Title: Philips FMEA
1Philips FMEA
- Failure Mode and Effect Analysis
2Content of the course
- Introduction
- Product - FMEA
- Blockdiagram , functiontree
- Process - FMEA
- Process-flowdiagram (macro-level) , micro-level
- Facilitatorskills
3FMEA Introduction
- Why FMEAs?
- Definition, Purpose, Types, Benefits
- Team Approach
4Why FMEAs?
- Appropriate recommended actions may not have been
taken. - Savings in engineering time.
- Reduction of changes immediately before
productionstart (Commercial Release).
5FMEA Definition
Structured group of activities which...
- Identify potential failure modes
- Prioritize actions
- Document the process.
6FMEA Purpose
Failures
Time
7FMEA Purpose
FMEAs are intended to ...
- Rate severity of failure modes
- Identify actions to reduce occurence
- Test adequacy of controls
8FMEA Types
Mechanical
Product- FMEA
Electrical
Optical
Mechanical
Process- FMEA
Electrical
Optical
9FMEA Sessions
10Benefits 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
11Voordelen Proces-FMEAs
Design
- Assess effects on all customers
- Identifies potential manufacturing and assembly
causes to focus controls on reducing occurrence
or increasing detection.
Proces
12Generating 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?
13Managing 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
14FMEA Team Approach
Support-team
15Product-FMEA Content
- Define FMEA-team
- Define scope
- Describe functions
- Brainstorming
- Function Trees
16Product-FMEA Team
17Product-FMEA Scope
Once coreteam is established ...
- Create Blockdiagram
- Identify the boundery for Analysis
- Confirm composition of support team.
18Blockdiagram
Component/Assembly
Screw
Weld
Adhesive
19Example blockdiagram (Settop Wildfire)
Smartcard PCB
Klicked
Front
Klicked
Display PCB
Klicked
Screwed
Screwed
Frame
Cover
PSU
20Determine 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.
21Describe Function
Generate Control Display
light speed information
22Describe Functions
- Thought starters ...
- Satisfy user
- Attract user
- Guarantee durability
- Easy to repare
- Safety requirements
23Brainstorming
24Functiontree
- 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.
25Constructing Functiontrees
26Functiontree Frontbutton (Settop)
Display Information
27Guidelines
- 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?
28Product-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
29Potential failure Modes
Failure Mode Type Example
No function Partial function
Not operational Not all of function operating
30Failure Modes Frontbutton
Function Tekst clear visible after 100x cleaning.
Failure Mode Type Example
No function No tekst available Partial
function Tekst partial available
31Product-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
32Effects failure
What are the effects of the failure relating to
- another part - the complete assembly - the
customer - the enduser - the governmental
regulations
33Product-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
34Product-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
35Severity (Weightfactor)
What is the severity of the effects?
36Ratingcriteria 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
37Rating 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
38Product-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
39Potential Cause of Failure
- A weakness in the design with a failure mode
as effect.
40Manufacturing misbuilds
Due to design Deficiencies
-
-
41Manufacturing misbuilds
Robust Design
-
-
42Cause of failure
Use Fishbone Diagram
Tekst on wrong location
Tekst unreadable
Inkt of poor quality
43Cause of failure Why-ladder
Tekst unreadable
Inkt doesnt stick
Surface roughness not ok.
level 1
WHY?
level 2
Designrequirement
WHY?
level 3
WHY?
44Sentencing Technique
Failure Mode
45Sentencing Technique - Example
Tekst unreadable
46Product-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
47Product-FMEA Occurrence
What is the possibility that the failure occurrs?
48Ratingcriteria 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
49Product-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
50Produkt-FMEA Action/Solution
- What are possible actions to
- - eliminate the failure
- - reduce effect
- - reduce occurrence.
51Product-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
52Define Evolutionfactor
- Cause not known 4
- Solution not known 3
- Solution not evaluated 2
- Solution not implemented 1
- Solution implemented 0
53Product-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
54Risk evaluation
- Severity (Weightfactor)
- Occurrence
- Evolutionfactor
- Risk maturity - grid
55Maturity 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
56Product-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
57Proces - FMEA Content
- FMEA-team
- Define scope
- Describe functions
58Proces-FMEA Team
59Process-FMEA Scope
- Create flow-diagram
- Define scope
- Define support-team.
60Process-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
61FMEA
62FMEA 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, ... )
63FMEA 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?
64FMEA 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.
65FMEA 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).
66FMEA 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.
67FMEA 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).
68FMEA 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)?
69FMEA 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.
70FMEA 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?
71FMEA 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,)
72FMEA
Software - tools at Philips
73(No Transcript)
74FMEA
THE END