CIC4001ENIG_M21_4-4_FMEA

CIC4001,5/15/16Version4-4DesignforSixSigma®GreenBelt(DOV)Module2.1FailureModesandEffectsAnalysis(FMEA)Module2.1FMEA--2CIC4001,5/15/16Version4-42.1FailureModesandEffectsAnalysis(FMEA)ObjectiveIdentifyandpreventproblemsfromoccurringinaproduct,serviceorprocessdesign,sotheteamcanbuildaproblemstatementthatfocusesonthemostsignificantareas,andultimatelydesignsolutionsthatwillpermanentlyeliminatethedefectorproblemKeyTopics•FMEAConcept:AnticipatingandPreventingProblems•FMEAMethod2.2BasicStatsReview2.5MonteCarlo2.6CPM2.1FMEA2.7ControlCharts2.4ProcessCapability2.3MSAModule2.1FMEA--3CIC4001,5/15/16Version4-4WhatisFMEA?FMEAisanacronymfor:FailureModesandEffectsAnalysisModule2.1FMEA--4CIC4001,5/15/16Version4-4FMEASummary:FailureModesandEffectsAnalysisisastructuredmethodforidentifying&rankingthesignificanceofvariousfailuremodesoftheprogram&theireffectsontheproductorcustomermFAILUREMODEANDEFFECTSANALYSIS(DESIGNFMEA)___System_X_Subsystem___ComponentFMEANumber:Description:6190015N01-CLILens(glass)PreparedBy:Gronczewski,RichterProject:RazorFMEADate(Orig.):12/3/2003DesignResponsibility:RichterRevisionDate:4/21/2004CoreTeam:Gronczewski,RichterActionResultsItem/FunctionPotentialFailureModePotentialEffectsofFailureSevPotentialCause(s)/MechanismsofFailureOccurCurrentDesignControlsDetectR.P.N.RecommendedActionsResponsibility&TargetCompletionDateActionsTakenSevOccDetR.P.N.lossofdisplayprotection;t-touchfunctionalitylost7dropcausesdisplaytopopoff3MEALT363nonetaken7lensadhesivedewetting3MEALT363nonetakentransfersimpactenergydamagetodisplay;damagetoHSCinterconnectionoft-touch7droporinstallationcauseslenstobepressedintoanddamagedisplay4MEALT384nonetakenshatters9hitbyheavyobject,lenscollideswithheavyobject(crackinitiatesfromcenter);typeofglass441441.Determinationoffailuredefinition(maxstrain@strainrate)FEA;2.Takehighspeedvideotounderstanddispersionofchips,ifany,whenshatteringoccurs;3.Characterizeusageprofileswhereinimpactoccurs;researchoccurrenceinotherindustriesthatuseglasssimilarly;researchCEstandardsforwatchesandotherglassbearingportableproductsandestablishRAI.1.Shrikanth10-15-032.Richter10-30-03.3.Safteygroup2-16-041.ExtensiveFEAandimpacttestingwascompleted10-15-03.Glassappearscapableofpassingdropandballimpacttestingrequiredforcertificationif/=0.70mm.Testingtofailurewithanti-shatterurethanecoatingonfirstsurfaceindicatednoglassfragmentsorshardswereexposed2-13-04.2.Nofailuresoccuredduringhigh-speedvideotesting10-31-03.PlanstouseAnti-splinterfilmsonthefrontorbacksurfaceoflenstomitigatesplinteringofglass.3.Safetyhasnotfounddataforsimilarusage.Contentionis,ifprotectivelayerisprovidedon2ndsurfaceseverityratingshouldremainat9.Ifaprotectivelayerisprovidedonthefirstsurfaceseverityratingwouldbereduced.FailuresshouldbetrackedduringProto-certtestingandALT.Safetytoreviewfinaldesignbeforeshipacceptance.Asof4-21-04nofailures9phoneflexedinpocket(crackinitiatesfromedge);typeofglass44144completesqueezetestingofunitsoroflensmountedtorepresentativesupportstructureSqueezetestingcompletedwithnofailures92472chips9phonedroppedorobjectdroppedonphone44144seeshatterspotentialfailuremodeaboveaboveseeshatterscracks9hitbyheavyobject,lenscollideswithheavyobject(crackinitiatesfromcenter);typeofglass44144seeshatterspotentialfailuremodeaboveaboveseeshattersscratchesdissatisfiedcustomer2keys,coins,etc2MEALT,Protocerttesting28nonetakenbirefringentbehaviorobscuresviewofdisplay4inmoldedstreses1Engineeringevaluation312nonetakenfallsoutLens/protectsdisplayUsingchemicallystrengthenedglass,lensflushwithhousing,staticanddynamicFEA.Proto-cert,MEALT.injury(eyes,hands);lossofdisplayprotection;t-touchfunctionalitylostFMEAworksheetforidentifyingthefailuremodeswiththehighestRiskPriorityNumber(RPN)Outputs:•Rankedgroupoffailuremodes•Impactsoffailuresoncustomer,productorprocess•RiskPriorityNumbers(RPN)beforeandaftercorrectiveaction•CorrectiveactiontoremoveorreducetheriskorimpactofafailuremodeModule2.1FMEA--5CIC4001,5/15/16Version4-4FMEAatSystemandSW/HWLevelSystemRequirementsSystemArchitectureHardwareRequirementsHardwareArchitectureSoftwareRequirementsSoftwareArchitectureGatherVOC’sKJ/KANOAnalysisHouseofQualityPughMatrixFMEAForSystemFMEAForHW&SWModule2.1FMEA--6CIC4001,5/15/16Version4-4ThreeUsesofFMEASystemFMEADesignFMEAProcessImprovementFMEA•SystemFMEA–Toassurequalityinourcustomer’ssystem•DesignFMEA–Tobuildqualityandproductivityintothedesignoftheproduct,andlowerriskoffailure–ApplicabletobothHW&SW•ProcessImprovementFMEA–Toanalyzeriskofprocessfailureandimproveandcontrol.FocusesonprocessinputsStepsingeneratinganytypeofFMEAareessentiallythesame.Differentiatorsarethescopeoftheprojectandtheplayers.84Module2.1FMEA--7CIC4001,5/15/16Version4-4WhydoweuseFMEAs?FMEAssaveonprototypedevelopment,andhelpidentifydesignandmanufacturingcontrolstoensurethatatanystage,adefectdoesn’t“escape”.Anticipatesandworksthroughissuestoflawlesslylaunchthenewproductsintoproduction81Module2.1FMEA--8CIC4001,5/15/16Version4-4Murphy’sRepellant•Murphy’sLawisasardonic,insightfulperspectiveintothepotentialforthingstogowrong.M