FMEA培訓(xùn)教材(英文版)(ppt 79頁).ppt

1、Philips FMEA,Failure Mode and Effect Analysis,Content of the course,Introduction Product - FMEA Blockdiagram , functiontree Process - FMEA Process-flowdiagram (macro-level) , micro-level Facilitatorskills,FMEA Introduction,Why FMEAs? Definition, Purpose, Types, Benefits Team Approach,Why FMEAs?,Appr

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

3、,Failures,Time,Rate severity of failure modes Identify actions to reduce occurence Test adequacy of controls,FMEA Purpose,FMEAs are intended to .,FMEA Types,Optical,Product- FMEA,Mechanical,Process- FMEA,Electrical,Mechanical,Electrical,Optical,FMEA Sessions,Benefits Product-FMEAs,Assess failure mod

4、e 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,Product,Voordelen Proces-FMEAs,Assess effects on all customers Identifies potential manufacturing and assembly causes to f

5、ocus controls on reducing occurrence or increasing detection.,Design,Proces,Generating FMEAs,FMEAs,Who initiates?,Failure Mode and Effect Analysis,Who updates?,Who is FMEA-customer?,Startingdate/revisiondate?,When completed?,How docu-mented?,When to discard?,Who prepares?,Managing FMEAs,Modification

6、 to a product or process is planned Component is to be used in new environment Customer rejections,FMEAs are living documents and are updated .,FMEA Team Approach,Support-team,Product-FMEA Content,Define FMEA-team Define scope Describe functions Brainstorming Function Trees,Product-FMEA Team,Product

7、-FMEA Scope,Create Blockdiagram Identify the boundery for Analysis Confirm composition of support team.,Once coreteam is established .,Blockdiagram,Component/Assembly,Screw,Weld,Adhesive,Example blockdiagram (Settop Wildfire),Front,Klicked,Display PCB,PSU,Smartcard PCB,Frame,Cover,Klicked,Klicked,Sc

8、rewed,Screwed,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?,Generate Control Display,Describe Function,light speed information,Describe Functions,Thought st

9、arters . Satisfy user Attract user Guarantee durability Easy to repare Safety requirements,Brainstorming,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 functio

10、ns of the product.,Constructing Functiontrees,Display Information,Functiontree Frontbutton (Settop),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 struct

11、ure by asking “Why is this function included?”,Product-FMEA Functions,Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-test,MC,ML,P,Potential failure Modes,No function Partial function,Failure Mode TypeExa

12、mple,Not operational Not all of function operating,Failure Modes: Frontbutton,No function No tekst available Partial function Tekst partial available,Function: Tekst clear visible after 100 x cleaning.,Failure Mode Type Example,Product-FMEA Modes of failure,Description Level 1,Description Level 2,Fu

13、nction,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-test,Tekst unread-able,MC,ML,P,Effects failure,What are the effects of the failure relating to:,- another part - the complete assembly - the customer - the enduser - the governmental regulations,Pro

14、duct-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,Product-FMEA Effects of failure,Description Level 1,Description Level 2,Function,Mode of Failure,Effect,

15、Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-test,Tekst unread-able,MC,ML,P,Assembly not possible to sale Customer dissatisfied,Severity (Weightfactor),What is the severity of the effects?,Criteria: Severity of effect,Class,Effect,Accepted failure,D,None,Safety failure,S,U

16、nacceptable risk,Non-conforming with safety,Correction is nescessary,A,Relative big risk,Correctie is recommended,B,risico,Correctie is nuttig,C,Ratingcriteria voor Severity (Weightfactor),Minimum risk,Correctie is usefull,C,Frontbutton/ Tekst readable after PQR- test,Failure Mode Tekst unreadable,E

17、ffects Assembly: unsaleable (A) Customer: Dissatisfied(A) Gov.Reg.: None (D),A,Rating of Weightfactor example,Sev.,Part,Function,Product-FMEA Weightfactor,Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-t

18、est,Tekst unread-able,MC,ML,P,Assembly not possible to sale Customer dissatisfied,A,Potential Cause of Failure,A weakness in the design with a failure mode as effect.,Manufacturing misbuilds,Due to design Deficiencies,+ -,+ -,Manufacturing misbuilds,Robust Design,+ -,+ -,Use Fishbone Diagram,Cause o

19、f failure,Tekst unreadable,Inkt of poor quality,Tekst on wrong location,Cause of failure “Why”-ladder,Designrequirement,WHY?,level 1,Tekst unreadable,WHY?,level 2,WHY?,level 3,Inkt doesnt stick,Surface roughness not ok.,Sentencing Technique,Failure Mode,Sentencing Technique - Example,Tekst unreadabl

20、e,Product-FMEA Cause,Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-test,Tekst unread-able,MC,ML,P,Assembly not possible to sale Customer dissatisfied,A,Tekst on wrong location,Product-FMEA Occurrence,Wh

21、at is the possibility that the failure occurrs?,Possible Failure Rates,Ranking,Probability of failure, 1 of 20,Very high,Moderate, 1 of 400, 1 of 15000,Low, 1 of 15000,4,5,3,2,1,Ratingcriteria occurrence, 1 of 3,Product-FMEA Occurrence,Description Level 1,Description Level 2,Function,Mode of Failure

22、,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-test,Tekst unread-able,MC,ML,P,Assembly not possible to sale Customer dissatisfied,A,Tekst on wrong location,5,Produkt-FMEA Action/Solution,What are possible actions to: - eliminate the failure - reduce effect - reduce o

23、ccurrence.,Product-FMEA Action/Solution,Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst clear visible after PQR-test,Tekst unread-able,MC,ML,P,Assembly not possible to sale Customer dissatisfied,A,Tekst on wrong location,5,No te

24、kst on buttons,JD,Define Evolutionfactor,Cause not known4 Solution not known3 Solution not evaluated2 Solution not implemented1 Solution implemented0,Product-FMEA Evolutionfactor,Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,Front,Button,Tekst c

25、lear visible after PQR-test,Tekst unread-able,MC,ML,P,Assembly not possible to sale Customer dissatisfied,A,Tekst on wrong location,5,No tekst on buttons,JD,1,Risk evaluation,Severity (Weightfactor) Occurrence Evolutionfactor Risk maturity - grid,Maturity Grid,Weight Factor,Evolution Factor,Evolutio

26、n Factor,S,A,B,C,D,0,1,2,3,4,0,1,2,3,4,3,7,5,4,5,1,2,3,Product-FMEA Electrical (Example),Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,P,Front end,Tuner,Put-through selected signal (SD12XX),Tuner gets disturbed by noise generated by 14-18V gener

27、ation,Tuner gives bad signal through,A,Low frequent noise is not filtered,5,ML,MC,Add bead in LNBA line, right next to tuner,GD,2,Proces - FMEA Content,FMEA-team Define scope Describe functions,Proces-FMEA Team,Process-FMEA Scope,Create flow-diagram Define scope Define support-team.,Process-FMEA (Ex

28、ample),Description Level 1,Description Level 2,Function,Mode of Failure,Effect,Cause,Action/ Solution,Resp.,P,Glue,Glue with cyano-acrylate,Join parts,Cyanoacrylate not well cured,Lifetime problems,A,Glue volume to high,5,ML,MC,Use activator,JD,2,FMEA,Tasks & Responsibilities.,FMEA Teamleader,Prepar

29、ation 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:,FMEA Teamleader,Preparation of the FMEA - s

30、ession: Distribute/display important information: agenda, FMEA-method Define tasks of the team-members: Who is the teamleader, facilitator, timekeeper, secretary?,Tasks of the teamleader:,FMEA Facilitator,Helps preparing the FMEA - session Supports the teamleader Takes care that FMEA-metholodgy is c

31、orrectly used Takes care of the team - process.,Tasks of the facilitator:,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).,

32、Tasks of the facilitator:,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.

33、,Tasks of the facilitator:,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:,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 t