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FMEA Objective, scope and goal(s):

Process ID

FMEA Type: Process


FMEA Number:
Prepared By:
FMEA Date:
Revision Date:

Process Lead
Core Team Members:

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New DET

Actions Taken

New RPN

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Owner

Completion
Date

New SEV

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Recommended
Action(s)

New OCC

DET

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Current Process Controls

RPN

Potential Failure Mode(s)

Potential Cause(s)/
Mechanism(s) of Failure

OCC

Process Step

SEV

Action Results
Potential Effect(s)
of Failure

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Process FMEA
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1

Column C

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RPN Value

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1

Process Step

FMEA Objective, scope and goal(s): Review capacitor assy/test process for potential failure modes and control/risk mitigation strategy

Process ID Fictional Capacitor Assembly/Test

FMEA Type: Process


FMEA Number: XXXX1
Prepared By: Anybody
FMEA Date: 9/18/2006
Process Lead Process Engineering Manager
Revision Date: A
Core Team Members: Swage line operator, Welding line operator, Impregration line operator, Line Supervisor, Process Engineering, Design Engineering, Quality Engineering, Process Engineering Manager

9 operator error, material

Swaging

hi-pot, corona, DF, IR

scrap

9 overheated dielectric, operator skill,


workmanship, tooling, swage
dimensions

Welding

leaks, dimensions, hi-pot, corona

scrap

8 fixtures, operator skill, chassis/cover


dimension not specified, material
type, contamination

Impregnation

corona

rework

5 machine (time, temp, oil quality),


operator

Impregnation

DF, low capacitance

scrap

9 machine (time, temp, oil quality),


operator

Welding

leaks, dimensions, hi-pot failure,


corona

rework

3 fixtures, operator skill, chassis/cover


dimension not specified, material
type, contamination

Curing

dimensions, soft, cap variation, DF

scrap or rework

3 variable compression time, variable


pressure, temp, humidity, time

Winding

capacitance, dimension

scrap

Testing Pads

damage to part

Testing

false failure

10 Helium leak test, ATP seat test,


thermal shock
4 can size
9 visual inspection, tooling, operator
quallification, electrical test

DET

PE/QE

Complete

18

PE/QE/Line
Spv
PE/QE/Line
Spv

Complete

18

Complete

1.5

14

Recommended
Action(s)

3.5 315 DOE to optimize parameter settings


for robustness
5 180 Review operator certification
requirements, mat'l requirements
2 162 Process capability analysis
Review operator certification
requirements

Owner

Completion
Date

Actions Taken

136 Process capability analysis


Review operator certification
requirements
6S station review

PE/QE/Line
Spv
IE

Complete

16

8 gas test, oil quality, water test, PM,


low temp seal, electrical test

80

Process capability analysis


Review operator certification
requirements

PE/QE/Line
Spv

Complete

10

3 gas test, oil quality, water test, PM,


low temp seal, electrical test

54

Process capability analysis


Review operator certification
requirements

PE/QE/Line
Spv

Complete

18

51

Process capability analysis


Review operator certification
requirements

PE/QE/Line
Spv

Complete

18

8 cap measurement, feel, dimension,


pressure/load cell,
humidity/temp/time

48

Process capability analysis

PE/QE

Complete

18

2 operator error, winding machine,


material (thickness, elongation,
damaged, curls)

8 FAV, measure capacitance,


dinemsions, hi-pot, PM, incoming
and at-station inspection, set-up
adjustment

32

Process capability analysis

PE/QE

Complete

12

scrap

2 operator error, fixturing, toolling error

3 visual inspection

12

None

---

None

12

retest

2 operator error, test fixture error

3 software error flag, verification


procedure, cal logs
0
0

12

None

---

None

12

0
0

0
0

0
0

8.5 Helium leak test, bubble test,


fixtures, QC dimension

New DET

9 time and temperature

scrap

New RPN

scrap

low capacitance

New SEV

leaks, dimensions

New OCC

Terminal brazing (cover and


cap_)
Assembly

Current Process Controls

RPN

Potential Cause(s)/
Mechanism(s) of Failure

OCC

Potential Effect(s)
of Failure

Potential Failure Mode(s)

SEV

Action Results
Process Step

8.5 Helium leak test, bubble test,


fixtures, QC dimension

0
0

Process FMEA
350
300

Fictional Capacitor Assembly/Test

250
200

RPN Value

150
100
50
0

Process Step

Product Design Severity Ranking Guidelines


Effect

Severity of Effect

Hazardous - without
warning

Failure mode affects safety and may endanger machine, assembly


operator, or end user. Failure will occur without warning. Production
stopped.

Hazardous - with
warning

Failure mode affects safety and may endanger machine, assembly


operator, or end user. Failure will occur with warning. Production
stopped.

System Failure

Item inoperable, loss of primary function, system failure. Major


disruption to production line. 100% of product may require repair or
may be scrapped.

Significant System
Degradation

Assembly functional, but with significant performance degradation.


Could pose major disruption to production line. Product may have to
be sorted and a portion (less than 100%) scrapped.

Moderate System
Degradation

Assembly functional, but with one or more non-critical functions


degraded. Minor disruption to production line. A portion (less than
100%) of the product may have to be scrapped (no sorting).

Minor System
Degradation

Assembly functional, but some non-critical function operating at


reduced performance. Minor disruption to production line. Rework
may be required on 100% of product.

Obvious Cosmetic

Significant cosmetic non-conformance. May lead to degradation over


time. Minor disruption to production line. The product will require
sorting and a portion (less that 100%) will require general cosmetic
rework.

Minor Cosmetic

Minor cosmetic non-conformance. Minor disruption to production line.


A portion (less than 100%) of the product may require some rework.

Very Minor
None

Very minor cosmetic defect. Defect detected by very discriminate


observation. A small portion (less than 50%) of the product may
require rework.
No effect.

General Severity Ranking Guidelines


Effect

Severity of Internal/External Effect

Liability

Failure will affect safety or compliance to law


Moderate to major reliability failures
End user recalls
Premature end-of-life (wear out)
Increased early life failures
Intermittent functionality

Reliability/reputation
at risk

Customer quality
inconveniences

Internal yield or
special handling
required

Unnoticed

Minor reliability failures


Customer line impact / lines down
Impacts the yield of customer
Wrong package / part / marking
Products performing marginally
Involved customer's special handling
Damaged the customer's equipment
Product assembly error
Damage to down stream equipment
Major yield hit
Significant line yield loss
Minor yield hit
Low line yield loss
Special internal handling, effort or annoyance
Unnoticed either internally or externally

nes
Ranking

10

2
1

Ranking
10

6
5
4
3
2
1

Probability of Failure

Extreme: Process is out of control and not capable

Uncontrolled: Process is generally not capable.


Failure occurrence is common.

Moderate: Process may generally be capable, but not


centered. Failures occur less frequently, but
common and standard variation causes exist and
have not been corrected.
Low: Defects related to common variation
Very Low: Process is capable and well centered.
Outlying variation occurs from time to time.
Remote: Process is capable, centered, and contains
excellent design margin.

Possible Failure
Rates

DPMO

>=1 in 2

500,000

1 in 3

310,000

1 in 6

158,000

1 in 15

67,000

1 in 44

23,000

1 in 161

6200

1 in 740

1350

1 in 4250

235

1 in 31,250

32

<=1 in 340,000

Sigma

Cpk

Ranking

<2.00

<0.34

10

>=2.00

>=0.34

>=2.50

>=0.47

>=3.00

>=0.61

>=3.50

>=0.76

>=4.00

>=0.91

>=4.50

>=1.07

>=5.00

>=1.23

>=5.50

>=1.33

>=6.00

>=1.50

Detection

Criteria: Likelihood that an Existing Defect will be


Detected by the Indicated Process Controls Before the
Assembly is Delivered to the End User

No Capability

Detection capability unknown. Unable to determine reliability of


assembly going to end user.

Very Remote

Very remote likelihood current process controls will detect a failure.

Remote

Remote likelihood current process controls will detect a failure.

Low Likelihood

Low likelihood current process controls will detect a failure.

Poor

Likelihood that current process controls will detect a failure is poor.

Likely

Process controls are likely to detect a failure. Room for error


substantial.

Capable

Process controls are capable, but leave room for human error.

Very Capable

Process controls capable of detecting failures. Processes have


easy detection capability and good reliability.

Highly Capable

Process controls are highly capable of detecting failures. SPC


program exists with good results or failures are extremely obvious.

Extremely Capable

Current process controls will detect the failure nearly without fail.
Good SPC program exists with data to back up results.

Detection Rate (likelihood


of finding defect)

Ranking

<30%

10

>30%

>40%

>50%

>60%

>70%

>80%

>90%

>95%

>99.5%

AIAG Compiled Ratings


Rating
10
9
8
7
6
5
4
3
2
1

Severity of effect
Hazardous and without
warning
Hazardous and with warning

Likelihood of Occurrence
Very high; failure is almost
inevitable

Loss of primary function


Reduced primary function
performance

High; repeated failures

Loss of secondary function


Reduced secondary function
performance
Minor defect noticed by most
customers
Minor defect noticed by some
customers
Minor defect noticed by
discriminating customers
No effect

Moderate; occasional failures

Low; relatively few failures

Remote: failure is unlikely

ngs
Ability to Detect
Cannot detect
Very remote chance of
detection
Remote chance of detection
Very low chance of detection
Low chance of detection
Moderate chance of detection
Moderately high chance of
detection

Almost certain detection

Potential Team Members


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6
7
8
9
10

Process Engineer - Generally the Team Leader


Production Operators
Industrial Engineer
Design Engineer
Quality Engineer
Reliability Engineer
Tooling Engineer
Maintenance Engineer
Project Manager
Others including Sales, QA/QC, Operations

Step
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Process Mapping Overview

Description
Identify the process to map
Ask the people most familiar with the process to help construct the map
Agree on the start and end points; defining the scope of the process to be mapped is important, otherwise the task can becom
Agree on the level of detail to use; its better to start out with less detail, increasing detail only as needed to accomplish your pu
Identify the sequence and the steps taken to carry out the process; walk the line if necessary
Construct the process map either from left to right or from top to bottom, using standard flow chart symbols and connecting the
Identify key process characteristics as potential sources of failure
Is the process standardized, or are the people doing the work in different ways?
Are steps repeated or out of sequence?
Are there steps where errors occur frequently?
Are there rework loops?
Analyze the results and document potential failure modes at each process step

Potential Failure Causes


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Omitted processing
Processing errors
Errors setting up work pieces
Missing parts
Wrong parts
Processing wrong work piece
Mis-operation
Adjustment error
Equipment not set up properly
Tools and/or fixtures improperly prepared
Poor control procedures
Improper equipment maintenance
Bad recipe
Fatigue
Lack of Safety
Hardware failure
Failure to enforce controls
Environment
Stress connections
Poor FMEA(s)

Potential Process Controls:


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3
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5
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13
14
15
16
17
18

Standardized work instructions/procedures


Fixtures and jigs
Mistake-proofing tooling and/or product design
Mechanical interference interfaces
Mechanical counters
Mechanical sensors
Electrical/Electronic sensors
Job sheets or Process packages
Bar coding with software integration and control
Marking
Training and related educational safeguards
Visual checks
Post process inspection/testing
Gage studies
Statistical Process Control
Design of experiments on the process/Robust process design
Preventive maintenance
Automation & Real Time Control