1of15000Low<1of1500045321Ratingcriteriaoccurrence31of3第四十八頁(yè)，共七十四頁(yè)。Product-FMEA–OccurrenceDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5第四十九頁(yè)，共七十四頁(yè)。Produkt-FMEA–Action/SolutionWhatarepossibleactionsto: -eliminatethefailure -reduceeffect -reduceoccurrence.第五十頁(yè)，共七十四頁(yè)。Product-FMEA–Action/SolutionDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5NotekstonbuttonsJD第五十一頁(yè)，共七十四頁(yè)。DefineEvolutionfactorCausenotknown 4Solutionnotknown 3Solutionnotevaluated 2Solutionnotimplemented 1Solutionimplemented 0第五十二頁(yè)，共七十四頁(yè)。Product-FMEA–EvolutionfactorDescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.FrontButtonTekstclearvisibleafterPQR-testTekstunread-ableMCMLPAssemblynotpossibletosaleCustomerdissatisfiedATekstonwronglocation5NotekstonbuttonsJD1第五十三頁(yè)，共七十四頁(yè)。RiskevaluationSeverity(Weightfactor)OccurrenceEvolutionfactorRiskmaturity-grid

第五十四頁(yè)，共七十四頁(yè)。MaturityGridWeightFactorEvolutionFactorEvolutionFactorSABCD012340123437545123第五十五頁(yè)，共七十四頁(yè)。Product-FMEA–Electrical(Example)DescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.PFrontendTunerPut-throughselectedsignal(SD12XX)Tunergetsdisturbedbynoisegeneratedby14-18VgenerationTunergivesbadsignalthroughALowfrequentnoiseisnotfiltered5MLMCAddbeadinLNBAline,rightnexttotunerGD2第五十六頁(yè)，共七十四頁(yè)。Proces-FMEA–ContentFMEA-teamDefinescopeDescribefunctionsPhilipsProces-FMEAContent第五十七頁(yè)，共七十四頁(yè)。Proces-FMEA–TeamProduction/-

process-engineerDesign-engineerCore-

team

Representativesof:ProductdevelopmentProcess-developmentProductionQualityPurchaseOwnerofthenextprocess….Support-

teamFacilitatororapplicationengineer第五十八頁(yè)，共七十四頁(yè)。Process-FMEA–ScopeCreateflow-diagramDefinescopeDefinesupport-team.第五十九頁(yè)，共七十四頁(yè)。Process-FMEA–(Example)DescriptionLevel1DescriptionLevel2FunctionModeofFailureEffectCauseAction/SolutionResp.PGlueGluewithcyano-acrylateJoinpartsCyanoacrylatenotwellcuredLifetimeproblemsAGluevolumetohigh5MLMCUseactivatorJD2第六十頁(yè)，共七十四頁(yè)。FMEA

Tasks&Responsibilities.第六十一頁(yè)，共七十四頁(yè)。FMEA–TeamleaderPreparationoftheFMEA-sessiondistributionoftheproducttotheparticipants1or2weeksbeforethemeetingtogatheralltherelevantinformation.Prepare(fill-in)FMEA-worksheetasgoodaspossible(functions,failuremodes,...)Tasksoftheteamleader:第六十二頁(yè)，共七十四頁(yè)。FMEA–TeamleaderPreparationoftheFMEA-session:Distribute/displayimportantinformation:agenda,FMEA-methodDefinetasksoftheteam-members:Whoistheteamleader,facilitator,timekeeper,secretary?Tasksoftheteamleader:第六十三頁(yè)，共七十四頁(yè)。FMEA–FacilitatorHelpspreparingtheFMEA-sessionSupportstheteamleaderTakescarethatFMEA-metholodgyiscorrectlyusedTakescareoftheteam-process.Tasksofthefacilitator:第六十四頁(yè)，共七十四頁(yè)。FMEA–FacilitatorPreparationoftheFMEA-sessionpreparationtogetherwiththeteam-leaderdefineagendaforthemeetingproduct-FMEA:createblockdiagramprocess-FMEA:createflowdiagramdefineparticipants(6-8persons).Tasksofthefacilitator:第六十五頁(yè)，共七十四頁(yè)。FMEA–FacilitatorSupportingtheteamleader:theteamleaderisfocussedontheproject(timing,technicalsollutions,…).ThefacilitatortakescareforcorrectapplyingoftheFMEA-proces.SupportstheteamleaderwiththepreparationofthemeetingandduringtheFMEA-session.Tasksofthefacilitator:第六十六頁(yè)，共七十四頁(yè)。FMEA–FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:arefunktionscorrectwrittendown(verb/noun)?areallfailuremodesmentioned,listed?areeffectsofthefailuremodescorrect?(noconfusionbetweencausesandeffects).Tasksofthefacilitator:第六十七頁(yè)，共七十四頁(yè)。FMEA–FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:Isforeacheffectaweigthfactormentioned,foreachcausetheprobabilityandforeachsollutiontheevolutionfactordefinedIstheFMEA-worksheetcompletelyfilled-in(actions,responsibleperson,date)?Tasksofthefacilitator:第六十八頁(yè)，共七十四頁(yè)。FMEA–FacilitatorTakingcareforcorrectapplyingFMEA-metholodgy:don’tloosetimewithlongdiscussionsaboutseverityan