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Philips FMEA

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Philips FMEA Failure Mode and Effect Analysis Content of the course FMEA Introduction Why FMEA s? Definition, Purpose, Types, Benefits Team Approach Why FMEA s? – PowerPoint PPT presentation

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Title: Philips FMEA


1
Philips FMEA
  • Failure Mode and Effect Analysis

2
Content of the course
  • Introduction
  • Product - FMEA
  • Blockdiagram , functiontree
  • Process - FMEA
  • Process-flowdiagram (macro-level) , micro-level
  • Facilitatorskills

3
FMEA Introduction
  • Why FMEAs?
  • Definition, Purpose, Types, Benefits
  • Team Approach

4
Why FMEAs?
  • Appropriate recommended actions may not have been
    taken.
  • Savings in engineering time.
  • Reduction of changes immediately before
    productionstart (Commercial Release).

5
FMEA Definition
Structured group of activities which...
  • Identify potential failure modes
  • Prioritize actions
  • Document the process.

6
FMEA Purpose
Failures
Time
7
FMEA Purpose
FMEAs are intended to ...
  • Rate severity of failure modes
  • Identify actions to reduce occurence
  • Test adequacy of controls

8
FMEA Types
Mechanical
Product- FMEA
Electrical
Optical
Mechanical
Process- FMEA
Electrical
Optical
9
FMEA Sessions
10
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
Proces
11
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
12
Generating FMEAs
Who initiates?
Who prepares?
Who updates?
Who is FMEA-customer?
When to discard?
Failure Mode and Effect Analysis
FMEAs
Startingdate/revisiondate?
How docu-mented?
When completed?
13
Managing FMEAs
FMEAs are living documents and are updated ...
  • Modification to a product or process is planned
  • Component is to be used in new environment
  • Customer rejections

14
FMEA Team Approach
Support-team
15
Product-FMEA Content
  • Define FMEA-team
  • Define scope
  • Describe functions
  • Brainstorming
  • Function Trees

16
Product-FMEA Team
17
Product-FMEA Scope
Once coreteam is established ...
  • Create Blockdiagram
  • Identify the boundery for Analysis
  • Confirm composition of support team.

18
Blockdiagram
Component/Assembly
Screw
Weld
Adhesive
19
Example blockdiagram (Settop Wildfire)
Smartcard PCB
Klicked
Front
Klicked
Display PCB
Klicked
Screwed
Screwed
Frame
Cover
PSU
20
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.

21
Describe Function
Generate Control Display
light speed information
22
Describe Functions
  • Thought starters ...
  • Satisfy user
  • Attract user
  • Guarantee durability
  • Easy to repare
  • Safety requirements

23
Brainstorming
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.

25
Constructing Functiontrees
26
Functiontree Frontbutton (Settop)
Display Information
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?

28
Product-FMEA Functions
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
29
Potential failure Modes
Failure Mode Type Example
No function Partial function
Not operational Not all of function operating
30
Failure Modes Frontbutton
Function Tekst clear visible after 100x cleaning.
Failure Mode Type Example
No function No tekst available Partial
function Tekst partial available
31
Product-FMEA Modes of failure
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
32
Effects failure
What are the effects of the failure relating to
- another part - the complete assembly - the
customer - the enduser - the governmental
regulations
33
Product-FMEA Tabel of effects
Frontbutton
Complete Assembly Difficult to sale
Customer Dissatisfied
Enduser Dissatisfied
Governmental regulation None
Another part None
Failure Mode Tekst unread-able
34
Product-FMEA Effects of failure
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
Assembly not possible to sale Customer dissatisfi
ed
35
Severity (Weightfactor)
What is the severity of the effects?
36
Ratingcriteria voor Severity (Weightfactor)
Criteria Severity of effect
Class
Effect
Non-conforming with safety
Safety failure
S
Correction is nescessary
Unacceptable risk
A
Correctie is recommended
Relative big risk
B
Correctie is usefull
Minimum risk
C
Correctie is nuttig
risico
C
Accepted failure
D
None
37
Rating of Weightfactor example
Sev.
Part
Frontbutton/ Tekst readable after PQR- test
Failure Mode Tekst unreadable
Effects Assembly unsaleable
(A) Customer Dissatisfied (A) Gov.Reg. None
(D)
Function
A
38
Product-FMEA Weightfactor
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
Assembly not possible to sale Customer dissatisfi
ed
A
39
Potential Cause of Failure
  • A weakness in the design with a failure mode
    as effect.

40
Manufacturing misbuilds
Due to design Deficiencies
-
-
41
Manufacturing misbuilds
Robust Design
-
-
42
Cause of failure
Use Fishbone Diagram
Tekst on wrong location
Tekst unreadable
Inkt of poor quality
43
Cause of failure Why-ladder
Tekst unreadable
Inkt doesnt stick
Surface roughness not ok.
level 1
WHY?
level 2
Designrequirement
WHY?
level 3
WHY?
44
Sentencing Technique
Failure Mode
45
Sentencing Technique - Example
Tekst unreadable
46
Product-FMEA Cause
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
Assembly not possible to sale Customer dissatisfi
ed
A
Tekst on wrong location
47
Product-FMEA Occurrence
What is the possibility that the failure occurrs?
48
Ratingcriteria occurrence
Possible Failure Rates
Ranking
Probability of failure
³ 1 of 3
5
Very high
gt 1 of 20
4
Moderate
3
gt 1 of 400
gt 1 of 15000
2
Low
lt 1 of 15000
1
49
Product-FMEA Occurrence
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
Assembly not possible to sale Customer dissatisfi
ed
5
A
Tekst on wrong location
50
Produkt-FMEA Action/Solution
  • What are possible actions to
  • - eliminate the failure
  • - reduce effect
  • - reduce occurrence.

51
Product-FMEA Action/Solution
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
Assembly not possible to sale Customer dissatisfi
ed
5
A
JD
Tekst on wrong location
No tekst on buttons
52
Define Evolutionfactor
  • Cause not known 4
  • Solution not known 3
  • Solution not evaluated 2
  • Solution not implemented 1
  • Solution implemented 0

53
Product-FMEA Evolutionfactor
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
MC
ML
P
Front
Button
Tekst clear visible after PQR-test
Tekst unread-able
Assembly not possible to sale Customer dissatisfi
ed
5
A
JD
1
Tekst on wrong location
No tekst on buttons
54
Risk evaluation
  • Severity (Weightfactor)
  • Occurrence
  • Evolutionfactor
  • Risk maturity - grid

55
Maturity Grid
Weight Factor
S
A
B
C
D
4
4
3
3
5
1
2
2
2
5
3
1
1
7
0
0
3
4
Evolution Factor
Evolution Factor
56
Product-FMEA Electrical (Example)
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
P
ML
MC
Front end
Tuner
Put-through selected signal (SD12XX)
Tuner gets disturbed by noise generated by 14-18V
generation
Tuner gives bad signal through
A
Low frequent noise is not filtered
5
Add bead in LNBA line, right next to tuner
GD
2
57
Proces - FMEA Content
  • FMEA-team
  • Define scope
  • Describe functions

58
Proces-FMEA Team
59
Process-FMEA Scope
  • Create flow-diagram
  • Define scope
  • Define support-team.

60
Process-FMEA (Example)
Description Level 1
Description Level 2
Mode of Failure
Function
Effect
Cause
Action/ Solution
Resp.
P
ML
MC
Glue
Glue with cyano-acrylate
Join parts
Cyanoacrylate not well cured
Lifetime problems
A
5
2
Glue volume to high
Use activator
JD
61
FMEA
  • Tasks Responsibilities.

62
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, ... )

63
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?

64
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.

65
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).

66
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.

67
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).

68
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)?

69
FMEA Facilitator
Tasks of the facilitator
  • Taking care for correct applying FMEA-metholodgy
  • dont loose time with long discussions about
    severity and probability. In case of doubt, take
    the worst case.

70
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?

71
FMEA Facilitator
Tasks of the facilitator
  • Taking care for the TEAM-process
  • Are all teammembers participating in discussions
  • Avoid long discussions between 2 persons, dont
    look for sollutions.(discuss difficult items in a
    small group separately)
  • An open-climate during the meeting is very
    important (dont look for guilty persons, try
    to know te real problems,)

72
FMEA
Software - tools at Philips
73
(No Transcript)
74
FMEA
THE END
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