失效模式及其影响分析培训教材.pptx

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1、HPhilips CFT Asia PacificInnovation & Industrial SupportCFT)FAILURE MODE and EFFECTS ANALYSIS 失失 效效 模模 式式 及及 其其 影影 响响 分分 析析Philips CFT Asia PacificInnovation & Industrial SupportJAY TAN HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 2FMEA Course ScheduleDay 2

2、 9.00Real-life P-FMEA exercise -contReview 10.30Tea-break 10.45D-FMEA 12.00Lunch 1.00Organization Aspect of FMEA 3.00Tea-break 3.30Maturity GridDay 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-lif

3、e P-FMEA exercise -cont HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 31INTRODUCTION TO FMEAHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 4Car 2: No Major Break downs 非 主 要 的 破 损 Few failures 很 少 的 失 效Car 1: Frequent

4、 Break downs 频 繁 地 破 损 Many minor components failures 许 多 的 小 部 件 失 效A reliability program ? Why necessary? 一一 个个 可可 靠靠 性性 的的 计计 划？划？ 为为 什什 么么 必必 须？须？HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 5 Customer Satisfaction 顾顾 客客 满满 意意Customer satisfaction means

5、: Never having to say youre sorry ! 顾 客 满 意 意 味 着： 决 不 要 说 对 不 起 ！HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 6 QUALITY ENGINEERING TOOLSTOOLS1 Design Review2 7 QC Tools3 New 7 QC Tools4 Statistical Process Control5 Design of Experiments6 Quality Function

6、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 PacificInnovation & Industrial SupportCZB698

7、-00-0006| 2022年1月21日星期五 | 7What is a FMEA?A structured, disciplined process to systematically and comprehensively, identify and document potential problems and weaknesses in a design or process so that design changes can be made or other corrective actions taken to prevent actual occurrence of failu

8、re 一 个 结 构 化 和 专专 业业 化化 的 过 程，它 能 系 统 和 综 合 地 找找 出出 并 记 录 在 设 计 和 工 艺 过 程 中 潜潜 在在 的的 问 题 和 缺 点 并 由 此 作 出 设 计 改 变 或 采 取 其 它 的 改 正 措 施 以 防防 止止 失 效 的 实 际 发 生HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 8Effect of FMEA on Process and Design changesDesign StartD

9、evelopmentProduction ReleaseProduction TimeNo of Engineering ChangesTraditional approachFMEA approachHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 9 TYPES of FMEATYPEALIASES DESCRIPTIONProduct Design FMEA * Focus on the product itself, review FMEA D-FMEA sys

10、tems, 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 processService * Focu

11、s on field service FMEA * Concerned with reliability, product application, maintainability HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 10Objective of FMEAFailure Mode & Effect Analysis (FMEA) is used to improveproduct reliability (considering usage, enviro

12、nment, lifetime etc.)quality of (purchased) parts (incl. hidden functions of a part)reproducibility of the product (reduction of fall off & repairs in assembly)reproducibility of the production process (handling, transport etc.)Focus on technical problemsLink with Maturity Grid and Risk Management!H

13、Philips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 11Types of RisksMarket Riskshaving the right producton the right timeTechnical Risksachieving the product specquality, reproducibilityProject Risksproject organisation, team aspects, resourcesMarketRisksTechnicalR

14、isksProjectRisksPlanningSpecificationKnow-how, capacityHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 12Use of FMEAA. Reliability Engineering - Reliability improvements.B. Producibility Analysis - Less repairs and scrap during manufacturing. - Improvement of

15、the Zero- Hour Quality.C. Production 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 PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 13100

16、 : 110 : 11 : 1PRODUCTDESIGNPROCESSDESIGNPRODUCTIONIMPROVEPRODUCTPAYBACKSLOWVISIBILITY/REWARDHIGH VISIBILITY/REWARDTIME500 : 1CONCEPTDESIGNQuality LeverHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 14Reliability Investigation by Means of FMEAPremises:The nor

17、mal functioning of the productQuestion:What is the influence of : use - time and environment on each componentPossibilities: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 ?HPhilips CFT

18、Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 15Producibility Analysis by Means of FMEAPremises:Measuring tool is: eg FOR/ppm Actions:Actions as outcome of theProcess Quality Control (P.Q.C.)Analysis: Focused on failures which are made and noticed during the production p

19、rocess.HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 162PROCESS FMEAHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 17FMEA for the Production ProcessSubject for Analysis: - flow chart and scenario of the production pro

20、cessFocused on: - manipulations of the operator- wrong (deviations) material- process - equipment- transport - storageHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 18Failure modeRPN2 = SO2D2ControlsCause 1RPNn = SOnDnControlsCause 1Development of a Process F

21、MEA : An OverviewProcess stepPurposeRPN1 = SO1D1ControlsCause 1EffectsSeverity, SOccurrence, OnDetection, DnHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 19Subject: Date: No Process step / Purpose Potential Failure ModePotential Effect on FailureSPotential c

22、auses on FailureO Current ControlDRPN Gravity FactorRecommended ActionOwner Completion DateAction Taken /ResultEvolution Factor1Mount actuator and install spring clip = Hold actuator in placeDifficulty in assembling spring clipLong cycle time8 Handling required to orientate clip 8Production Monitori

23、ng Chart, Opr skill chart42562Cut LDGU , Mount LDGU to line pen housing = Assemble LDGULens and grating contaminationFail Grating Adjustment8Handling 4 Reject at adjustment stn132 Cutting machine dirty3Weekly maintenance4963Mount and secure flex assy = Assemble Flex AssyESDLDGU damage by contact aff

24、ecting long/short term reliability8Handling by operator2 Reject at adjustment stn81284Solder actuator & LDGU to Flex Assy = Connect actuator,LDGU and FlexFailure Mode & Effect Analysis - ProcessHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 20Process FMEA Pro

25、cedure5 Steps: Establish the Process Flow Analyze the Process Establish purpose of each operation and the possible failure modes Define the weak points of the Process Establish actions and responsibilitiesHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 21Step

26、1 -Establish Process FlowTake 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

27、 conditions Testing & quality controlMake of the assembly process a: PROCESS FLOWCHARTHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 22Process Flow Chart (eg)Mount partHandling processGlue partAdjustment processTestingMount subassyHandling processMount partTe

28、stingStation1Station2Station3Station4HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 23Process Flow Chart (eg)EquipmentsLightpen carrierLightpen carrierPress-on toolLightpen carrierMounting fixtureElectric screwdriverScrew dispenserLDGU cutting/insertion machi

29、neLightpen carrierSoldering equipmentGrating adjustmentmachineGlue dispenser andcuring unitMount actuatr &install spring clipMount & secure flexassemblyCut LDGU leads &mount LDGU intoLightpen housingSolder actuator andLDGU to flex assyGrating & glueing ofLDGUMount rack & wirespringAssembly processHP

30、hilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 24Subject: No Process step / Purpose Potential Failure ModePotential Effect on FailureSPotential causes on FailureOCurrent ControlDRPN1Mount actuator and install spring clip = Hold actuator in place2Cut LDGU , Moun

31、t LDGU to line pen housing = Assemble LDGU3Mount and secure flex assy = Assemble Flex AssyFailure Mode and Effect Analysis ChartHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 25Step 2 - Analysis of the ProcessExamination of: How the purpose of the process/ope

32、ration are realised by the designers/engineers. What are the working conditions * static * dynamicHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 26Step3 -Establish purpose of each operation and the possible failure modes What is the purpose of the process ste

33、p ? Which deviations are possible ? ( FAILURE MODE ) What is the effect of that deviation on the producibility? ( EFFECT ) What is the cause of that deviation ? ( CAUSE )HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 27MATERIALMANMACHINEMETHODMEASUREMENTENVIR

34、ONMENTPROCESSProductFunctionsProductFunctionsProductFunctionsProcess Cause - Effect InvestigationPOTENTIALCAUSEEFFECTPOTENTIALFAILUREPOTENTIALHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 28Potential Failure Modes* Failure means any one or more of the follow

35、ing -failure to perform/deliver function -failure to meet design 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,

36、not as a symptom recognisable by the customer* use brainstorming to ensure completeness Examples : corroded cracked deformed oxidised leaking fractured malformed flattened non-sticking contaminatedHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 29Subject: No P

37、rocess step / Purpose Potential Failure ModePotential Effect on FailureSPotential causes on FailureOCurrent ControlDRPN1Mount actuator and install spring clip = Hold actuator in placeDifficulty in assembling spring clip2Cut LDGU , Mount LDGU to line pen housing = Assemble LDGULens and grating contam

38、ination3Mount and secure flex assy = Assemble Flex AssyESDFailure Mode and Effect Analysis ChartHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 30Effects ( Process FMEA )Each failure mode may have undesirable side effects on some or all the following:1.End-use

39、r (product)2.Down-stream process (next operation)3.Local processAll 3 effects should be considered in any process FMEAHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 31Severity (Process-FMEA)RatingDegreeEffects on Effect on down End User Stream/Local process1M

40、inor * not noticeable * 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

41、cust dissatisfaction * 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

42、assessment of the seriousness of the effectHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 32Subject: No Process step / Purpose Potential Failure ModePotential Effect on FailureSPotential causes on FailureOCurrent ControlDRPN1Mount actuator and install spring

43、clip = Hold actuator in placeDifficulty in assembling spring clipLong cycle time - capacity loss82Cut LDGU , Mount LDGU to line pen housing = Assemble LDGULens and grating contaminationFail Grating Adjustment83Mount and secure flex assy = Assemble Flex AssyESDLDGU damage by contact affecting long/sh

44、ort term reliability8Failure Mode and Effect Analysis ChartHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 33Potential Cause(s) of Failure* How the failure mode could occur, described in terms of something correctable or controllable* list, using brainstorming

45、 or Fault Tree Analysis (FTA), every conceivable failure cause assignable to each failure mode* causes should be specific, e.g. “operator error” or “machine problem” are examples of causes which are not specific enough* causes may or may not be mutually exclusive -if eradicating a cause has a direct

46、 impact on the failure mode, then,the cause is said to be exclusive to the failure mode -when causes are not mutually exclusive, Design of Experiments may be use to identify the root causes (minor contributors) or thosewhich can be most easily controlledHPhilips CFT Asia PacificInnovation & Industri

47、al SupportCZB698-00-0006| 2022年1月21日星期五 | 34Fault Tree exampleProblemCause ACause BCause CA1A2B1B2HPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 35Occurrence (P-FMEA)Rating DegreeBased on SPC Base on failure rate1RemoteCpK 1.67 1.33 50 ppm3LowCpK 1.00 250 ppm

48、41000 ppm5Moderate CpK Hold actuator in placeDifficulty in assembling spring clipLong cycle time8 Handling required to orientate clip 82Cut LDGU , Mount LDGU to line pen housing = Assemble LDGULens and grating contaminationFail Grating Adjustment8Handling 4 Cutting machine dirty33Mount and secure fl

49、ex assy = Assemble Flex AssyESDLDGU damage by contact affecting long/short term reliability8Handling by operator2Failure Mode and Effect Analysis ChartHPhilips CFT Asia PacificInnovation & Industrial SupportCZB698-00-0006| 2022年1月21日星期五 | 37Current controls* Current controls are descriptions of cont

50、rols that:(a) prevent the failure mode from occurringor(b) detects the failure mode should it occur* Examples of process controls:- fixture fool-proofing- SPC- inspection either at the subject operation- testing or at the subsequent operations- gauge R & R- preventive maintenance- operator training-