Example - Cleaning Process

PRODUCT:
FMEA NO.
SUBSY STEMS
PAGE OF
PROCES S FMEA
DRA WING OR SPEC:
EXAMPL E - PA RTS CL EANING INSIDE CL EA NROOM REV:
PROCESS DESCRIPTION POTENTIA L POTENTIA L S POTENTIA L O CURRENT D RPN A CT ION CORRECTIVE RES ULTING
FAILURE MODE EFFECTS OF CA USE(S) OF CONTROLS PRIORIT Y ACTION
FUNCTION FA ILURE FA ILURE S O D RPN
Cl ean p o t en t i al l y
c o n t ami n at ed p ar t s
t o Co d e 100
c l ean r o o m
r eq u i r emen t s
Co n t ami n at ed p ar t s
es c ap e c l ean i n g p r o c es s
Pr o d u c t f ai l u r e d u e
t o c o n t ami n at ed
s u r f ac es , r el i ab i l i t y
f ai l u r es
8 In ad eq u at e
c l ean l i n es s s p ec s
f o r n ew d es i g n ed
p ar t s
5 Mat er i al s l ab t es t
f o r NVR
3 120 B Dev el o p
c l ean l i n es s
s p ec i f i c at i o n s
an d r ev i ew
c u r r en t
p r o c es s es
8 3 3 48
Cl ean i n g r es i d u e o n
p ar t s
Fai l p ar t i c l e c o u n t
t es t
6 In c o mp l et e c l ean i n g
c y c l e
6 Vi s u al
i n s p ec t i o n , n o
s et p l an
8 288 A In s t al l t i mer t o
p r ev en t o p er at o r
f r o m ad j u s t i n g
c l ean i n g c y c l e
6 3 1 18
Eq u i p men t
mal f u n c t i o n s
3 War n i n g l i g h t
t emp er at u r e n o t
met , n o c o n t r o l
f o r o v er h eat
5 90 C A d d au t o
s h u t d o w n f o r
o v er t emp
6 3 1 18
Co n t ami n at ed
c l ean i n g s o l u t i o n
d u e t o f ai l u r e t o
c o mp l et e PM as
s c h ed u l ed
2 Vi s u al
i n s p ec t i o n t w i c e
p er s h i f t
6 72 C A d d ex t r a f i l t er s
t o s y s t em
6 2 3 36
Pr ev en t p ar t s f r o m
b ei n g d amag ed
Par t s d amag ed , b r o k en ,
b en t o r s t ai n ed
Par t s r ej ec t ed ,
s c r ap p ed
5 In c o r r ec t r ac k s u s ed
d u e t o av ai l ab i l i t y
6 No i n s t r u c t i o n s 10 300 A A d d r ac k t y p e t o
p r o c es s
i n s t r u c t i o n s ,
ev al u at e
av ai l ab i l i t y
5 2 1 10
Op er at o r n o t t r ai n ed
d u e t o j o b r o t at i o n
2 L ead w o r k er
mo n i t o r s an d
t r ai n s n ew
emp l o y ees
2 20 D A d d r ac k t y p e t o
p r o c es s
i n s t r u c t i o n s ,
ev al u at e
av ai l ab i l i t y
5 2 1 10
DETECTION OCCURRENCE SEVERITY RPN = O x S x D
Example - Accounting Process
Example - Design Rules
PRODUCT:
FMEA NO.
SUBSYSTEMS
PAGE OF
PROCESS FMEA
DRAWING OR SPEC:
EXAMPLE - PROCESS-SPECIFIC DESIGN RULES REV:
PROCESS DESCRIPTION POTENTIAL POTENTIAL S POTENTIAL O CURRENT D RPN ACTION CORRECTIVE ULTING
FAILURE MODE EFFECTS OF CAUSE(S) OF CONTROLS PRIORITY ACTION
FUNCTION FAILURE FAILURE S O D RPN
Anal og si gnal used
to process a sensor
si gnal
Output stuck - high or
low
Instrumentati on
shows zero readout
8
Short ci rcuit due to
i nsuffi ci ent space
al lotment between
conductors
2
Computer
simul ati on
10 160 A
100% test to
veri fy val i dity of
design rul es
8 2 1 16
DETECTION OCCURRENCE SEVERITY RPN = O x S x D
Example - Reducing Occurrence
PRODUCT:
FMEA NO.
SUBSYSTEMS
PAGE OF
PROCESS FMEA
DRAWING OR SPEC:
EXAMPLE - REDUCING OCCURRENCE REV:
PROCESS DESCRIPTION POTENTIAL POTENTIAL S POTENTIAL O CURRENT D RPN A CTION CORRECTIVE ULTING
FAILURE MODE EFFECTS OF CAUSE(S) OF CONTROLS PRIORITY ACTION
FUNCTION FAILURE FAILURE S O D RPN
Deposi t a uni form,
defect-free oxi de at
desi re thi ckness
Parti cul ate
contami nati on
Reduced rel i abi l i ty 6
Fl aki ng of the
quartzware
7
Inspect oxi de
after deposi ti on
4 168 B
Increase
frequency of
quartz cl eani ng
6 2 4 48
Impl ement an
automated
vi si on
i nspecti on
system
6 2 1 12
DETECTION OCCURRENCE SEVERITY RPN = O x S x D
Example - New Equipment or Process
PRODUCT:
FMEA NO.
SUBSYSTEMS
PAGE OF
PROCESS FMEA
DRAWING OR SPEC:
EXAMPLE - NEW EQUIPMENT OR PROCESS REV:
PROCESS DESCRIPTION POTENTIAL POTENTIAL S POTENTIAL O CURRENT D RPN A CTION CORRECTIVE ULTING
FAILURE MODE EFFECTS OF CAUSE(S) OF CONTROLS PRIORITY ACTION
FUNCTION FAILURE FAILURE S O D RPN
Connect devi ce to
ci rcui t
Open ci rcui t Non-functi onal
ci rcui t
9 Li fted wi re at the
devi ce due to non-
opti mi zed wi rebond
process
6 Conduct
process
opti mi zati on at
wi rebond
4 216 A Document
process wi ndow
i n process spec
to assure that
the process
meets vi sual
and
performance
standards
9 2 4 72
Crateri ng on the
devi ce due to non-
opti mi zed wi rebond
process
4 Conduct
process
opti mi zati on at
wi rebond
4 144 B Same 9 2 4 72
Broken wi re at the
l ead frame due to
non-opti mi zed
wi rebond process
3 Conduct
process
opti mi zati on at
wi rebond
4 108 B Same 9 2 4 72
DETECTION OCCURRENCE SEVERITY RPN = O x S x D
Example - Weakness of Manual Inspection
PRODUCT:
FMEA NO.
SUBSYSTEMS
PAGE OF
PROCESS FMEA
DRAWING OR SPEC:
EXAMPLE - WEAKNESS OF MANUAL INSPECTION REV:
PROCESS DESCRIPTION POTENTIAL POTENTIAL S POTENTIAL O CURRENT D RPN ACTION CORRECTIVE ULTING
FAILURE MODE EFFECTS OF CAUSE(S) OF CONTROLS PRIORITY ACTION
FUNCTION FAILURE FAILURE S O D RPN
Pack and ship right
product to the right
customer
Mixed product Fails to meet
customer
requirements and
expectations
8 Mis-read product
label
3 Visual
inspection of
product label
8 192 B Install barcode
system for
product
identification
8 1 1 8
DETECTION OCCURRENCE SEVERITY RPN = O x S x D