1.1Philips FMEA Failure Mode and Effect Analysis1.2Content of the coursevIntroductionvProduct - FMEAvBlockdiagram , functiontree vProcess - FMEAvProcess-flowdiagram (macro-level) , micro-levelvFacilitatorskills1.3FMEA IntroductionvWhy FMEAs?vDefinition, Purpose, Types, BenefitsvTeam ApproachFMEA-PhilipsIntroduction1.4Why FMEAs?vAppropriate recommended actions may not have been taken.vSavings in engineering time.vReduction of changes immediately before productionstart (Commercial Release).1.5FMEA DefinitionvIdentify potential failure modesvPrioritize actionsvDocument the process.Structured group of activities which. 1.6FMEA PurposeFailuresTimeC R(Productionstart)FMEA1.7vRate severity of failure modesvIdentify actions to reduce occurencevTest adequacy of controlsFMEA PurposeFMEAs are intended to . 1.8FMEA Types OpticalProduct-FMEA MechanicalProcess-FMEA Electrical MechanicalElectricalOptical1.9FMEA SessionsFMEA onEVT ModelFMEA onFirst MechanicalWorking ModelFMEA onPart FilesFMEA onL1 Board(ftbo L2)FMEA onL0 Board(ftbo L1)FMEA onL0 Schematics(ftbo L0)FMEA onArchitecturesMechanicalElectricalFMEA onchosenArchitecture1.10Benefits Product-FMEAsvAssess failure mode effects on all customers.vAids in evaluating testspecificationsvEvaluation of design relating to DFM DFA DFT vIncreases the possibility to detect possible failure modes.ProcesProduct1.11Voordelen Proces-FMEAsvAssess effects on all customersvIdentifies potential manufacturing and assembly causes to focus controls on reducing occurrence or increasing detection.DesignProces1.12Generating FMEAs FMEAsWho initiates?Failure Mode and Effect AnalysisWho updates?Who is FMEA-customer?Startingdate/revisiondate?When completed?How docu-mented?When to discard?Who prepares?1.13Managing FMEAs vModification to a product or process is plannedvComponent is to be used in new environmentvCustomer rejectionsFMEAs are living documents and are updated .1.14FMEA Team ApproachCore-teamSupport-team1.15Product-FMEA ContentvDefine FMEA-team vDefine scopevDescribe functionsBrainstormingFunction TreesPhilipsProduct-FMEA Content1.16Product-FMEA TeamDesign-EnginieerProduction/ process-enginieerCore-team Representitives from:developmentproductionqualitypurchasetestdept.SupportteamFacilitator1.17Product-FMEA ScopevCreate BlockdiagramvIdentify the boundery for AnalysisvConfirm composition of support team.Once coreteam is established .1.18BlockdiagramComponent/AssemblyPart XPart YPart ZServiceOther systemsAssemblyUserScrewWeldAdhesive1.19Example blockdiagram (Settop Wildfire)FrontKlickedDisplay PCBPSUSmartcard PCBFrameCoverKlickedKlickedScrewedScrewed1.20Determine FunctionsvDescribes the intent of the designvMust be measureble or set at an actionable levelvRepresents all wants, both spoken and unspoken.What are the functions of the design?1.21VerbIndicates action, occurrence, beingGenerateControlDisplayNounIndicates what the action relates toDescribe Functionlightspeedinformation1.22Describe FunctionsThought starters .vSatisfy uservAttract uservGuarantee durabilityvEasy to reparevSafety requirements1.23Brainstorming1.24Functiontree vProvides an organized approach to identify the essential features of a productvDefines all spoken and unspoken requirementsvProvides the team with a clear overview of all the functions of the product.1.25FirstlevelSecondLevelConstructing FunctiontreesThirdLevelHOW?WHY ?1.26DisplayInformationFunctiontree Frontbutton (Settop) HOW?Must be printable and resistance te wear.PQR-Cleantest. Tekst clearly visibleafter x-times cleaning.WHY?1.27GuidelinesvBrainstorm all functions (VERB-NOUN)vDocument individual functions by asking“How is this function achieved?”vRepeat left to right, until actionable levelvWork right to left and check structure by asking “Why is this function included?”1.28Product-FMEA FunctionsDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible afterPQR-testMCMLP1.29Potential failure ModesNo functionPartial function Failure Mode TypeExampleNot operationalNot all of function operating1.30Failure Modes: FrontbuttonNo function No tekst availablePartial function Tekst partial availableFunction: Tekst clear visible after 100x cleaning.Failure Mode Type Example1.31Product-FMEA Modes of failureDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLP1.32Effects failureWhat are the effects of the failure relating to:- another part- the complete assembly- the customer- the enduser- the governmental regulations1.33Product-FMEA Tabel of effectsFailureModeTekstunread-ableFrontbuttonCompleteAssemblyDifficultto saleCustomerDissatisfiedEnduserDissatisfiedGovernmental regulationNoneAnotherpartNone1.34Product-FMEA Effects of failureDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfied1.35Severity (Weightfactor)What is the severity of the effects?1.36Criteria: Severity of effectClassEffectAccepted failureDNoneSafety failureSUnacceptable riskNon-conforming with safetyCorrection is nescessary ARelative big riskCorrectie is recommendedBrisicoCorrectie is nuttigCRatingcriteria voor Severity (Weightfactor)Minimum riskCorrectie is usefullC1.37Frontbutton/Tekst readable after PQR-testFailureModeTekst unreadableEffects Assembly: unsaleable (A)Customer: Dissatisfied(A)Gov.Reg.: None (D)ARating of Weightfactor exampleSev.PartFunction1.38Product-FMEA WeightfactorDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedA1.39Potential Cause of Failure A weakness in the design with a failure mode as effect.1.40Manufacturing misbuilds Due to design Deficiencies+-+-1.41Manufacturing misbuildsRobust Design+-+-1.42Use Fishbone DiagramCause of failureTekst unreadableInkt of poor qualityTekst on wrong location1.43Cause of failure “Why”-ladderDesignrequirementWHY?level 1Tekst unreadableWHY?level 2WHY?level 3Inkt doesnt stickSurface roughness not ok. 1.44Sentencing TechniqueFailure ModeCould result inEffectDue toCause1.45Sentencing Technique - Example TekstunreadableCould result inDissatisfiedcustomerDue toSurfaceroughness(designreq.)1.46Product-FMEA CauseDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location1.47Product-FMEA Occurrence What is the possibility thatthe failure occurrs?1.48Possible Failure RatesRankingProbability of failure 1 of 20Very highModerate 1 of 400 1 of 15000Low 1 of 1500045321Ratingcriteria occurrence 1 of 31.49Product-FMEA OccurrenceDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location51.50Produkt-FMEA Action/SolutionWhat are possible actions to:- eliminate the failure- reduce effect - reduce occurrence.1.51Product-FMEA Action/SolutionDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location5No tekst on buttonsJD1.52Define Evolutionfactor vCause not known4vSolution not known3vSolution not evaluated2vSolution not implemented1vSolution implemented01.53Product-FMEA EvolutionfactorDescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.FrontButtonTekst clear visible after PQR-testTekst unread-ableMCMLPAssembly not possible to saleCustomerdissatisfiedATekston wrong location5No tekst on buttonsJD11.54Risk evaluationvSeverity (Weightfactor) vOccurrence vEvolutionfactorvRisk maturity - grid1.55Maturity Grid Weight FactorEvolution FactorEvolution FactorSABCD012340123437 5451231.56Product-FMEA Electrical (Example)DescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.PFront endTunerPut-through selected signal (SD12XX)Tuner gets disturbed by noise generated by 14-18V generationTuner gives bad signal throughALow frequent noise is not filtered5MLMCAdd bead in LNBA line, right next to tunerGD21.57Proces - FMEA ContentvFMEA-team vDefine scopevDescribe functionsPhilipsProces - FMEA Content1.58Proces-FMEA TeamProduction/- process-engineerDesign-engineerCore-team Representatives of :ProductdevelopmentProcess-developmentProductionQualityPurchaseOwner of the next process .Support-teamFacilitator or application engineer1.59Process-FMEA ScopevCreate flow-diagram vDefine scopevDefine support-team.1.60Process-FMEA (Example)DescriptionLevel 1DescriptionLevel 2FunctionMode of FailureEffectCauseAction/SolutionResp.PGlueGlue with cyano-acrylateJoin partsCyanoacrylate not well curedLifetime problemsAGlue volume to high5MLMCUse activatorJD21.61FMEA Tasks & Responsibilities.1.62FMEA TeamleadervPreparation of the FMEA - sessiondistribution 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:1.63FMEA TeamleadervPreparation of the FMEA - session:Distribute/display important information:agenda, FMEA-methodDefine tasks of the team-members:Who is the teamleader, facilitator, timekeeper, secretary?Tasks of the teamleader:1.64FMEA FacilitatorvHelps preparing the FMEA - sessionvSupports the teamleadervTakes care that FMEA-metholodgy is correctly usedvTakes care of the team - process.Tasks of the facilitator:1.65FMEA FacilitatorvPreparation of the FMEA - sessionpreparation together with the team-leaderdefine agenda for the meetingproduct-FMEA : create blockdiagramprocess-FMEA: create flowdiagramdefine participants (6-8 persons).Tasks of the facilitator:1.66FMEA FacilitatorvSupporting 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.Tasks of the facilitator:1.67FMEA FacilitatorvTaking 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:1.68FMEA FacilitatorvTaking care for correct applying FMEA-metholodgy:Is for each effect a weigthfactor mentioned, for each cause the probability and for each sollution the evolutionfactor definedIs the FMEA-worksheet completely filled-in (actions, responsible person, date)?Tasks of the facilitator: 1.69FMEA FacilitatorvTaking care for correct applying FMEA-metholodgy:dont loose time with long discussions about severity and probability. In case of doubt, take the worst case. Tasks of the facilitator:1.70FMEA FacilitatorvTaking care for the TEAM-process:Are the different teamroles defined by the teamleader. Who is theTeamleader?Facilitator?Timekeeper?Secretary?Tasks of the facilitator:1.71FMEA FacilitatorvTaking care for the TEAM-process:Are all teammembers participating in discussionsAvoid 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,)Tasks of the facilitator:1.72FMEA Software - tools at Philips1.73FMEA LibraryDesignerConsult the LibrarySearch for solutionsConsultFMEAToolFMEA ReportsFollow-up actionsFMEA SessionConsultFill inFMEA FacilitatorFMEA MaintenanceteamMaintain the FMEA LibraryFilter the remarksPOOLof remarks QualityEngineeringDevelopmentPurchasingOrg. and Eff.Proc. Impr. TeamNew Remarks1.74FMEA THE END