FMEA失效模式及其影響分析

1、HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCFTCFTF FAILURE AILURE M MODE and ODE and E EFFECTS FFECTS A ANALYSISNALYSIS 失失 效效 模模 式式 及及 其其 影影 響響 分分 析析Philips CFT Asia PacificInnovation & Industrial SupportJAY TAN HPhilips

2、 CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 2FMEA Course ScheduleFMEA Course ScheduleDay 2Day 2 9.00 Real-life P-FMEA exercise -contReview 10.30 Tea-break 10.45D-FMEA 12.00 Lunch 1.00 Organization Aspect

3、 of FMEA 3.00 Tea-break 3.30 Maturity GridDay 1Day 1 9.00IntroductionIntro to FMEA Process FMEA10.30Tea-break10.45Process -FMEA (cont) 12.00Lunch 1.00Real-life P-FMEA exercise 3.30Tea-break 3.45 Real-life P-FMEA exercise -cont HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industr

4、ial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 31 1INTRODUCTION INTRODUCTION TO TO FMEAFMEAHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 4Car 2:No Major Break downs 非 主

5、 要 的 破 損Few failures 很 少 的 失 效Car 1:Frequent Break downs 頻 繁 地 破 損Many minor components failures 許 多 的 小 部 件 失 效A reliability program ?A reliability program ? Why Why necessary?necessary? 一一 個(gè)個(gè) 可可 靠靠 性性 的的 計(jì)計(jì) 劃？劃？ 為為 什什 么么 必必 須？須？HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Indu

6、strial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 5 Customer SatisfactionCustomer Satisfaction 顧顧 客客 滿滿 意意Customer satisfaction means: Customer satisfaction means: Never having to say youre Never having to say youre sorry !sorry ! 顧 客 滿 意 意 味 著： 決 不 要 說 對(duì) 不 起 ！HPhilips C

7、FT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 6 QUALITY ENGINEERING TOOLSQUALITY ENGINEERING TOOLSTOOLS1 Design Review2 7 QC Tools3 New 7 QC Tools4 Statistical Process Control5 Design of Experiments6 Quality

8、 Function Deployment7 Failure Mode and Effects Analysis APPLICATION Design Quality AssuranceData analysis/Problem-solvingBusiness Process Mgt, QFPHolding the improvementQuality breakthroughsMeeting customer requirementFool-proof Design & processes HPhilips CFT Asia PacificPhilips CFT Asia Pacifi

9、cInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 7What is a FMEA?What is a FMEA?A structured, disciplineddisciplined process to systematically and comprehensively, identifyidentify and document potentialpotential problems and weaknesses in a design

10、 or process so that design changes can be made or other corrective actions taken to preventprevent actual occurrence of failure 一 個(gè) 結(jié) 構(gòu) 化 和 專專 業(yè)業(yè) 化化 的 過 程，它 能 系 統(tǒng) 和 綜 合 地 找找 出出 并 記 錄 在 設(shè) 計(jì) 和 工 藝 過 程 中 潛潛 在在 的的 問 題 和 缺 點(diǎn) 并 由 此 作 出 設(shè) 計(jì) 改 變 或 采 取 其 它 的 改 正 措 施 以 防防 止止 失 效 的 實(shí) 際 發(fā) 生HPhilips CFT Asia Pac

11、ificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 8Effect of FMEA on Process and Design changesEffect of FMEA on Process and Design changesDesign StartDevelopmentProduction ReleaseProduction TimeNo of Engineering ChangesTr

12、aditional approachFMEA approachHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 9 TYPES of FMEATYPES of FMEATYPEALIASES DESCRIPTIONProduct Design FMEA * Focus on the product itself, review FMEA D-FMEA

13、 systems, parts & componentsProcess Production FMEA * Focus on the manufacturing process, FMEA P-FMEA review each process stepApplication Downstream customers * Focus on customers processFMEA Manufacturing FMEA * Primarily interested in compatibility between your product &customers processSe

14、rvice * Focus on field service FMEA * Concerned with reliability, product application, maintainability HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 10Objective of FMEAObjective of FMEAFailure Mode

15、 & Effect Analysis (FMEA) is used to Failure Mode & Effect Analysis (FMEA) is used to improveimproveproduct reliability (considering usage, environment, lifetime etc.)quality of (purchased) parts (incl. hidden functions of a part)reproducibility of the product (reduction of fall off & re

16、pairs in assembly)reproducibility of the production process (handling, transport etc.)Focus on technical problemsFocus on technical problemsLink with Link with Maturity GridMaturity Grid and and Risk Management!Risk Management!HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industr

17、ial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 11Types of RisksTypes of RisksMarket RisksMarket Riskshaving the right producton the right timeTechnical RisksTechnical Risksachieving the product specquality, reproducibilityProject RisksProject Risksproject organisation, t

18、eam aspects, resourcesMarketMarketRisksRisksTechnicalTechnicalRisksRisksProjectProjectRisksRisksPlanningPlanningSpecificationSpecificationKnow-how, capacityKnow-how, capacityHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-

19、00-0006| 7 July 2022 | 12Use of FMEAUse of FMEAA. Reliability EngineeringA. Reliability Engineering - Reliability improvements.B. Producibility AnalysisB. Producibility Analysis - Less repairs and scrap during manufacturing. - Improvement of the Zero- Hour Quality.C. Production Process AnalysisC. Pr

20、oduction Process Analysis - Less repairs and scrap. - Determination of process control points. - Process release.A and B during development phase. C during work preparation phase.HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZ

21、B698-00-0006| 7 July 2022 | 13100 : 1100 : 110 : 110 : 11 : 11 : 1PRODUCTPRODUCTDESIGNDESIGNPROCESSPROCESSDESIGNDESIGNPRODUCTIONPRODUCTIONIMPROVEIMPROVEPRODUCTPRODUCTPAYBACKSLOWLOWVISIBILITY/VISIBILITY/REWARDREWARDHIGHHIGH VISIBILITY/ VISIBILITY/REWARDREWARDTIMETIME500 : 1500 : 1CONCEPTCONCEPTDESIGN

22、DESIGNQuality LeverQuality LeverHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 14Reliability Investigation by Means of FMEAReliability Investigation by Means of FMEAPremisesPremises:The normal funct

23、ioning of the productQuestionQuestion:What is the influence of : use - time and environment on each componentPossibilitiesPossibilities:a. wear, b. rust, c. material fatigue, d. contamination, e. deformation under load (creep)f. ageing, g. process failures. What is the effect on product functions ?W

24、hat is the effect on product functions ?HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 15Producibility Analysis by Means of FMEAProducibility Analysis by Means of FMEAPremisesPremises:Measuring tool

25、 is: eg FOR/ppm ActionsActions:Actions as outcome of theProcess Quality Control (P.Q.C.)AnalysisAnalysis: Focused on failures which are made and noticed during the production process.HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial Suppo

26、rtCZB698-00-0006| 7 July 2022 | 162 2PROCESS FMEAPROCESS FMEAHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 17FMEA for the Production ProcessFMEA for the Production ProcessSubject for AnalysisSubjec

27、t for Analysis: - flow chart and scenario of the production processFocused onFocused on: - manipulations of the operator- wrong (deviations) material- process - equipment- transport - storageHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industri

28、al SupportCZB698-00-0006| 7 July 2022 | 18Failure modeRPN2 = SO2D2ControlsCause 1RPNn = SOnDnControlsCause 1Development of a Process FMEA : An OverviewDevelopment of a Process FMEA : An OverviewProcess stepPurposeRPN1 = SO1D1ControlsCause 1EffectsSeverity, SSeverity, SOccurrence, OOccurrence, On nDe

29、tection, DDetection, Dn nHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 19Subject: Subject: D ate: D ate: N oN o Process step / PurposeProcess step / Purpose Potential Potential Failure M odeFailure

30、 M odePotential Effect Potential Effect on Failureon FailureS SPotential Potential causes on causes on FailureFailureO OC urrent C urrent C ontrolC ontrolD DRPNRPNG ravity G ravity FactorFactorRecom m ended Recom m ended A ctionA ctionO w nerO w ner C om pletion C om pletion D ateD ateA ction A ctio

31、n Taken Taken /Result/ResultEvolution Evolution FactorFactor1M ount actuator and i nstal l spri ng cl i p = Hol d actuator i n pl aceD i f f i cul ty i n assem bl i ng spri ng cl i pLong cycl e ti m e8 Handl i ng requi red to ori entate cl i p 8Producti on M oni tori ng Chart, O pr ski l l chart4256

32、2Cut LD G U , M ount LD G U to l i ne pen housi ng = Assem bl e LD G ULens and grati ng contam i nati onFai l G rati ng Adj ustm ent8Handl i ng 4 Rej ect at adj ustm ent stn132 Cutti ng m achi ne di rty3W eekl y m ai ntenance4963M ount and secure f l ex assy = Assem bl e Fl ex AssyESDLD G U dam age

33、by contact af f ecti ng l ong/short term rel i abi l i ty8Handl i ng by operator2 Rej ect at adj ustm ent stn81284Sol der actuator & LD G U to Fl ex Assy = Connect actuator, LD G U and Fl exFailure M ode & Effect A nalysis - ProcessFailure M ode & Effect A nalysis - ProcessHPhilips CFT A

34、sia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 20Process FMEA ProcedureProcess FMEA Procedure5 5 StepsSteps: Establish the Process Flow Analyze the Process Establish purpose of each operation and the possible fai

35、lure modes Define the weak points of the Process Establish actions and responsibilitiesHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 21Step 1 Step 1 -Establish Process Flow-Establish Process FlowTa

36、ke into account the: Specification for manufacturing System Structure:- manufacturing strategy (manual/automatic etc)- technologies, processes & equipment- line & factory layout- suppliers, transport, material flow System operation, control and maintenance System environmental conditions Tes

37、ting & quality controlMake of the assembly process a: PROCESS FLOWCHARTHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 22Process Flow Chart (Process Flow Chart (egeg) )Mount partHandling processG

38、lue partAdjustment processTestingMount subassyHandling processMount partTestingStation1Station2Station3Station4HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 23Process Flow Chart (Process Flow Chart

39、 (egeg) )EquipmentsLightpen carrierLightpen carrierPress-on toolLightpen carrierMounting fixtureElectric screwdriverScrew dispenserLDGU cutting/insertion machineLightpen carrierSoldering equipmentGrating adjustmentmachineGlue dispenser andcuring unitMount actuatr &install spring clipMount &

40、secure flexassemblyCut LDGU leads &mount LDGU intoLightpen housingSolder actuator andLDGU to flex assyGrating & glueing ofLDGUMount rack & wirespringAssembly processHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB6

41、98-00-0006| 7 July 2022 | 24Subj ect: Subj ect: N oN o Process step / PurposeProcess step / Purpose Potential Potential Failure M odeFailure M odePotential Effect Potential Effect on Failureon FailureS SPotential Potential causes on causes on FailureFailureO OC urrent C urrent C ontrolC ontrolD DRPN

42、RPN1M ount actuator and M ount actuator and install spring clip = install spring clip = H old actuator in placeH old actuator in place2C ut LD G U , M ount C ut LD G U , M ount LD G U to line pen LD G U to line pen housing = A ssem ble housing = A ssem ble LD G ULD G U3M ount and secure flex M ount

43、and secure flex assy = A ssem ble Flex assy = A ssem ble Flex A ssyA ssyFailure Mode and Effect Analysis ChartHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 25Step 2 Step 2 - Analysis of the Process

44、- Analysis of the ProcessExamination of: How the purpose of the process/operation are realised by the designers/engineers. What are the working conditions * static * dynamicHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-0

45、0-0006| 7 July 2022 | 26Step3Step3 -Establish purpose of each operation and -Establish purpose of each operation and the possible failure modesthe possible failure modes What is the purpose of the process step ? Which deviations are possible ? ( FAILURE MODE ) What is the effect of that deviation on

46、 the producibility? ( EFFECT ) What is the cause of that deviation ? ( CAUSE )HPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 27MATERIALMATERIALMANMANMACHINEMACHINEMETHODMETHODMEASUREMENTMEASUREMENTE

47、NVIRONMENTENVIRONMENTPROCESSPROCESSProductProductFunctionsFunctionsProductProductFunctionsFunctionsProductProductFunctionsFunctionsProcess Cause - Effect InvestigationProcess Cause - Effect InvestigationPOTENTIALPOTENTIALCAUSECAUSEEFFECTEFFECTPOTENTIALPOTENTIALFAILUREFAILUREPOTENTIALPOTENTIALHPhilip

48、s CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 28Potential Failure ModesPotential Failure Modes* Failure means any one or more of the following - failure to perform/deliver function - failure to meet desig

49、n intent - failure to meet customer expectations - something undesirable, e.g. a noisy projector - application problem, e.g. wrong application* failure could occur, but will not necessarily occur* describe in “physical” or technical terms, not as a symptom recognisable by the customer* use brainstor

50、ming to ensure completeness Examples :Examples :corrodedcorrodedcrackedcrackeddeformeddeformedoxidisedoxidisedleakingleakingfracturedfracturedmalformedmalformedflattenedflattenednon-stickingnon-stickingcontaminatedcontaminatedHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industri

51、al SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 29Subj ect: Subj ect: N oN o Process step / PurposeProcess step / Purpose Potential Potential Failure M odeFailure M odePotential Effect Potential Effect on Failureon FailureS SPotential Potential causes on causes on FailureF

52、ailureO OC urrent C urrent C ontrolC ontrolD DRPNRPN1M ount actuator and i nstal l spri ng cl i p = Hol d actuator i n pl aceD ifficulty in D ifficulty in assem bling assem bling spring clipspring clip2Cut LD G U , M ount LD G U to l i ne pen housi ng = Assem bl e LD G ULens and Lens and grating gra

53、ting contam inatiocontam ination n3M ount and secure f l ex assy = Assem bl e Fl ex AssyESDESDFailure Mode and Effect Analysis ChartHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 30Effects ( Process

54、 FMEA )Effects ( Process FMEA )Each Each failure mode may have undesirable side effects on some or all the following:1.End-user (product)2.Down-stream process (next operation)3.Local processAll 3All 3 effects should be considered in any process FMEAHPhilips CFT Asia PacificPhilips CFT Asia PacificIn

55、novation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 31Severity (Process-FMEA)Severity (Process-FMEA)RatingRatingDegreeDegreeEffects on Effects on Effect on down Effect on down End UserEnd User Stream/Local process Stream/Local process1Minor * not noticea

56、ble * no effect2low * slightly noticeable * no impact/limited effect3 * limited impact on both4Moderate * cust dissatisfaction * may require minor rework5 * reduced performance * may req. unscheduled rework6 * perform. Deterioration * may cause damage to equip.7High * high deg. of cust dissatisfacti

57、on * may cause serious disruption8 * loss of sub-system function, * may require major rework may endanger machine /operator9Very high * safety-related * production line shut down 10 * non-compliance with * saftety of prod personnel threatened government regulations Severity is the assessment of the

58、seriousness of the effectHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 32Subj ect: Subj ect: N oN o Process step / PurposeProcess step / Purpose Potential Potential Failure M odeFailure M odePotent

59、ial Effect Potential Effect on Failureon FailureS SPotential Potential causes on causes on FailureFailureO OC urrent C urrent C ontrolC ontrolD DRPNRPN1M ount actuator and i nstal l spri ng cl i p = Hol d actuator i n pl aceD i f f i cul ty i n assem bl i ng spri ng cl i pLong cycle Long cycle tim e

60、 - capacity tim e - capacity lossloss8 82Cut LD G U , M ount LD G U to l i ne pen housi ng = Assem bl e LD G ULens and grati ng contam i nati onFail G rating Fail G rating A djustm entA djustm ent8 83M ount and secure f l ex assy = Assem bl e Fl ex AssyESDLD G U dam age LD G U dam age by contact by

61、contact affecting affecting long/short term long/short term reliabilityreliability8 8Failure Mode and Effect Analysis ChartHPhilips CFT Asia PacificPhilips CFT Asia PacificInnovation & Industrial SupportInnovation & Industrial SupportCZB698-00-0006| 7 July 2022 | 33Potential Cause(s) of FailurePotential Cause(s) of