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1、 欢迎访问龙在天涯欢迎访问龙在天涯 site: http:/ bbs: http:/ 龙在天涯成立于 2 0 0 1年 10月，我们定位于一个关于 S P C , F ME A , D OE , S i x S i g ma , 品质体系，品质管理的综合网站！ 从它成立开始到现在已经有一年的时间啦，目前它的发展良好，这里吸引了一大批优秀的品质统计 6 s i g ma 爱好者 和专业人士！ 我们的目标是建立国内最好的品质/ 质量的专业网站。本站及时提供大量的最新专业文章，以及相关的资料下载， 内容丰富，我们提供的就是你想要的，另外本站新设立了一个论坛供大家交流，短短的一个月已经有几百名质量工
2、程师和多位 6 s i g ma 黑带加盟 1.1 Philips FMEA Failure Mode and Effect Analysis 1.2 龙在天涯龙在天涯 http:/ bbs: http:/ Content of the course ?Introduction ?Product - FMEA ?Blockdiagram , functiontree ?Process - FMEA ?Process-flowdiagram (macro-level) , micro-level ?Facilitatorskills 1.3 龙在天涯龙在天涯 http:/ bbs: http:/
3、 FMEA Introduction ?Why FMEAs? ?Definition, Purpose, Types, Benefits ?Team Approach FMEAFMEA- -PhilipsPhilips IntroductionIntroduction 1.4 龙在天涯龙在天涯 http:/ bbs: http:/ Why FMEAs? ?Appropriate recommended actions may not have been taken. ?Savings in engineering time. ?Reduction of changes immediately
4、before productionstart (Commercial Release). 1.5 龙在天涯龙在天涯 http:/ bbs: http:/ FMEA Definition Structured group of activities which. ?Identify potential failure modes ?Prioritize actions ?Document the process. 1.6 龙在天涯龙在天涯 http:/ bbs: http:/ FMEA Purpose Failures Time C R (Productionstart) FMEA 1.7 龙在
5、天涯龙在天涯 http:/ bbs: http:/ FMEA Purpose FMEAs are intended to . ?Rate severity of failure modes ?Identify actions to reduce occurence ?Test adequacy of controls 1.8 龙在天涯龙在天涯 http:/ bbs: http:/ FMEA Types Product- FMEA Product- FMEA Optical Mechanical Electrical Mechanical Electrical Process- FMEA Pro
6、cess- FMEA Optical 1.9 龙在天涯龙在天涯 http:/ bbs: http:/ FMEA Sessions FMEA on EVT Model FMEA on First Mechanical Working Model FMEA on Part Files FMEA on L1 Board (ftbo L2) FMEA on L0 Board (ftbo L1) FMEA on L0 Schematics (ftbo L0) FMEA on Architectures Mechanical Electrical FMEA on chosen Architecture 1
7、.10 龙在天涯龙在天涯 http:/ bbs: http:/ Benefits Product-FMEAs ?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. Product Product Proces 1.11 龙在天涯龙在天涯 http:/ bbs: htt
8、p:/ Voordelen Proces-FMEAs Design ?Assess effects on all customers ?Identifies potential manufacturing and assembly causes to focus controls on reducing occurrence or increasing detection. Proces Proces 1.12 龙在天涯龙在天涯 http:/ bbs: http:/ Generating FMEAs Who prepares?Who initiates?Who updates? FMEAs F
9、ailure Mode and Effect Analysis Failure Mode and Effect Analysis Who is FMEA- customer? When to discard? Startingdate/ revisiondate? How docu- mented? When completed? 1.13 龙在天涯龙在天涯 http:/ bbs: http:/ Managing FMEAs FMEAs are living documents and are updated . ?Modification to a product or process is
10、 planned ?Component is to be used in new environment ?Customer rejections 1.14 龙在天涯龙在天涯 http:/ bbs: http:/ FMEA Team Approach Core- team Support- team 1.15 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Content ?Define FMEA-team ?Define scope ?Describe functions Brainstorming Function Trees PhilipsPhilips
11、 ProductProduct- -FMEA FMEA ContentContent 1.16 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Team Design- Enginieer Production/ process-enginieer Core- team Representitive s from: development production quality purchase testdept. . Support team Facilitator 1.17 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA S
12、cope Once coreteam is established . ?Create Blockdiagram ?Identify the boundery for Analysis ?Confirm composition of support team. 1.18 龙在天涯龙在天涯 http:/ bbs: http:/ Blockdiagram Component/ Assembly Part X Part Y Part Z Service Other systems Assembly User Screw Weld Adhesive 1.19 龙在天涯龙在天涯 http:/ bbs:
13、http:/ Example blockdiagram (Settop Wildfire) Front Klicked Display PCB PSU Klicked Klicked Screwed Smartcard PCB Cover Screwed Frame 1.20 龙在天涯龙在天涯 http:/ bbs: http:/ Determine Functions What are the functions of the design? ?Describes the intent of the design ?Must be measureble or set at an action
14、able level ?Represents all wants, both spoken and unspoken. 1.21 龙在天涯龙在天涯 http:/ bbs: http:/ Describe Function Verb Verb Indicates action, occurrence, being Generate Control Display Noun Noun Indicates what the action relates to light speed information 1.22 龙在天涯龙在天涯 http:/ bbs: http:/ Describe Funct
15、ions Thought starters . ?Satisfy user ?Attract user ?Guarantee durability ?Easy to repare ?Safety requirements 1.23 龙在天涯龙在天涯 http:/ bbs: http:/ Brainstorming 1.24 龙在天涯龙在天涯 http:/ bbs: http:/ Functiontree ?Provides an organized approach to identify the essential features of a product ?Defines all spo
16、ken and unspoken requirements ?Provides the team with a clear overview of all the functions of the product. 1.25 龙在天涯龙在天涯 http:/ bbs: http:/ Constructing Functiontrees First level Second Level Third Level WHY ? HOW? 1.26 龙在天涯龙在天涯 http:/ bbs: http:/ Functiontree Frontbutton (Settop) WHY? HOW? Display
17、 Information Must be printable and resistance te wear. PQR-Cleantest. Tekst clearly visible after x-times cleaning. 1.27 龙在天涯龙在天涯 http:/ bbs: http:/ Guidelines ?Brainstorm all functions (VERB-NOUN) ?Document individual functions by asking “How is this function achieved?” ?Repeat left to right, until
18、 actionable level ?Work right to left and check structure by asking “Why is this function included?” 1.28 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Functions Description Level 1 Description Level 2 Function ButtonTekst clear visible after PQR- test Mode of Failure EffectCauseAction/ Solution Resp. M
19、C M L P Front 1.29 龙在天涯龙在天涯 http:/ bbs: http:/ Potential failure Modes No function Partial function Failure Mode TypeExample Not operational Not all of function operating 1.30 龙在天涯龙在天涯 http:/ bbs: http:/ Failure Modes: Frontbutton Function: Tekst clear visible after 100x cleaning. No functionNo teks
20、t available Partial functionTekst partial available Failure Mode TypeExample 1.31 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Modes of failure Description Level 1 Description Level 2 Function ButtonTekst clear visible after PQR- test Mode of Failure EffectCauseAction/ Solution Resp. M C M L P Tekst unr
21、ead- able Front 1.32 龙在天涯龙在天涯 http:/ bbs: http:/ Effects failure What are the effects of the failure relating to: - another part - the complete assembly - the customer - the enduser - the governmental regulations 1.33 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Tabel of effects Frontbutton Failure Mode
22、 Tekst unread- able Complete Assembly Difficult to sale Customer Dissatisfied Enduser Dissatisfied Governmental regulation None Another part None 1.34 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Effects of failure Description Level 1 Description Level 2 Function ButtonTekst clear visible after PQR- tes
23、t Mode of Failure EffectCauseAction/ Solution Resp. M C M L P Tekst unread- able FrontAssembly not possible to sale Customer dissatisfied 1.35 龙在天涯龙在天涯 http:/ bbs: http:/ Severity (Weightfactor) What is the severity of the effects? 1.36 龙在天涯龙在天涯 http:/ bbs: http:/ Ratingcriteria voor Severity (Weigh
24、tfactor) Criteria: Severity of effectClassEffect Safety failure S Unacceptable risk Non-conforming with safety Correction is nescessary A Relative big risk Correctie is recommended B risico Correctie is nuttig C Minimum risk Correctie is usefull C D Accepted failureNone 1.37 龙在天涯龙在天涯 http:/ bbs: htt
25、p:/ Rating of Weightfactor example Frontbutton / Tekst readable after PQR- test Failure Mode Tekst unreadable Effects Assembly: unsaleable (A) Customer: Dissatisfied(A) Gov.Reg.: None(D) Part Function A S e v. 1.38 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Weightfactor Resp. M C M L A Description Lev
26、el 1 Mode of Failure Description Level 2 Function ButtonTekst clear visible after PQR- test EffectCauseAction/ Solution P Tekst unread- able FrontAssembly not possible to sale Customer dissatisfied 1.39 龙在天涯龙在天涯 http:/ bbs: http:/ Potential Cause of Failure A weakness in the design with a failure mo
27、de as effect. 1.40 龙在天涯龙在天涯 http:/ bbs: http:/ Manufacturing misbuilds + - + - Due to design Deficiencies 1.41 龙在天涯龙在天涯 http:/ bbs: http:/ Manufacturing misbuilds + - + - Robust Design 1.42 龙在天涯龙在天涯 http:/ bbs: http:/ Cause of failure Use Fishbone DiagramUse Fishbone Diagram Tekst on wrong location
28、Tekst unreadable Inkt of poor quality 1.43 龙在天涯龙在天涯 http:/ bbs: http:/ Cause of failure “Why”-ladder Tekst unreadableTekst unreadable Inkt doesnt stick Designrequirement WHY? level 1 WHY? level 2 Surface roughness not ok. WHY? level 3 1.44 龙在天涯龙在天涯 http:/ bbs: http:/ Sentencing Technique Failure Mod
29、e Could result in Effect Due to Cause 1.45 龙在天涯龙在天涯 http:/ bbs: http:/ Sentencing Technique - Example Tekst unreadable Could result in Dissatisfied customer Due to Surface roughness (designreq.) 1.46 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Cause Resp. M C M L A Description Level 1 Mode of Failure D
30、escription Level 2 Function ButtonTekst clear visible after PQR- test EffectCauseAction/ Solution P Tekst unread- able FrontAssembly not possible to sale Customer dissatisfied Tekst on wrong location 1.47 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Occurrence What is the possibility that the failure oc
31、currs? 1.48 龙在天涯龙在天涯 http:/ bbs: http:/ Ratingcriteria Ratingcriteria occurrenceoccurrence Possible Failure RatesRankingProbability of failure 1 of 20 Very high Moderate 1 of 400 1 of 15000 Low 1 of 15000 4 5 3 2 1 1 of 3 1.49 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Occurrence Resp. M C M L A Descr
32、iption Level 1 Mode of Failure Description Level 2 Function ButtonTekst clear visible after PQR- test EffectCauseAction/ Solution P 5 Tekst unread- able FrontAssembly not possible to sale Customer dissatisfied Tekst on wrong location 1.50 龙在天涯龙在天涯 http:/ bbs: http:/ Produkt-FMEA Action/Solution What
33、 are possible actions to: - eliminate the failure - reduce effect - reduce occurrence. 1.51 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Action/Solution Resp. M C M L A JD Description Level 1 Mode of Failure Description Level 2 Function ButtonTekst clear visible after PQR- test EffectCauseAction/ Soluti
34、on P 5 Tekst unread- able FrontAssembly not possible to sale Customer dissatisfied Tekst on wrong location No tekst on buttons 1.52 龙在天涯龙在天涯 http:/ bbs: http:/ Define Evolutionfactor ?Cause not known4 ?Solution not known3 ?Solution not evaluated2 ?Solution not implemented1 ?Solution implemented0 1.5
35、3 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Evolutionfactor Resp. M C M L A JD 1 Description Level 1 Mode of Failure Description Level 2 Function ButtonTekst clear visible after PQR- test EffectCauseAction/ Solution P 5 Tekst unread- able FrontAssembly not possible to sale Customer dissatisfied Tekst
36、 on wrong location No tekst on buttons 1.54 龙在天涯龙在天涯 http:/ bbs: http:/ Risk evaluation ?Severity (Weightfactor) ?Occurrence ?Evolutionfactor ?Risk maturity - grid 1.55 龙在天涯龙在天涯 http:/ bbs: http:/ Maturity Grid Weight Factor Evolution FactorEvolution Factor SABCD 0 1 2 3 4 0 1 2 3 4 3 7 5 4 512 3 1.
37、56 龙在天涯龙在天涯 http:/ bbs: http:/ Product-FMEA Electrical (Example) Description Level 1 Description Level 2 Function TunerPut-through selected signal (SD12XX) Tuner gets disturbed by noise generated by 14-18V generation Resp. A M L M C GD 2 Mode of Failure EffectCauseAction/ Solution P Tuner gives bad
38、signal through Front end 5 Low frequent noise is not filtered Add bead in LNBA line, right next to tuner 1.57 龙在天涯龙在天涯 http:/ bbs: http:/ Proces - FMEA Content ?FMEA-team ?Define scope ?Describe functions PhilipsPhilips Proces Proces - - FMEA FMEA ContentContent 1.58 龙在天涯龙在天涯 http:/ bbs: http:/ Proc
39、es-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 1.59 龙在天涯龙在天涯 http:/ bbs: http:/ Process-FMEA Scope ?Create flow
40、-diagram ?Define scope ?Define support-team. 1.60 龙在天涯龙在天涯 http:/ bbs: http:/ Process-FMEA (Example) Resp. A M L M C JD 2 Description Level 1 Mode of Failure Description Level 2 Function Glue with cyano- acrylate Join parts EffectCauseAction/ Solution P Lifetime problems GlueCyanoacrylate not well c
41、ured 5Use activator Glue volume to high 1.61 FMEA Tasks & Responsibilities. 1.62 龙在天涯龙在天涯 http:/ bbs: http:/ 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 informat
42、ion. Prepare (fill-in) FMEA-worksheet as good as possible (functions, failure modes, . ) 1.63 龙在天涯龙在天涯 http:/ bbs: http:/ 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? 1.64 龙在天涯龙在天涯 http:/ bbs: http:/ FMEA Facilitator Tasks of the facilitator: ?Helps preparing the FMEA - session ?Supports the t