Philips
FMEA
Failure Mode and Effect Analysis
1.1
Content of the course

Introduction

Product - FMEA


Process - FMEA


Blockdiagram , functiontree
Process-flowdiagram (macro-level) , micro-level
Facilitatorskills
1.2
FMEA – Introduction


Introduction

Why FMEA’s?
Definition, Purpose,
Types, Benefits
Team Approach
1.3
Why FMEA’s?



Appropriate recommended
actions may not have been
taken.
Savings in engineering time.
Reduction of changes
immediately before
productionstart (Commercial
Release).
1.4
FMEA – Definition
Structured group of activities
which...

Identify potential failure modes

Prioritize actions

Document the process.
1.5
Failures
FMEA – Purpose
FMEA
C R
(Productionstart)
Time
1.6
FMEA – Purpose
FMEA’s are intended to ...



Rate severity of failure modes
Identify actions to reduce occurence
Test adequacy of controls
1.7
FMEA – Types
Mechanical
ProductFMEA
Electrical
Optical
Mechanical
ProcessFMEA
Electrical
Optical
1.8
FMEA Sessions
FMEA on
Architectures
FMEA on
chosen
Architecture
FMEA on
L0 Schematics
(ftbo L0)
FMEA on
First Mechanical
FMEA on Working Model
Part Files
FMEA on
L0 Board
(ftbo L1)
FMEA on
EVT Model
FMEA on
L1 Board
(ftbo L2)
1.9
Benefits – Product-FMEA’s
Product

Proces



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.
1.10
Voordelen – Proces-FMEA’s
Design
Proces

Assess effects on all customers

Identifies potential manufacturing
and assembly causes to focus
controls on reducing occurrence or
increasing detection.
1.11
Generating FMEA’s
Who initiates?
When to
discard?
How documented?
Who prepares?
Who updates?
Failure
Mode
and
FMEAs
Effect
Analysis
Who is FMEAcustomer?
Startingdate/
revisiondate?
When
completed?
1.12
Managing FMEA’s
FMEA’s are living documents
and are updated ...



Modification to a product or process
is planned
Component is to be used in new
environment
Customer rejections
1.13
FMEA – Team Approach
Coreteam
Supportteam
1.14
Product-FMEA – Content
Product-FMEA
Content

Define FMEA-team

Define scope

Describe functions
» Brainstorming
» Function Trees
1.15
Product-FMEA – Team
Facilitator
Support
team
DesignEnginieer
Production/
process-enginieer
Representitive
s from:
• development
Coreteam
• production
• quality
• purchase
• testdept.
• ...
1.16
Product-FMEA – Scope
Once coreteam is established ...



Create Blockdiagram
Identify the boundery for Analysis
Confirm composition of support
team.
1.17
Blockdiagram
Assembly
Service
Part
X
Screw
Component/
Assembly
Weld
Part
Y
User
Other
systems
Adhesive
Part
Z
1.18
Example blockdiagram (Settop Wildfire)
Smartcard PCB
Klicked
Front
Klicked
Display PCB
Klicked
Cover
Screwed
Frame
Screwed
PSU
1.19
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.
1.20
Describe Function
Verb
Indicates action,
occurrence, being
Generate
Control
Display
Noun
Indicates what the
action relates to
light
speed
information
1.21
Describe Functions
Thought starters ...





Satisfy user
Attract user
Guarantee durability
Easy to repare
Safety requirements
1.22
Brainstorming
1.23
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.
1.24
Constructing Functiontrees
WHY ?
HOW?
Second
Level
First
level
Third
Level
1.25
Functiontree – Frontbutton (Settop)
HOW?
Must be printable and
resistance te wear.
WHY?
PQR-Cleantest. Tekst clearly visible
after x-times cleaning.
Display
Information
1.26
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?”
1.27
Product-FMEA – Functions
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/ Resp. M M
C
P
L
Solution
Tekst
clear
visible
after
PQRtest
1.28
Potential failure Modes
Failure Mode Type
Example
No function
Not operational
Partial function
Not all of function operating
1.29
Failure Modes: Frontbutton
Function: Tekst clear visible after 100x cleaning.
Failure Mode Type
Example
No function
No tekst available
Partial function
Tekst partial available
1.30
Product-FMEA – Modes of failure
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
1.31
Effects failure
What are the effects of
the failure relating to:
- another part
- the complete assembly
- the customer
- the enduser
- the governmental regulations
1.32
Product-FMEA – Tabel of effects
Frontbutton
Failure
Mode
Tekst
unread-
Another
Complete
part
Assembly
None
Difficult
Customer
Enduser
Dissatisfied
Dissatisfied
Governmental
regulation
None
to sale
able
1.33
Product-FMEA – Effects of failure
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
Assembly
not
possible to
sale
Customer
dissatisfied
1.34
Severity (Weightfactor)
What is the severity of the effects?
1.35
Ratingcriteria voor Severity
(Weightfactor)
Effect
Criteria: Severity of effect
Non-conforming
with safety
Safety failure
Unacceptable
risk
Correction is nescessary
Relative big
risk
risico
Minimum risk
Class
S
A
Correctie is recommended
Correctie is
is usefull
nuttig
Correctie
B
C
C
1.36
None
Accepted failure
D
Rating of Weightfactor– example
S
e
v.
Part
Failure
Function
Effects
Mode
Frontbutton
Tekst
/
unreadable
Assembly: unsaleable
(A)
Customer: Dissatisfied
(A)
Gov.Reg.: None
(D)
A
Tekst
readable
after PQR-
test
1.37
Product-FMEA – Weightfactor
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
Assembly
not
possible to
sale
A
Customer
dissatisfied
1.38
Potential Cause of Failure
A weakness in the design with a
failure mode as effect.
1.39
Manufacturing misbuilds
Due to design Deficiencies
+
+
-
1.40
Manufacturing misbuilds
Robust Design
+
+
-
1.41
Cause of failure
Use Fishbone Diagram
Tekst on wrong location
Tekst
unreadable
Inkt of poor quality
1.42
Cause of failure – “Why”-ladder
Tekst unreadable
Inkt doesn’t stick
Surface roughness
level 1
WHY?
not ok.
level 2
WHY?
Designrequirement
level 3
WHY?
1.43
Sentencing Technique
Could result in
Failure
Mode
Effect
Due to
Cause
1.44
Sentencing Technique Example
Could result in
Tekst
unreadable
Due to
Dissatisfied
customer
Surface
roughness
(designreq.)
1.45
Product-FMEA – Cause
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
Assembly
not
possible to
sale
Tekst
A
on wrong
location
Customer
dissatisfied
1.46
Product-FMEA – Occurrence
What is the possibility that
the failure occurrs?
1.47
Ratingcriteria
occurrence
Probability of failure
Very high
Moderate
Low
Possible Failure Rates
Ranking
1 of 3
5
> 1 of 20
4
> 1 of 400
3
> 1 of 15000
2
< 1 of 15000
1
1.48
Product-FMEA – Occurrence
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
Assembly
not
possible to
sale
Tekst
A
5
on wrong
location
Customer
dissatisfied
1.49
Produkt-FMEA – Action/Solution
What are possible actions to:
- eliminate the failure
- reduce effect
- reduce occurrence.
1.50
Product-FMEA – Action/Solution
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
Assembly
not
possible to
sale
Tekst
on wrong
No tekst
on
buttons
JD
A
5
location
Customer
dissatisfied
1.51
Define Evolutionfactor





Cause not known
Solution not known
Solution not evaluated
Solution not implemented
Solution implemented
4
3
2
1
0
1.52
Product-FMEA – Evolutionfactor
Description
Level 1
Front
Description
Function
Level 2
Button
Mode of
Failure
Effect
Cause
Action/
Resp. M
C
M
L
P
Solution
Tekst
clear
visible
after
PQRtest
Tekst
unreadable
Assembly
not
possible to
sale
Tekst
on wrong
No tekst JD
on
buttons
A 1
5
location
Customer
dissatisfied
1.53
Risk evaluation

Severity (Weightfactor)

Occurrence

Evolutionfactor

Risk maturity - grid
1.54
Maturity Grid
S
Weight Factor
A
B
C
4
3
2
1
0
Evolution Factor
D
4
5
1
3
2
5
7
3
4
3
2
1
0
Evolution Factor
1.55
Product-FMEA – Electrical
Description
Description
Level 1
Level 2
Front
end
Tuner
Function
Mode of
Failure
Effect
Cause
Action/
Solution
Put-through
Tuner gets
selected signal disturbed by
(SD12XX)
noise generated
by 14-18V
generation
Tuner gives
bad signal
through
Low frequent Add bead
noise is not in LNBA
line, right
filtered
(Example)
Resp. M M
C L
GD
P
A 2 5
next to
tuner
1.56
Proces - FMEA – Content
Proces - FMEA
Content

FMEA-team

Define scope

Describe functions
1.57
Proces-FMEA – Team
Facilitator or application engineer
Supportteam
Production/process-engineer
Design-engineer
Coreteam
Representatives
of :
•
Productdevelopment
•
Process-development
•
Production
•
Quality
•
Purchase
•
Owner of the next
process
•
….
1.58
Process-FMEA – Scope



Create flow-diagram
Define scope
Define support-team.
1.59
Process-FMEA – (Example)
Description
Description
Level 1
Level 2
Glue
Glue with
cyanoacrylate
Function
Mode of
Failure
Effect
Cause
Action/
Solution
Join
parts
Cyanoacrylate
not well cured
Lifetime
problems
Glue
volume
to high
Resp. M M
C L
Use
JD
activator
P
A 2 5
1.60
FMEA
Tasks & Responsibilities.
1.61
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, ... )
1.62
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?
1.63
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.
1.64
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).
1.65
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.
1.66
FMEA – Facilitator
Tasks of the facilitator:

Taking care for correct applying FMEAmetholodgy:
»
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).
1.67
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)?
1.68
FMEA – Facilitator
Tasks of the facilitator:

Taking care for correct applying
FMEA-metholodgy:
»
don’t loose time with long discussions
about severity and probability. In case of
doubt, take the ‘worst case’.
1.69
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?
1.70
FMEA – Facilitator
Tasks of the facilitator:

Taking care for the TEAM-process:
»
Are all teammembers participating in
discussions
»
Avoid long discussions between 2 persons,
don’t look for sollutions.(discuss difficult
items in a small group separately)
»
An ‘open-climate’ during the meeting is very
important (don’t look for ‘guilty persons’, try
to know te real problems,…)
1.71
FMEA
Software - tools
at Philips
1.72
Engineering
Development
Purchasing
Quality
Org. and Eff.
Proc. Impr.
Team
"POOL"
of remarks
FMEA
Maintain the FMEA Library
Maintenance
Filter the remarks
team
New
Remarks
FMEA Library
FMEA
Tool
FMEA Reports
Follow-up actions
Designer
Consult the Library
Search for solutions
Consult
Consult
Fill in
FMEA Facilitator
1.73
FMEA Session
FMEA
THE END
1.74