7 David Merrill - Polarion Software - FMEA Analysis in Electronics Industry Product Development

8/10/2019 7 David Merrill - Polarion Software - FMEA Analysis in Electronics Industry Product Development

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Polarion Software

FMEA Analysis in

Electronics Industry ProductDevelopment

Example The iPad3

David Merrill

System Engineer


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It has been said:

People dont plan to fail,

they fail to plan.


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With FMEA Risk Analysis:

People plan to fail,

and then do something

about it.


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www.polarion.com

What happens when Things fail?

What causes the Failure?

How bad is the Failure and whatdoes it affect?

How often with the failure Occur?

What Actions should we take to

limit the risk?

Polarion FMEA Analysis


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First 30 Days at Apple when iPad3 Released

New iPad releases and heats up Apple sells 3 Million new iPads in 3 days

ConsumerReports.org reports iPad overheats 45 Minutes of game playing heats to 116 F

Very active User Forums light up with complaints about being toohot to handle

Apple Comments: It isnt a problem, but you can replacethe new iPad if you want to.

Paranoid-AndroidRe: New iPad overheating?Mar 18, 2012 11:47 PM

Mine does get warm on thelower left side. Not super hot,but uncomfortablywarm. I hope it is a defect thatApple will fix. I will returnotherwise.

iPad LTE 64

Source: http://news.consumerreports.org Source: http://discussions.apple.com


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iPad Case Study

Why is this interesting for FMEA Risk Analysis? Popular Device and Public Hype

New iPad fuels other Apple Product Sales

Q1 2012 Revenue - $9.1B iPad, $6.5B Mac Computers

iPad is Mechatronics Physical Device

Circuit Boards, Intelligent Processor Technology

Innovative Human Interface

Firmware, Software, Apple Ecosystem The Cause is Unknown

Is it a Software Problem, a Hardware Problem?

No boundaries between Hardware and Software

Will it be fixed? When?

Will iPad users just have to get used to it?


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www.polarion.com

Severity Linked with Description What is the severity of the Failure? Loss of Revenue? Brand Equity? Life? Scored 1 10 (10 = most severe) Consider FMEA origins Military, Space Flight, Automotive

Occurrence

Linked with Overview of Cause Scored 1 10 (10 = occurs frequently)

Detection Linked with Overview of Controls

Scored 1 10 (10 = failure goes undetected)

RPN - Risk Priority Number Severity * Occurrence * Detection Calculated 1 to 1000 (1000 = most severe Risk)

Polarion FMEA Analysis and Scoring


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www.polarion.com

Identify Actions to Reduce, Avoid, Eliminate Risk

Plan Actions Create Change Requests

Create Tasks to involve Stakeholders and Experts

Take Actions Create New Requirements

Design Specifications

Build Test Cases

New RPN New Risk Priority Number New Severity * New Occurrence * New Detection

Goal: New RPN


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www.polarion.com

Traditionally, FMEA Analysis is an un-traceable, un-auditable spreadsheet.

PolarionRequirements

What FMEA looks like without

Polarion


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www.polarion.com

Polarion Answers Risk Questions:

When was the Risk first detected? Requirements Elicitation Design Testing

Prototype Manufacturing

Who made changes to FMEA?When were changes made?

What were the changes to FMEA?

How does FMEA Analysis impact ALL otherdevelopment artifacts and work items?

PolarionWith Polarion, FMEA Analysis

are Traceable and Auditable


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www.polarion.com

FMEA is WorkItem type risk Link role: Risk AssessesRequirement

Link role: Task, Requirement, Change Request Mitigates Risk

Can be standalone document Can be included in Requirements Document

Part of WBS Project Work Breakdown Structure

FMEA Special Attributes Cause, Effect (WorkItem Description), Controls, Actions

Detection, Severity, Occurrence, RPN (Before Actions)

New Detection, Severity, Occurrence, New RPN (After Actions)

FMEA Workflow Analysis: Perform initial scoring

Actions Pending: Plan actions, create mitigating WorkItems

Actions Taken: linked WorkItems are complete

Polarion Challenge: ntegrate

FMEA into Polarion


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www.polarion.com

FMEA Traceability Trace Risk to All other project artifacts

Test Case -> FMEA Risk -> Change Request -> New Requirement

Software Design -> FMEA Risk -> New Task -> New Test Case Integrate FMEA seamlessly wherever it is needed.

FMEA History Who found the failure?

What was done about it?

When was it done?

Who approved (or did not approve) the actions?

FMEA Auditability Demonstrate the evolution of Risk Analysis

Demonstrate proper investigation into Design and Manufacturing

Address Business Risk and Technical Risk

Actions Taken: validate linked Work Items are complete

Polarion Challenge:

ntegrate FMEA with A!M


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Solution: Integrate FMEA with All

Development Artifacts

Requirements

User Stories Test Cases

FMEA Risk

Assessed By

Design

Tasks

ChangeRequest

Requirements

Mitigated by


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www.polarion.com

iPad Overheats Cause: Overuse with 4G, Gaming, External Power

Severity: 4

Occurrence: 2

Detection: 10

Actions to Be Taken Change Request: Improved Heat Sync

Task: Build Improved Cover

Test Case: Test Heat Operations

Polarion Scenario:

iPad FMEA "#erheating


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www.polarion.com

iPad dropped in Water Cause: Not paying attention

Severity: 10

Occurrence: 1

Detection: 10

Actions to Be Taken Change Request: Improved Case Seals

Task: Build Waterproof Cover

Polarion Scenario:

iPad dro$$ed in Water


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www.polarion.com

Analyze Product Development

Understand and Predict Failure

Understand and Plan Mitigating Actions

Take Actions. Audit Actions

Avoid Failure

PolarionPlan %or Failure


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Polarion Software

Thank You

David Merrill

System Engineer

Documents

7 David Merrill - Polarion Software - FMEA Analysis in Electronics Industry Product Development