FMEA SPC英文教学PPT

Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 1BG MDSQuality managementPlanDoStudyActFMEAControl Plan(S)PCFMEA&(S)PC training moduleThis training module is based upon and should be studied together with the AIAG reference manuals.Change authority for this document:Quality manager BG MDS Fons SiebenChapterContents1Acknowledgement/References2Potential Failure Mode and Effect Analysis3Process considerations&the need for process control4Stages in SPC and process analysis(QMAPS)5Control Charts&Out of Control Conditions6From FMEA thru Control Planning to SPC -Process documentation7Terminology and abbreviations:CRIT/SIGN/KEY/NORMAL8Flow diagram STATISTICAL PROCESS CONTROL9Statistical methods/calculation of control limits10Capability Indices and formulas11Cpk interpretation and relation to PPMUCLLCLVariation2000-10-31updatedTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 2BG MDSQuality management2000-07-11UZW-B0/H100-13This training module is related to:FMEA&(S)PC procedureUZW-B0/H100-13Acknowledgement/ReferencesElementReference Manual(RM)and/or procedureFMEARM:Potential Failure Mode and effect AnalysisADVANCED PRODUCT QUALITY PLANNING/Control PlansRM:Advanced Product Quality Planning andControl Plan APQPPRODUCT(CUSTOMER)SPECIFIC CONTROLPLANSUZW-B0/H100-39:Procedure Testspecifications and Test specsCRITICAL&SIGNIFICANT CHARACTERISTICSRM:QS9000 manual(Issued by AIAG)MEASUREMENT SYSTEM ANALYSIS/GAGE R&RRM:MEASUREMENT SYSTEMS ANALYSIS:(Issued by AIAG)UZW-B0/H000-10:Calibration&GageR&RSTATISTICAL PROCESS CONTROLRM:STATISTICAL PROCESS CONTROL:(Issued by AIAG)(S)PC forms/Process LogUZF-B0/H100-13:Charts for Process ControlFMEA&(S)PC training moduleUZV1-B0/H100-13:Training module SPCPRODUCTION PART APPROVAL PROCESSRM:Production Part Approval Process PPAP(Issued by AIAG)CHANGE MANAGEMENTUZW-B0/H500-01:Change ProcedureTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 3BG MDSQuality managementPotential Failure Mode&Effect AnalysisAn FMEA is a systemized group of activities,intended to:Recognize and evaluate the potential failure of a product/process and its effects.Identify actions which could eliminate or reduce the chance of the potential failure occurring.Document the process.It is complementary to the design process of defining positively what a design must do to satisfy the customerRef:FMEA Reference manual(AIAG)2000-07-11BrainstormingTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 4BG MDSQuality managementPotential Failure Mode&Effect AnalysisRef:FMEA Reference manual(AIAG)2000-07-11 Brain storming Team effort Risk analysis tool Preventive/On Time=BEFORE THE EVENT!*)Interface FMEA deals with the specific aspects of the customised LCD module in its intended application.The focus is on all interface aspects like Electro optical matching-Mechanical fit,robustness-Assembly aspects etc.The interface FMEA can only be done effectively together with the customer.&Types of FMEADesign FMEA(DFMEA)Process FMEA(PFMEA)Interface FMEA*)Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 5BG MDSQuality managementPotential Failure Mode&Effect Analysis:Process overviewRef:FMEA Reference manual(AIAG)2001-03-23 Evaluate action resultsJSeverityscale 1-10JOccurrence(likelihood)scale 1-10JDetectabilityscale 1-10Establish new RPN=S x O x DRisk Priority Number Describe:LFunction of parts or process stepsLPotential Failure modeLPotential effects of Failure Describe and Plan recommended actions Predict RPN Close the loop/continuous improvementJWork on next problem in the priority rowJLearn from problem solving/previous designsJReflect the learnings in documentation:FMEA/Control Plans/Design rules/learning modules etc EvaluateLSeverityscale 1-10LOccurrence(likelihood)scale 1-10LDetectabilityscale 1-10Find RPN=S x O x DRisk Priority NumberPlanDoStudyActFMEAControl Plan(S)PCTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 6BG MDSQuality managementWorking formats Design FMEA(preferred format)Ref:FMEA Reference manual(AIAG)UZW-B0/H100-132000-12-29POTENTIALFAILURE MODE AND EFFECTS ANALYSIS(DESIGN FMEA)Page 1 of 1 SystemSubsystemComponent Design Responsibility Prepared ByType/Models(Year)Key Date FMEADate(Orig.)(Rev.)Core Team(Name/Function)Actions ResultsItemFunctionPotential FailureModePotentialEffect(s)ofFailureSEVClassPotential Cause(s)Mechanism(S)of FailureOccurCurrent Design ControlsDetectRPNRecommendedAction(s)Resp&TargetCompletitionDateActionsTakenSEVOccDetRPNTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 7BG MDSQuality managementWorking formats Process FMEA(Preferred format)Ref:FMEA Reference manual(AIAG)UZW-B0/H100-132000-12-29POTENTIALFAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)Page 1 of 1Item Process Responsibility Prepared ByType/Models(Year)Key Date FMEADate(Orig.)(Rev.)Core Team(Name/Function)Actions ResultsProcessFunctionRequirementsPotential FailureModePotentialEffect(s)ofFailureSEVClassPotential Cause(s)Mechanism(S)of FailureOccurCurrent Process ControlsDetectRPNRecommendedAction(s)Resp&TargetCompletitionDateActionsTakenSEVOccDetRPNTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 8BG MDSQuality managementD/PFMEA:Some practical implicationsRef:FMEA Reference manual(AIAG)UZW-B0/H100-132001-03-23Steps wrt improvement actions:Establish initial FMEA,and select the items for actions.Identify the recommended actions,and at the same time estimate the predicted RPN(register at the right side under Actions results).Note:When the recommended actions are-for the time being-an investigation,this new estimated RPN is of course identical to the original,pending the result of the investigation.When actions have been completed,the resulting RPN is again to be established.This new situation becomes now the new current.controls,and is to be moved towards these related columns.Living documents&learning:Above implies that the FMEA list reflects only the best current knowledge,and history is not documented.Where it is considered to be necessary to keep the history for learning reasons,a front page should be considered to keep record of the important historical events.Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 9BG MDSQuality managementWorking formats FMEA(Old format/see previous pages for preferred formats)Ref:FMEA Reference manual(AIAG)UZW-B0/H100-13Form:FAILURE MODE AND EFFECT ANALYSISPhilips ComponentsMDS/Liquid Crystal DisplaysCells&ModulesFAILURE MODE AND EFFECT ANALYSISSubject:DESIGN :PROCESS :RESP.:REPORT NR.:DATE:SHEET NR.:NAME OFPART ORPRESENT SITUATIONIMPROVED SITUATIONCLASSPROCESSSTEPFUNCTIONFAILURE MODECAUSEEFFECT ON PRODUCTLEVELFAILUREDETECTIONPSD RPNRECOMMENDEDACTIONSRESPON-SIBLEDATEACTIONTAKENPSDRPN P =PROBABILITY OF OCCURRENCE S=SEVERITY OF THE FAILURE D=UNLIKELIHOOD OF DETECTION RPN=P x S x D=RISK PRIORITY NUMBER Class of Characteristics:CRIT=Critical(Safety/Compliance)SIGN=Significant(Fit/Function)KEY or N2001-03-23Old format:Do not use anymore!Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 10BG MDSQuality managementWorking formats Control PlanRef:FMEA Reference manual(AIAG)UZW-B0/H100-132000-12-29 CONTROL PLANPage 1 of 1PrototypePre-launchProductionKey Contact/PhoneDate(Orig.)Date(Rev.)Control Plan NumberPart Number/Latest Change LevelCore Team(Name/Function)Customer Engineering Approval/Date(If Reqd)Part Name/DescriptionSupplier/Plant Approval/DateCustomer Quality Approval/Date(If Reqd)Supplier/PlantSupplier CodeOther Approval/Date(If Reqd)Other Approval/Date(If Reqd)CharacteristicsMethodsSamplePart/ProcessNumberProcess Name/OperationDescriptionMachine,Device,Jig,ToolsFor Mfg.NoProductProcessSpecialChar.Class.Product/ProcessSpecification/ToleranceEvaluation/MeasurementTechniqueSizeFreq.Control MethodReaction PlanForm:PROCESS STEP CONTROL PLAN(Preferred version)(for product specific control plans:see proc Test specs:UZW-B0/H100-39)Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 11BG MDSQuality managementWorking formats Control PlanRef:FMEA Reference manual(AIAG)UZW-B0/H100-132001-03-23Control Plan:Methods:For CRIT/SIGN char.,reference to gage/SPC documents is obliged.Reactions if Out-of-Control Conditions are encounteredParameterClassProduct/Process SpecificationEvaluation MethodIf CRIT/SIGN,ref.to Doc.Sample/Size FrequencyForm:PROCESS STEP CONTROL PLAN:(Old format/see previous pages for preferred version)Old format:Do not use anymore!Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 12BG MDSQuality managementConsiderations around PROCESSProcesses are important!Almost all quality gurus and almost all management gurus agree that:processes must be defined,the most important processes must be identified and given special attention,all processes must be managed,all processes must be improved.Of course,it may be easier to manage departments or functions.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 13BG MDSQuality managementConsiderations around PROCESSDeming on processesWilliam Edwards Deming suggested thatstakeholders will benefit if managers:focus on processes,understand variability,develop a learning culture,value people.See “The new economics”(1993)W E Deming,Harvard U PRef:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 14BG MDSQuality managementConsiderations around PROCESSWhat is a process?EFQM definition:A process is a sequence of steps which adds value by producing required outputs from a variety of inputs.A better definition:A process is a network of interdependent componentsthat work together to achieve benefits for thestakeholders.Wherever work is being done by one or more peoplethere is a process.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 15BG MDSQuality managementConsiderations around PROCESSA useful process modelProductEquipmentPeopleProceduresMaterials ManagementServiceInformationRef:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 16BG MDSQuality managementConsiderations around PROCESSA very useful process modelProductEquipmentPeopleProceduresMaterials ManagementServiceInformationMeasureMeasureName:xxx yyyAim:To zzzzRef:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 17BG MDSQuality managementRef:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Every process is part of a larger processTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 18BG MDSQuality managementA business organisationRef:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 19BG MDSQuality managementProcesses within processesAny process can be broken down into manysub-processes.Any process can be regarded as part of a larger process.To get world class performance from a process you need world class behaviour from your workers.Managers must set up the conditions so that workerscan behave in a world class way.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 20BG MDSQuality managementProcess improvementWe can improve a process by:improving the performance of the equipment,improving the procedures,improving the behaviour of the workers,improving the flow of information,improving the behaviour of the manager.improving the quality of the inputs,Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 21BG MDSQuality managementProcess redesignWhen redesigning a process we should consider:The quality of the inputs The capability of the equipment The ability of the workers The procedures Information needs The ability of the manager.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 22BG MDSQuality managementPerformance measurementYou need to measure those things which will help you to:Your metrics should:Be measurable,Be unbeatable,Encourage the right behaviour.assess the current performance,detect changes in performance,find the causes of changes,improve performance,benchmark your performance.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 23BG MDSQuality managementWhat should we measure?What metrics will best help us to:Control the process,Compare the process,Improve the process?Would it be better to measure:Yield,First pass yield,or DPMO(Defects per million opportunities)?Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 24BG MDSQuality managementPerformance improvementTo improve process performance we might strive to:Increase certain performance measurementsEg.Yield,Price,Sales volume,Strength Decrease certain performance measurements.Eg.Cycle time,Impurity,Cost,Ovality Keep the average of the performance measurements on target.Eg.Delivery time,Viscosity,Diameter,Reduce the variability of the performance measurements.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 25BG MDSQuality managementWhy are processes difficult to manage?Difficulties result from:complexity,variability,interactions or synergies,feedback,delays,dynamic complexity.wrong metrics,Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 26BG MDSQuality managementDynamic complexityA process has dynamic complexity if an actiontaken on the process has more than oneoutcome,with the outcomes occurring:at different locations,at different times.The person taking the action may be awareof only one outcome,and may never see thefull consequences of the action.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 27BG MDSQuality managementSub-optimisationOptimising all of the sub processes will notoptimise the macro-process.The danger of sub-optimisation is reducedif people understand how their process fitsinto the larger process.It is dangerous to give people only theminimum information you think they need todo their jobs.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 28BG MDSQuality managementSummaryOnly through process management will youachieve business excellence.Process management is difficult.Management of departments or functionsmay be easier.Measurement and variability probably cause thegreatest difficulties.Ref:PD Components Foundation training for Breakthrough Champions/Mr Caulcutt2000-12-29Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 29BG MDSQuality managementThe need for process controlDetection -Tolerates wastePrevention-Avoids wasteRef:SPC Reference manual(AIAG)2000-07-11Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 30BG MDSQuality managementProcess control and Process CapabilityIn Control but not capable of meeting the spec.limits LCL/UCL.Variation from common causes excessiveLCLUCLOut of control.Special causes presentIn control.Special causes eliminatedProcessControlIn Control andcapableProcessCapabilityTimeTTRef:SPC Reference manual(AIAG)2000-07-11Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 31BG MDSQuality managementStages of the continual process improvement cycle1:Analyze the process What should the process be doing?What can go wrong?What is the process doing?Achieve a state of statistical control.Determine Capability2:Maintain the processMonitor process performanceDetect special cause variation and act upon it.3:Improve the process Change the process to better understand common cause variation.Reduce the common cause variation.Ref:SPC Reference manual(AIAG)Use mapping techniques:Risk mapping:FMEAQMAP:Visualizing is a great support2000-07-11PlanDoStudyActFMEAControl Plan(S)PCPlanDoStudyActFMEAControl Plan(S)PCPlanDoStudyActFMEAControl Plan(S)PCTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 32BG MDSQuality managementMapping the process:QMAP/Highest level A0TransformationInput(I)Output(O)directivesStandards/norms/parametersControl(C)Mechanism(M)operatorSpraying/etchinginstallationGlass plates(types)Multi Electrode PlatesMasksolvent5 elementsInputTransformationMechanismControlOutputOper.AOper.BOper.CMechanism:People/machineControls:Norms/parametersE.g.results for feedbackDescribeInput(s)DescribeOutput(s)In the context of a moresophisticated flow diagram:2000-07-11Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 33BG MDSQuality managementMapping the process:QMAP,the zooming in principleA0A1.1A1.2A1.3A1.4A2.1A2.2A2.3A2.4Functions of the processSub-processesTransformations2000-07-11Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 34BG MDSQuality managementMapping the process:QMAP:ExamplePre-treatmentSuppliers/Inc.Insp.UnpackCleaning/drying2.1MaskDesignPlottingCleaningPhotolithoCoatingExposureDevelopment2.2Etching2.3Post-treatmentStrippingCleaningDrying2.4Coating Spraying Pre-bake CoolingExposureDevelopment KOH Water Rins&DryPatterning:Level A1Photolitho:Level A22000-07-11Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 35BG MDSQuality managementControl charts:3 phasesUpper Control LimitControl LimitLower Control LimitUCLCLLCL1:Collection:Gather data and plot on a chart2:Control:Calculate trial control limits from process data Identify special causes of variation and act upon them3:Analysis and improvement Quantify common cause variation:take action to reduce itRef:SPC Reference manual(AIAG)2000-07-11Repeat these 3 phases for continuous improvementPlanDoStudyActFMEAControl Plan(S)PCTraining module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 36BG MDSQuality managementControl charts:Out of control conditions(OOCC)UCLCLLCLUCLCLLCLUCLCLLCLOne point above UCL or under LCL7 points in a row steadily increasing or decreasing7 points in a row above or under the central line2000-07-11Training module,related to FMEA&(S)PC procedure UZW-B0/H100-13Doc:UZV1-B0/H100-13/Sheet 37BG MDSQuality managementFrom FMEA thru Control Planning to SPCDesign FMEACritical/SignificantCharacteristicsProcess FMEAControl Plan Process related Product related(customer specific)Preliminary statistical capability studySPCSteps to FMEA(Brain storm technique)Use flow diagrams/QMAPs e