PCB內(nèi)層AOI檢測PFMEA分析范例

PotentialFailureModeandEffectAnalysis,,,,,,,,,,,,,,,,,

過程潛在失效模式及后果分析,,,,,,,,,,,,,,,,,

（PFMEA）,,,,,,,,,,,,,,,,,

項目Item：,雙面板/多層板double-side/multi-layersPCB,,,,FMEA編號FMEANo.：,,FMEA-D/F(I)-04,,"編制日期Peparedate：

2015-07-07",,,,"編制

Prepareby：",,,,

類型Type：,PCB,,,,關鍵日期KeyDate：,,,,"內(nèi)容版本

contentVersion：B1",,,,"審批

Approvalby：",,,,

過程責任Responsibility,內(nèi)層AOIinnerlayerAOI,,,,"修訂日期

ModifyDate：",,2019/7/1,,工廠批準plantapproval：,,,,,,,,

核心小組coreteam：,,,,,,,,,,,,,,,,,

"1.如果客戶有指定產(chǎn)品及過程特性符號，按客戶要求標識；2.客戶沒有指定，則按如公司規(guī)定標識。產(chǎn)品特性符號表示:“◆”,過程特性符號表示:“▲”。classificationsymboldescription：1.marksymbolpercustomer'sspecificsymbol;2.ifnospecificsymbolfromcustomer，marksymbolasbelow:“◆”forproductspecialcharacteristic,and“▲”forprocessspec",,,,,,,,,,,,,,,,,

"過程

功能processfunction

要求

requirement","潛在失

效模式potentialfailuremode","潛在失

效后果potentialfailureeffect",嚴重度S,級別classification,"潛在失效

起因/機理potentialfailurecause/mechanism",頻度O,"現(xiàn)行過程

控制預防currentprocesscontrolmethod","現(xiàn)行過程

控制探測

currentprocessdetection",探測度D,"R

P

N",建議措施adviceaction,責任及目標完成日期responsibility&duedate,措施結果actionresult,,,,

,,,,,,,,,,,,,采取的措施actionadopted,S,O,D,"R

P

N"

調(diào)取資料：對型號、版本號核實inputdata:verifythepartnumberandversion,型號、版本與實測板不符合partnumberandversionisnotconsistantwiththewaitingAOIboards,"無法測試、效率低failtoAOI,lowefficiency",3,,操作員調(diào)錯工程資料operatorinputthewrongengineeringdata,3,調(diào)工程資料按工卡版本號inputtheengineeringdataaccordingtoMI,調(diào)出資料后再核對工卡和資料的型號、版本號是否一致verifytheP/NandversionofinputdatawiththeonesinMI,6,54,無none,,,,,,

,,,,,工程部資料未更新操作員未核對engineeringdataisnotupdatedandisnotverifiedbyoperator,,,,,,無none,,,,,,

機器驗證,設備異常無法確認,無法測試failtoAOI,3,,AOI室內(nèi)參溫濕度異常,2,按照WI要求管控溫濕度,每4小時檢查一次checkonceevery4hours,6,36,無none,,,,,,

,,,,,參數(shù)、設備異常,5,標準板掃描,每天均需用標準板對機器進行校驗,5,75,無none,,,,,,

"參數(shù)設定：按工卡要求的補償系數(shù)，最小線寬線距，板厚等設置分辨率及其它測試條件parametersetup:setparameterslikecompensatecoefficient,min.tracewidth/clearance,boardthickness,resolutionandothertestingconditionetc.",公差太大deviationistoolarge,缺口和線突漏掃skipscanthedefectofnickandtraceprotruding,5,,未按工卡公差計算notcompensateaccordingtothemanufacturinginstruction,2,計算補償前核對工卡要求的公差值checkcompensatevalueonMIrequirementbeforecalculateitscompensation,領班復核資料foremanreviewthedata,7,70,無none,,,,,,

,公差太小deviationistoosmall,效率低lowefficiency,3,,,,,,,42,無none,,,,,,

,分辨率過大resolutionistoohigh,"缺口、線突、開短路漏掃描skipscanthedefectofnick,traceprotruding,openandshort",5,,未按WI要求設置分辨率notsetresolutionaccordingtoWI,2,培訓操作員按WI要求設置分辨率trainoperatortosetresolutionaccordingtoWI,領班復核分辨率foremanreviewtheresolution,7,70,無none,,,,,,

,分辨率過小resolutionistoolow,效率低lowefficiency,3,,未按WI要求設置分辨率notsetresolutionaccordingtoWI,3,培訓操作員按WI要求設置分辨率trainoperatortosetresolutionaccordingtoWI,領班復核分辨率foremanreviewtheresolution,7,42,無none,,,,,,

,設定錯誤wrongsetting,假點多、無法掃描toomanyfakeandfailtoscan,3,,未按工卡設定notsetaccordingtoMI,3,培訓員工按工卡作業(yè)trainoperatortooperateaccordingtoMI,領班復核板厚設定foremanreviewtheboardthicknesssetting,7,63,無none,,,,,,

,材質(zhì)設定錯誤wrongmaterialsetting,"無法掃描、漏掃描failtoscan,skipscan",5,,操作員疏忽設定錯誤operatorwrongsettingbymistake,2,"①、培訓員工按要求設定材質(zhì)；②、定專人做測試資料及參數(shù)調(diào)整領班負責審核

①、trainoperatortosetmaterialperrequirement②、dedicateoperatortomaketestingdataandparameteradjustment,thenforemanre-check",領班復核材質(zhì)設定foremanreviewthematerialsetting,7,70,無none,,,,,,

掃描：使用計算機分析CAD數(shù)據(jù)與實際掃描數(shù)據(jù)之間的差異，以找出缺陷Scan:analysethediscrepancybetweentheCADdataandtheactualscandatabyusingcomputertodetectdefects,缺點面積過大defectareaistoolarge,漏掃描skipscan,5,,更換料號或新料號時缺點面積初始化，員工未發(fā)現(xiàn)operatordon’tfindoutthedefectareainitializationwhenpartnumberchangeornewpartnumber,3,培訓員工在更新料號時必須確認面積值trainoperatortoverifytheareavaluewhenchangepartnumber,領班復核缺點面積設定foremanreviewthesettingofdefectarea,7,105,指定專人做資料dedicateoperatortomakedata,生產(chǎn)部prod.Dept.2016.6.30,指定專人做資料dedicateoperatortomakedata,5,2,7,70

,缺點面積過小defectareaistoosmall,假點多掃描效率低lowefficiencyduetotoomanyfake,3,,,,,,,63,無none,,,,,,

,定位問題未及時反饋notfeedbacktimelyaboutfixedlocationproblem,批量不良產(chǎn)生poorqualityoccursbybatches,5,,操作員未按要求及時反饋operatordon'tfeedbackproblemtimelyasrequired,2,要求員工必須及時反饋定位問題requireoperatortofeedbackfixedlocationproblemtimely,首件檢驗記錄firstarticleinspectionrecord,5,50,"首件掃描做記錄，操作員看到記錄才可批量生產(chǎn)scanthefirstarticleandrecordit,onlyoperatorhavetherecordcanheputboardsintobatchproduction",生產(chǎn)部prod.Dept.2016.6.30,"首件掃描做記錄，操作員看到記錄才可批量生產(chǎn)scanthefirstarticleandrecordit,onlyoperatorhavetherecordcanheputboardsintobatchproduction",5,2,5,50

掃描：使用計算機分析CAD數(shù)據(jù)與實際掃描數(shù)據(jù)之間的差異，以找出缺陷Scan:analysethediscrepancybetweentheCADdataandtheactualscandatabyusingcomputertodetectdefects,漏做標識missinglabel,"重復掃描，影響效率scanrepeatly,affectefficiency",5,,操作員疏忽漏做或錯做標識missinglabelduetooperator'smistakeorwronglabel,2,嚴格根據(jù)掃描編號在板邊做相應的標識markscanningnumberonboardedge,QC檢修時復核編號QCreviewthenumberwhenrepair,7,70,無none,,,,,,

,標識錯誤wronglabel,漏修理missingrepair,5,,,,,,,70,無none,,,,,,

,假點多toomanyfake,"測試時間長，漏掃testtimeistoolong,missingscan",3,,板面垃圾sundriesonsurface,3,測試掃描前用粘塵轆清潔板面cleanboardsurfacewithstickyrollerspriortoscanning,目視自檢self-inspectionbyvisual,7,63,無none,,,,,,

,,,,,板面氧化oxideonsurface,3,測試掃描前先處理板面氧化treatsurfaceoxidepriortoscan,目視自檢self-inspectionbyvisual,7,63,無none,,,,,,

,,,,,參數(shù)設置不當wrongparametersetting,2,根據(jù)最小線寬線距設定檢板分辨率（詳見WI）setinspectionresolutionbasedonmin.tracewidthandspace(refertoWIformoredetails),"操作員測試時自檢,領班審核operatorself-inspect,andforemanreviewit",7,42,無none,,,,,,

,漏掃描skipscan,"影響電性功能,嚴重造成報廢affectelectricityperformance,evenleadstoscrap",5,,掃描過程混板boardmixingduringscanning,3,已測試板和待測試板必須區(qū)分放置separatefinishedAOIboardsandwaitingforAOIboardsindifferentarea,每班檢查標識與板是否對應區(qū)分checkwhetherlabelsarerightforboardsseparationeveryshift,7,105,"已掃描的板用油性筆在板邊注明測試序號區(qū)分

marktestingserialnumberonthescannedboardedgewithgreasypen",生產(chǎn)部prod.Dept.2016.6.30,"已掃描的板用油性筆在板邊注明測試序號區(qū)分

marktestingserialnumberonthescannedboardedgewithgreasypen",5,2,7,70

,,,,,機器異常machineisabnormal,1,"①、同批板機臺相互進行對比測試②、維修和廠商定期保養(yǎng)機器

①、comparisontestingforAOImachinewiththesamelotboards②、maintainingdepartmentandsuppliermaintainAOImachineperiodically",測試記錄testingrecord,6,30,無none,,,,,,

,,"影響做板品質(zhì)及電性能,嚴重造成報廢affectPCBqualityandelectricity,evenleadstoscrap",5,,參數(shù)不當或工程資料和操作補償有誤unproperparameterorwrongengineeringdataandwrongoperatingcompensation,2,"定專人做測試資料及參數(shù)調(diào)整。領班負責審核dedicateoperatortomaketestingdataandparameteradjustment,thenforemanre-check",操作員測試時自檢operatorself-inspectionwhentesting,6,60,無none,,,,,,

"檢修：對AOI機掃描曝出的缺陷進行分析和確認，將OK板和待檢修板嚴格分開repair:analyseandverifythedefectsthatscannedbyAOI,andseparatetheOKboardsandwaitingrepairboardindifferentarea","檢修：對AOI機掃描曝出的缺陷進行分析和確認，將OK板和待檢修板嚴格分開repair:analyseandverifythedefectsthatscannedbyAOI,andseparatetheOKboardsandwaitingrepairboardindifferentarea",漏修理missingrepair,4,,操作員疏忽漏批號及時間標識lotnumberandtimelabelmissingduetooperatormistake,2,在批量掃描之前先寫好批號及時間標識recordthelotnumberandtimelabelpriortobatchscanning,QC檢修時復核QCreviewpriortorepair,7,56,無none,,,,,,

,未檢查板面序號notinspecttheboardserialnumber,漏修理missingrepair,5,,操作員未按要求檢查operatordon'thandleaccordingtorequirement,2,要求員工修理前先確認板面序號requireoperatortochecktheserialnumberpriortorepair,操作員自檢、領班抽檢operatorself-inspectandforemanspot-check,7,70,無none,,,,,,

,判斷錯誤wrongjudgement,漏修理造成報廢missingrepairleadstoscrap,5,,操作員對線路半成品檢驗標準把握不準確operatorisnotfamiliarwiththeinspectionstandardofPCB,2,"培訓半成品標準,對操作員進行理論與實際操作的考核trainoperatoraboutPCBstandard,andassessthemwiththetheoryknowledgeandactualoperation",操作員自檢、領班抽檢operatorself-inspectandforemanspot-check,7,70,無none,,,,,,

,漏檢missinginspection,"做板品質(zhì)及電性能,嚴重造成報廢affectPCBqualityandelectricityperformance,evenleadstoscrap",5,,檢修過程混板boardmixingduringrepair,2,合格板和不合格測試必須區(qū)分放置separatetheOKboardsandnonconformityboardsindifferentarea,每班檢查標識與板是否對應區(qū)分checkwhetherlabelsarerightforboardsseparationeveryshift,7,70,無none,,,,,,

,,,,,操作技能和判定標準不熟悉operatorisnotskilledandisnotfamiliarwiththeacceptancestandard,2,AOI操作員培訓上崗on-jobtrainingforAOIoperators,檢查是否有合格上崗證,6,60,無none,,,,,,

蝕檢inspection,擦花scratch,"開路,銅面劃傷open,scratchoncoppersurface",5,,板間沒有隔膠片notplasticfilmseparatedbetweenbo