Philips FMEA

Failure Mode and Effect

Analysis

1.1
 Content of the course
 Introduction
 Product - FMEA
 Blockdiagram , functiontree
 Process - FMEA
 Process-flowdiagram (macro-level) , micro-level
 Facilitatorskills

1.2
 FMEA – Introduction
 Why FMEA’s?
FM
EA-  Definition, Purpose,
Phi
l ips Types, Benefits
 Team Approach
Introduction

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 Time 1.6
(Productionstart)
 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
Product-
Product- Electrical
FMEA
FMEA
Optical

Mechanical
Process-
Process-
FMEA Electrical
FMEA
Optical

1.8
FMEA
Sessions i c a l
ech an FMEA on
M FMEA on
First Mechanical
EVT Model

FMEA on Working Model

FMEA on Part Files
chosen
FMEA on Architecture
Architectures

FMEA on
L0 Schematics FMEA on
(ftbo L0) L0 Board FMEA on
(ftbo L1) L1 Board
El e c t (ftbo L2)
rical 1.9
Benefits – Product-FMEA’s
Product
 Assess failure mode effects on all
Product
customers.
 Aids in evaluating testspecifications
Proces
 Evaluation of design relating to
DFM DFA DFT

 Increases the possibility to detect

possible failure modes.

1.10
Voordelen – Proces-FMEA’s
Design
 Assess effects on all customers

Proces
Proces
 Identifies potential manufacturing
and assembly causes to focus
controls on reducing occurrence or
increasing detection.

1.11
 Generating FMEA’s
Who initiates? Who prepares? Who updates?

When to Failure
Failure
Who is FMEA-
discard? customer?
Mode
Mode
FMEAsand
and
How docu- Effect
Effect Startingdate/
mented? Analysis
Analysis 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

Core-
team

Support-
team
1.14
 Product-FMEA – Content

 Define FMEA-team
Ph Define scope
ilip 
s
 Describe functions
Product-FMEA
» Brainstorming
Content
» Function Trees

1.15
 Product-FMEA – Team
Facilitator

Support Representitive
team s from:
• development
Design-
Enginieer Core- • production
team • quality
Production/
process-enginieer • 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
Service Assembly

Part Screw Component/ Weld Part

X Assembly Y

User
Other Adhesive Part
systems Z 1.18
 Example blockdiagram (Settop
Wildfire)
Smartcard PCB

Klicked

Klicked
Front Display PCB

Klicked

Screwed Screwed
Cover Frame 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
Verb Noun
Noun
Indicates action, Indicates what the
occurrence, being action relates to

Generate light
Control speed
Display 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
HOW? WHY ?
Second
Level
First Third
level Level

1.25
 Functiontree – Frontbutton
(Settop)
HOW? WHY?
Must be printable and PQR-Cleantest. Tekst clearly visible
resistance te wear. 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 Description Mode of Action/ Resp. M M P
Function Effect Cause
Failure C L
Level 1 Level 2 Solution

Front Button Tekst

clear
visible
after
PQR-
test

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 Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst

clear unread-
visible able
after
PQR-
test

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 Another Complete Customer Enduser Governmental

regulation
Mode part Assembly

Tekst None Difficult Dissatisfied Dissatisfied

None

unread- to sale

able

1.33
 Product-FMEA – Effects of
failure
Description Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst Assembly

clear unread- not
visible able possible to
after sale
PQR-
test Customer
dissatisfied

1.34
Severity (Weightfactor)

What is the severity of the effects?

1.35
Ratingcriteria voor Severity
(Weightfactor)
Effect Criteria: Severity of effect Class
Non-conforming
Safety failure
with safety
S

Unacceptable Correction is nescessary

risk A
Correctie is recommended
Relative big
risk
B

Correctie is
is usefull
nuttig
risico
Minimum risk Correctie C
C
1.36

None Accepted failure D

 Rating of Weightfactor–
example
S
Part
Failure Effects e
v.
Function Mode
Assembly: unsaleable (A)
Frontbutton Tekst Customer: Dissatisfied (A) A
/ unreadable Gov.Reg.: None (D)

Tekst
readable
after PQR-
1.37
test
 Product-FMEA –
Weightfactor
Description Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst Assembly

A
clear unread- not
visible able possible to
after sale
PQR-
test 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
Designrequirement
WHY?
level 3 1.43
WHY?
Sentencing Technique

Could result in Effect

Failure
Mode Due to
Cause

1.44
Sentencing Technique -
Example
Dissatisfied
Could result in customer
Tekst
unreadable
Due to Surface
roughness
(designreq.)

1.45
 Product-FMEA – Cause
Description Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst Assembly

Tekst A
clear unread- not
visible able possible to on wrong
after sale
PQR- location
test Customer
dissatisfied

1.46
Product-FMEA – Occurrence

What is the possibility that

the failure occurrs?

1.47
 Ratingcriteria
occurrence

Probability of failure Possible Failure Rates Ranking

Very high ≥ 1 of 3 5
> 1 of 20 4

Moderate > 1 of 400 3

> 1 of 15000 2

Low < 1 of 15000 1

1.48
Product-FMEA – Occurrence
Description Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst Assembly 5

Tekst A
clear unread- not
visible able possible to on wrong
after sale
PQR- location
test 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 Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst Assembly JD 5

Tekst No tekst A
clear unread- not
visible able possible to on
on wrong
after sale buttons
PQR- location
test Customer
dissatisfied

1.51
Define Evolutionfactor
 Cause not known 4
 Solution not known 3
 Solution not evaluated 2
 Solution not implemented 1
 Solution implemented 0

1.52
 Product-FMEA –
Evolutionfactor
Description Description Mode of
Function Effect Cause Action/ Resp. M M P
Failure C L
Level 1 Level 2 Solution

Front Button Tekst Tekst Assembly 5

clear unread- not Tekst No tekst JD A 1
visible able possible to on
on wrong
after sale buttons
PQR- location
test Customer
dissatisfied

1.53
 Risk evaluation

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

1.54
 Maturity Grid
Weight Factor
S A B C D

4 4
3 5 1 2 3
2 3 5 2
1 7 1
0 3 4 0
Evolution Factor Evolution Factor
1.55
 Product-FMEA – Electrical
(Example)

Description Description Mode of Action/

Function Effect Cause Resp. M M P
Failure
Level 1 Level 2 C L
Solution

Front Tuner Put-through Tuner gets Tuner gives Low frequent Add bead GD A 2 5
end selected signal disturbed by bad signal noise is not in LNBA
through line, right
(SD12XX) noise generated filtered
next to
by 14-18V tuner
generation

1.56
 Proces - FMEA – Content

 FMEA-team
Ph Define scope
ilip 
s
 Describe functions
Proces - FMEA
Content

1.57
 Proces-FMEA – Team
Facilitator or application engineer

Representatives
of :
Support-
team • Productdevelopment
• Process-development
Production/- • Production
process-engineer Core- • Quality
team • Purchase
Design-engineer
• 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 Mode of Action/

Function Effect Cause Resp. M M P
Failure
Level 1 Level 2 C L
Solution

Glue Glue with Join Cyanoacrylate Lifetime

problems
Glue Use JD A 2 5
cyano- parts not well cured volume activator
acrylate to high

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 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).

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
 Development
Engineering Purchasing
Quality Org. and Eff. Proc. Impr.
Team

"POOL"
of remarks

FMEA Maintain the FMEA Library

Maintenance
New Filter the remarks
Remarks team

FMEA Library
FMEA FMEA Reports Consult the Library
Designer
Tool Search for solutions
Follow-up actions

Consult
Fill Consult
in
FMEA Facilitator
1.73

FMEA Session
FMEA

THE END

1.74