IntelTrainingmaterialFMEA

6sigmasite::::(forPBsuppliers)ProcessFMEATrainingandApplicationRev0226sigmasite::•ObjectivesandKeyresults•IntroductionandBackground•TypesofFMEAandApplications•DevelopinganFMEA•Cause/EffectRelationship•ExampleProcessFMEAs•Exercise•Appendices36sigmasite::•UnderstandtheProcessFMEAmethodology•ApplytheProcessFMEAmethodologytohelpsolvecurrentprocessrelatedproblems46sigmasite::•UNDERSTANDING:uponcompletionparticipantsareabletodemonstrateanunderstandingofprocessFMEA¾KnowtheFMEAterminology¾KnowhowtodevelopaprocessFMEA¾KnowtheFMEArankingandprioritizingsystem56sigmasite::•APPLICATION:applyprocessFMEAtoaprocess¾Resultwillbeaprioritizedsetofpotentialfailures¾Actionstoaddresspotentialfailureswillbeplanned¾PresentanFMEAwithcorrectiveactionsformanagementreview66sigmasite::•FMEAisastructuredapproachforanalyzingpotentialfailures•Itisananalyticaltechniqueintendedto:¾Identifypotentialfailuremodes¾Assesstheirpotentialeffectsandcauses¾Assessthecontrolandcontainmentoffailures¾Identifyandprioritizeactionsthatwouldeliminateorreducepotentialfailures76sigmasite::•FMEAisaprocessofaskingquestionsandsupplyinganswers...FMEATerm¾Whatcangowrong?failuremode¾Whatmighthappenifitgoeswrong?effect¾Howbadistheconsequence?severity¾Whatmightmakeitgowrong?cause¾Howlikelyisittogowrong?occurrence¾Howwouldweknowifitwentwrong?control¾Howareitseffectsprevented?containment¾Whatshouldbedoneaboutthingsrecommendedthatmaygowrong?actions86sigmasite::¾thatrelatesandorganizesthequestionsandanswers¾thatassessesrisks¾thatprioritizesactions96sigmasite::•FMEAwasoriginallydevelopedbytheaerospaceindustryinthe1960sasatoolforimprovinghardwaredesign•TheuseofFMEAhasexpandedtootherindustries¾automotive¾semiconductor•Themethodologyhasbeenexpandedtoincludetheanalysisofprocessfailures106sigmasite::•DesignFMEA(DFMEA)¾FMEAappliedtoacomplete(end)product¾Usuallyperformedatthedesignstage¾Usedtoidentifydesignfeaturesthatwilleliminateorreducepotentialproductfailures•EquipmentFMEA¾FMEAappliedtoaspecificpieceofequipment¾Usedtoidentifyequipmentimprovements116sigmasite::•ProcessFMEA(PFMEA)¾FMEAappliedtofailuresthatcouldoccurinorbeinducedbyamanufacturingprocess¾Usedtoreducethefrequencyandimpactofprocessfailures126sigmasite::•TheprimarypurposeofPFMEAistoreducethefrequencyandimpactofexcursionsby:¾Eliminatingpotentialcausesofexcursions¾Improvingcontrolandcontainmentofexcursionsthatdooccur¾Enhancingprocesscontrols¾Improvingpreventivemaintenanceprograms¾Developingexcursionresponseplans136sigmasite::•OtherusesofPFMEA¾Avehicleforpreserving,transferring,andsharingknowledge¾Atrainingtool¾Ameansofprovidinginputtoequipmentvendorsfordesignimprovements146sigmasite::•ThegreatestbenefitofPFMEAiswhenitisdevelopedduringtheintroductionofanewmaterial/processandpriortomakingchangestoprocessequipment,materials,ormethods.e.g.Newdryfilm,Directmetallization,NewcableforTDRtester•PFMEAcanalsobeappliedtoanexistingprocesstopreventpotentialexcursionsorinresponsetoexcursionstodevelopandprioritizeactionstopreventrecurrence.e.g.Delamination,PTHvoid,Soldermaskpeeloff156sigmasite::•ThestepsindevelopingaProcessFMEAarestraightforward¾Aflowchartofthestepsisprovided¾Althoughthestepsarestraightforwardconsistencyintheuseoftermsanddefinitionsisimportant¾Resultsaredocumentedonatemplate166sigmasite::(RPN1/RPN2)PrioritizeFailuresModesDeviseRecommendedActionsAssignOwner(s)toActionsYesNoIdentifyPotentialFailureModes176sigmasite::(FMEA)ModelFailureModeHowcanproductfailtomeetrequirements?CausesWhatcausedthefailuremode?ControlHowtopreventcauseoffailuremode?ContainmentHowtopreventshippingdefectiveproduct?SeverityOccurrenceDetectionRiskPriorityNumb