Philips FMEA

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Philips FMEA

• Failure Mode and Effect Analysis

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Content of the course

• Introduction
• Product - FMEA
• Blockdiagram , functiontree
• Process - FMEA
• Process-flowdiagram (macro-level) , micro-level
• Facilitatorskills

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FMEA Introduction

• Why FMEAs?
• Definition, Purpose, Types, Benefits
• Team Approach

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Why FMEAs?

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

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FMEA Definition
Structured group of activities which...

• Identify potential failure modes
• Prioritize actions
• Document the process.

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FMEA Purpose
Failures
Time
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FMEA Purpose
FMEAs are intended to ...

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

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FMEA Types
Mechanical
Product- FMEA
Electrical
Optical
Mechanical
Process- FMEA
Electrical
Optical
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FMEA Sessions
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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
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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
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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?
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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

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FMEA Team Approach
Support-team
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Product-FMEA Content

• Define FMEA-team
• Define scope
• Describe functions
• Brainstorming
• Function Trees

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Product-FMEA Team
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Product-FMEA Scope
Once coreteam is established ...

• Create Blockdiagram
• Identify the boundery for Analysis
• Confirm composition of support team.

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

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Describe Function
Generate Control Display
light speed information
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Describe Functions

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

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Brainstorming
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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.

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Constructing Functiontrees
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Functiontree Frontbutton (Settop)
Display Information
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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?

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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
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Potential failure Modes
Failure Mode Type Example
No function Partial function
Not operational Not all of function operating
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Failure Modes Frontbutton
Function Tekst clear visible after 100x cleaning.
Failure Mode Type Example
No function No tekst available Partial
function Tekst partial available
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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
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Effects failure
What are the effects of the failure relating to
- another part - the complete assembly - the
customer - the enduser - the governmental
regulations
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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
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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
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Severity (Weightfactor)
What is the severity of the effects?
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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
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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
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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
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Potential Cause of Failure

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

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Manufacturing misbuilds
Due to design Deficiencies
-
-
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Manufacturing misbuilds
Robust Design
-
-
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Cause of failure
Use Fishbone Diagram
Tekst on wrong location
Tekst unreadable
Inkt of poor quality
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Cause of failure Why-ladder
Tekst unreadable
Inkt doesnt stick
Surface roughness not ok.
level 1
WHY?
level 2
Designrequirement
WHY?
level 3
WHY?
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Sentencing Technique
Failure Mode
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Sentencing Technique - Example
Tekst unreadable
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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
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Product-FMEA Occurrence
What is the possibility that the failure occurrs?
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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
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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
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Produkt-FMEA Action/Solution

• What are possible actions to
• - eliminate the failure
• - reduce effect
• - reduce occurrence.

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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
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Define Evolutionfactor

• Cause not known 4
• Solution not known 3
• Solution not evaluated 2
• Solution not implemented 1
• Solution implemented 0

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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
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Risk evaluation

• Severity (Weightfactor)
• Occurrence
• Evolutionfactor
• Risk maturity - grid

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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
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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
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Proces - FMEA Content

• FMEA-team
• Define scope
• Describe functions

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Proces-FMEA Team
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Process-FMEA Scope

• Create flow-diagram
• Define scope
• Define support-team.

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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
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FMEA

• Tasks Responsibilities.

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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, ... )

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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?

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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.

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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).

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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.

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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).

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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)?

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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.

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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?

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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,)

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FMEA
Software - tools at Philips
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FMEA
THE END