Philips FMEA English

1.1

Philips FMEA

Failure Mode and Effect Analysis

1.2

Content of the course

Introduction Product - FMEA

Blockdiagram , functiontree Process - FMEA

Process-flowdiagram (macro-level) , micro-level Facilitatorskills

1.3

FMEA – Introduction

Why FMEA’s? Definition, Purpose,

Types, Benefits Team Approach

FMEA-FMEA-Philips

PhilipsIntroductionIntroduction

1.4

Why FMEA’s?

Appropriate recommended actions may not have been taken.

Savings in engineering time. Reduction of changes

immediately before productionstart (Commercial Release).

1.5

FMEA – Definition

Identify potential failure modes

Prioritize actions

Document the process.

Structured group of activities which...

1.6

FMEA – PurposeFa

ilure

s

TimeC R(Productionstart)

FMEA

1.7

Rate severity of failure modes Identify actions to reduce occurence Test adequacy of controls

FMEA – Purpose

FMEA’s are intended to ...

1.8

FMEA – Types

Optical

Product-FMEA

Product-FMEA

Mechanical

Process-FMEA

Process-FMEA

Electrical

Mechanical

Electrical

Optical

1.9

FMEA Sessions FMEA on

EVT ModelFMEA onFirst MechanicalWorking ModelFMEA on

Part Files

FMEA onL1 Board(ftbo L2)

FMEA onL0 Board(ftbo L1)

FMEA onL0 Schematics

(ftbo L0)

FMEA onArchitectures

Mechanical

Electrical

FMEA onchosen

Architecture

1.10

Benefits – Product-FMEA’s 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.

Proces

ProductProduct

1.11

Voordelen – Proces-FMEA’s

Assess effects on all customers

Identifies potential manufacturing and assembly causes to focus controls on reducing occurrence or increasing detection.

Design

ProcesProces

1.12

Generating FMEA’s

FMEAs

Who initiates?

Failure Mode and

Effect Analysis

Failure Mode and

Effect Analysis

Who updates?

Who is FMEA-customer?

Startingdate/revisiondate?

When completed?

How docu-mented?

When to discard?

Who prepares?

1.13

Managing FMEA’s

Modification to a product or process is planned

Component is to be used in new environment

Customer rejections

FMEA’s are living documents and are updated ...

1.14

FMEA – Team Approach

Core-team

Support-team

1.15

Product-FMEA – Content

Define FMEA-team

Define scope

Describe functions

» Brainstorming

» Function Trees

PhilipsPhilips

Product-FMEA Product-FMEA ContentContent

1.16

Product-FMEA – Team

Design-Enginieer

Production/ process-enginieer

Core-team

Representitives from:

• development

• production

• quality

• purchase

• testdept.

• ...

Supportteam

Facilitator

1.17

Product-FMEA – Scope

Create Blockdiagram Identify the boundery for Analysis Confirm composition of support

team.

Once coreteam is established ...

1.18

Blockdiagram

Component/Assembly

Part X

Part Y

Part Z

Service

Other systems

Assembly

User

Screw Weld

Adhesive

1.19

Example blockdiagram (Settop Wildfire)

FrontKlicked Display PCB

PSU

Smartcard PCB

FrameCover

Klicked

Klicked

ScrewedScrewed

1.20

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?

1.21

VerbVerb

Indicates action, occurrence, being

GenerateControlDisplay

NounNoun

Indicates what the action relates to

Describe Function

lightspeedinformation

1.22

Describe Functions

Thought starters ... Satisfy user Attract user Guarantee durability Easy to repare Safety requirements

1.23

Brainstorming

1.24

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.

1.25

Firstlevel

SecondLevel

Constructing Functiontrees

ThirdLevel

HOW? WHY ?

1.26

DisplayInformation

Functiontree – Frontbutton (Settop)

HOW?

Must be printable and resistance te wear.

PQR-Cleantest. Tekst clearly visible

after x-times cleaning.

WHY?

1.27

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?”

1.28

Product-FMEA – Functions

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after

PQR-test

MC

ML

P

1.29

Potential failure Modes

No function

Partial function

Failure Mode Type Example

Not operational

Not all of function operating

1.30

Failure Modes: Frontbutton

No function No tekst available

Partial function Tekst partial available

Function: Tekst clear visible after 100x cleaning.

Failure Mode Type Example

1.31

Product-FMEA – Modes of failure

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-

able

MC

ML

P

1.32

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

Product-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

1.34

Product-FMEA – Effects of failure

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-

able

MC

ML

P

Assembly not

possible to sale

Customerdissatisfied

1.35

Severity (Weightfactor)

What is the severity of the effects?

1.36

Criteria: Severity of effect ClassEffect

Accepted failure DNone

Safety failureS

Unacceptable risk

Non-conforming with safety

Correction is nescessary A

Relative big risk

Correctie is recommendedB

risico Correctie is nuttigC

Ratingcriteria voor Severity (Weightfactor)

Minimum risk Correctie is usefull C

1.37

Frontbutton/

Tekst readable

after PQR-

test

Failure

Mode

Tekst unreadable

Effects

Assembly: unsaleable (A)

Customer: Dissatisfied (A)

Gov.Reg.: None (D)

A

Rating of Weightfactor– example

Sev.

Part

Function

1.38

Product-FMEA – Weightfactor

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-

able

MC

ML

P

Assembly not

possible to sale

Customerdissatisfied

A

1.39

Potential Cause of Failure

A weakness in the design with a failure mode as effect.

1.40

Manufacturing misbuilds

Due to design Deficiencies

+-

+-

1.41

Manufacturing misbuilds

Robust Design

+-

+-

1.42

Use Fishbone DiagramUse Fishbone Diagram

Cause of failure

Tekst unreadable

Inkt of poor quality

Tekst on wrong location

1.43

Cause of failure – “Why”-ladder

Designrequirement

WHY?level 1

Tekst unreadableTekst unreadable

WHY?level 2

WHY?level 3

Inkt doesn’t stickSurface roughness

not ok.

1.44

Sentencing Technique

Failure Mode

Could result in Effect

Due to

Cause

1.45

Sentencing Technique - Example

Tekstunreadable

Could result inDissatisfied

customer

Due to Surfaceroughness

(designreq.)

1.46

Product-FMEA – Cause

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-able

MC

ML

P

Assembly not

possible to sale

Customerdissatisfied

ATekst

on wrong

location

1.47

Product-FMEA – Occurrence

What is the possibility that

the failure occurrs?

1.48

Possible Failure Rates RankingProbability of failure

> 1 of 20

Very high

Moderate > 1 of 400

> 1 of 15000

Low < 1 of 15000

4

5

3

2

1

Ratingcriteria Ratingcriteria occurrenceoccurrence

1 of 3

1.49

Product-FMEA – Occurrence

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-able

MC

ML

P

Assembly not

possible to sale

Customerdissatisfied

ATekst

on wrong

location

5

1.50

Produkt-FMEA – Action/Solution

What are possible actions to:

- eliminate the failure

- reduce effect

- reduce occurrence.

1.51

Product-FMEA – Action/Solution

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-able

MC

ML

P

Assembly not

possible to sale

Customerdissatisfied

ATekst

on wrong

location

5No tekst on

buttons

JD

1.52

Define Evolutionfactor

Cause not known 4 Solution not known

3 Solution not evaluated 2 Solution not implemented

1 Solution implemented 0

1.53

Product-FMEA – Evolutionfactor

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp.

Front Button Tekst clear

visible after PQR-test

Tekst unread-able

MC

ML

P

Assembly not

possible to sale

Customerdissatisfied

ATekst

on wrong

location

5No tekst on

buttons

JD 1

1.54

Risk evaluation

Severity (Weightfactor)

Occurrence

Evolutionfactor

Risk maturity - grid

1.55

Maturity Grid

Weight Factor

Evolution Factor Evolution Factor

S A B C D

0

1

2

3

4

0

1

2

3

4

3

7

5

4

5 1 2

3

1.56

Product-FMEA – Electrical (Example)

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp. P

Front end

Tuner Put-through selected signal

(SD12XX)

Tuner gets disturbed by

noise generated by 14-18V generation

Tuner gives bad signal through

ALow frequent noise is not

filtered

5

ML

MC

Add bead in LNBA line, right

next to tuner

GD 2

1.57

Proces - FMEA – Content

FMEA-team

Define scope

Describe functions

PhilipsPhilips

Proces - FMEA Proces - FMEA ContentContent

1.58

Proces-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

Process-FMEA – Scope

Create flow-diagram Define scope Define support-team.

1.60

Process-FMEA – (Example)

Description

Level 1

Description

Level 2Function Mode of

FailureEffect Cause Action/

Solution

Resp. P

Glue Glue with cyano-

acrylate

Join parts

Cyanoacrylate not well cured

Lifetime problems

AGlue volume to high

5

ML

MC

Use activator

JD 2

1.61

FMEA

Tasks & Responsibilities.

1.62

FMEA – 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, ... )

Tasks of the teamleader:

1.63

FMEA – 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?

Tasks of the teamleader:

1.64

FMEA – Facilitator

Helps preparing the FMEA - session

Supports the teamleader

Takes care that FMEA-metholodgy is

correctly used

Takes care of the team - process.

Tasks of the facilitator:

1.65

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).

Tasks of the facilitator:

1.66

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.

Tasks of the facilitator:

1.67

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:

1.68

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 the facilitator:

1.69

FMEA – Facilitator

Taking care for correct applying

FMEA-metholodgy:» don’t loose time with long discussions

about severity and probability. In case of

doubt, take the ‘worst case’.

Tasks of the facilitator:

1.70

FMEA – Facilitator

Taking care for the TEAM-process:» Are the different teamroles defined by the

teamleader. Who is the» Teamleader?

» Facilitator?

» Timekeeper?

» Secretary?

Tasks of the facilitator:

1.71

FMEA – Facilitator

Taking care for the TEAM-process:» Are all teammembers participating in discussions

» Avoid long discussions between 2 persons, don’t look for

sollutions.(discuss difficult items in a small group separately)

» An ‘open-climate’ during the meeting is very important (don’t

look for ‘guilty persons’, try to know te real problems,…)

Tasks of the facilitator:

1.72

FMEA

Software - tools at

Philips

1.73

FMEA Library

DesignerConsult the Library

Search for solutions

Consult

FMEATool

FMEA Reports

Follow-up actions

FMEA Session

ConsultFill in

FMEA Facilitator

FMEA Maintenance

team

Maintain the FMEA Library

Filter the remarks

"POOL"of remarks

QualityEngineering Development

PurchasingOrg. and Eff. Proc. Impr.

Team

New Remarks

1.74

FMEA

THE END