03810-Process Failure Mode and Effects nalysis (for PB suppliers).pdf
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1、 欢迎访问欢迎访问 6sigma 品质网品质网 site: http:/ bbs: http:/ 6 品质网,原名龙在天涯成立于 2 0 0 1年 10月,我们定位于一个关于 S P C , F ME A , D OE , S i x S i g ma , 品质体系,品质管理, 企 业管理的综合网站! 从它成立开始到现在已经有一年的时间啦,目前它的发展良好,这里吸引了一大批优秀的品质统计, 企业管理,6 s i g ma 爱好 者和专业人士! 我们的目标是建立国内最好的品质/ 质量管理的专业网站。本站及时提供大量的最新专业文章,以及相关的资料下载,内容 丰富,我们提供的就是你想要的,另外本站新
2、设立了一个 6 品质论坛供大家交流,已经有几百名质量工程师,企业管理 人士和多位 6 s i g ma 黑带加盟。 1欢迎访问6sigma品质网 site: http:/ bbs: http:/ Process Failure Mode and Effects Analysis (for PB suppliers) Process FMEA Training and Application Rev 02 2欢迎访问6sigma品质网 site: http:/ bbs: http:/ Contents Objectives and Key results Introduction and Bac
3、kground Types of FMEA and Applications Developing an FMEA Cause/Effect Relationship Example Process FMEAs Exercise Appendices 3欢迎访问6sigma品质网 site: http:/ bbs: http:/ Objectives Understand the Process FMEA methodology Apply the Process FMEA methodology to help solve current process related problems 4
4、欢迎访问6sigma品质网 site: http:/ bbs: http:/ Key Results UNDERSTANDING: upon completion participants are able to demonstrate an understanding of process FMEA ?Know the FMEA terminology ?Know how to develop a process FMEA ?Know the FMEA ranking and prioritizing system 5欢迎访问6sigma品质网 site: http:/ bbs: http:
5、/ Key Results APPLICATION: apply process FMEA to a process ?Result will be a prioritized set of potential failures ?Actions to address potential failures will be planned ?Present an FMEA with corrective actions for management review 6欢迎访问6sigma品质网 site: http:/ bbs: http:/ What is FMEA? FMEA is a str
6、uctured approach for analyzing potential failures It is an analytical technique intended to: ?Identify potential failure modes ?Assess their potential effects and causes ?Assess the control and containment of failures ?Identify and prioritize actions that would eliminate or reduce potential failures
7、 7欢迎访问6sigma品质网 site: http:/ bbs: http:/ What is FMEA? FMEA is a process of asking questions and supplying answers. FMEA Term ? What can go wrong? failure mode ? What might happen if it goes wrong?effect ? How bad is the consequence? severity ? What might make it go wrong? cause ? How likely is it t
8、o go wrong? occurrence ? How would we know if it went wrong? control ? How are its effects prevented? containment ? What should be done about things recommended that may go wrong?actions 8欢迎访问6sigma品质网 site: http:/ bbs: http:/ What is FMEA? .but in a systematic manner ?that relates and organizes the
9、 questions and answers ?that assesses risks ?that prioritizes actions 9欢迎访问6sigma品质网 site: http:/ bbs: http:/ Background FMEA was originally developed by the aerospace industry in the 1960s as a tool for improving hardware design The use of FMEA has expanded to other industries ?automotive ?semicond
10、uctor The methodology has been expanded to include the analysis of process failures 10欢迎访问6sigma品质网 site: http:/ bbs: http:/ Applications of FMEA Design FMEA (DFMEA) ?FMEA applied to a complete (end) product ?Usually performed at the design stage ?Used to identify design features that will eliminate
11、 or reduce potential product failures Equipment FMEA ?FMEA applied to a specific piece of equipment ?Used to identify equipment improvements 11欢迎访问6sigma品质网 site: http:/ bbs: http:/ Applications of FMEA Process FMEA (PFMEA) ?FMEA applied to failures that could occur in or be induced by a manufacturi
12、ng process ?Used to reduce the frequency and impact of process failures 12欢迎访问6sigma品质网 site: http:/ bbs: http:/ Why Use PFMEA? The primary purpose of PFMEA is to reduce the frequency and impact of excursions by: ?Eliminating potential causes of excursions ?Improving control and containment of excur
13、sions that do occur ?Enhancing process controls ?Improving preventive maintenance programs ?Developing excursion response plans 13欢迎访问6sigma品质网 site: http:/ bbs: http:/ Why Use PFMEA? Other uses of PFMEA ?A vehicle for preserving, transferring, and sharing knowledge ?A training tool ?A means of prov
14、iding input to equipment vendors for design improvements 14欢迎访问6sigma品质网 site: http:/ bbs: http:/ When Should FMEA be Used? The greatest benefit of PFMEA is when it is developed during the introduction of a new material/process and prior to making changes to process equipment, materials, or methods.
15、 e.g. New dry film, Direct metallization, New cable for TDR tester PFMEA can also be applied to an existing process to prevent potential excursions or in response to excursions to develop and prioritize actions to prevent recurrence. e.g. Delamination, PTH void, Solder mask peel off 15欢迎访问6sigma品质网
16、site: http:/ bbs: http:/ Developing a PFMA The steps in developing a Process FMEA are straight forward ?A flow chart of the steps is provided ?Although the steps are straight forward consistency in the use of terms and definitions is important ?Results are documented on a template 16欢迎访问6sigma品质网 si
17、te: http:/ bbs: http:/ PFMEA Flowchart Assemble Team Gather Data Set Objective/Scope All Modes Considered? Select a Failure Mode Identify all Possible Causes of Failure Mode Identify all Effects of Failure Mode Determine Current Controls for Causes Determine Current Containment for Effects Assign a
18、Severity Ranking to Each Effect Assign an Occurrence Ranking to Each Cause Assign a Detection Ranking to Each Control Assign a Detection Ranking to Each Containment Calculate Risk Priority Numbers (RPN1/RPN2) Prioritize Failures Modes Devise Recommended Actions Assign Owner(s) to Actions YesNo Ident
19、ify Potential Failure Modes 17欢迎访问6sigma品质网 site: http:/ bbs: http:/ Failure Mode Effects Analysis (FMEA) Model Failure Mode How can product fail to meet requirements? Causes What caused the failure mode? Control How to prevent cause of failure mode? Containment How to prevent shipping defective pro
20、duct? SeverityOccurrenceDetection Risk Priority Number (RPN) = Severity x Occurrence x Detection A score/rank scale is assigned to Severity, Occurrence and Detection criteria. Worst case situation will have the highest score. 18欢迎访问6sigma品质网 site: http:/ bbs: http:/ Process FMEA Example Product Name
21、:HAL PCBProcess Engineer:WY KongDate:18 Mar 1999Rev:1.0 Process:Pressing, Solder mask, E-testEquipment Name Process StepPotential Failure ModePotential Effect(s) of Failure S E V Potential Cause(s) of Failure O C C Current Controls D E T 1 RPN1Current Containment D E T 2 RPN2 Pressing process Solder
22、 mask process Electrical test Lamination void Pit and Dent on copper foil After pressing thickness over requirement. Solder mask on pads Open / Short boards escaped Delamination Short trace Protrusion Finished board thickness out of spec. Impedance out of spec. Cosmetic rejected by customer. Poor so
23、lderability. E-test open. Customer line down Customer RMA 6 5 3 5 8 Insufficient vacuum Copper foil quality problem Layup operator grove dust Press plate dirty Particle on air fall on the foil. Incoming laminate over specification. Lay up Operator mistake Scratched Exposure artwork Wrong exposure ar
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