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Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Blueprint for Breakthrough
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Define Measure Analyze Improve Control H
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Systems Quality C
Determine BMG
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Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Analyze Phase Potential Deliverables
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Project Recap & Remaining Session 1 Deliverables H
ID Variation: ANOVA
Breakthrough Management Group
B Planning for DOE BMG B
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Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Background
Failure Modes and Effects Analysis (FMEA)
First developed in the 1950s
Appropriated by NASA in the 1960s for the space program
Ford Motor Company was the first North American company to widely
implement the use of FMEAs
Types of FMEA
System Top-level, early stage analysis of complex systems
Design Systems, subsystems, parts & components early in design
stage
Process Focuses on process flow, sequence, equipment, tooling,
gauges, inputs, outputs, set points, etc
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Who? When?
Who constructs the FMEA?
The Black Belt is the team leader.
The process owner inherits the finished FMEA.
Use the process mapping, C&E matrix team.
May need to add a rep from quality, a supplier, reliability
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Why?
Warm up exercise:
You have 60 seconds to document:
What would you want to know about a defect?
For the process:
FMEA improves the reliability of the process
An FMEA identifies problems before they occur
FMEA serves as a record of improvement & knowledge
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
FMEA Inputs and Outputs
Detailed
Process Map Actions designed
to prevent failures
or detect effects.
C&E Matrix
Historical record
FMEA of improvement
projects under-
taken
Control Plan
Inputs to the
Customer Control Plan
Requirements
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
6s Process FMEA -- Terminology
FMEA: A systematic analysis of a process used to identify potential
failures and to prevent their occurrence
Potential Failure mode: The manner in which the process could
potentially fail to meet the process requirements.
Potential Failure Effect: The results of the failure mode on the customer.
Severity: An assessment of the seriousness of a failure mode. Severity
applies to the effects only.
Cause: How the failure could occur, described in terms of something that
can be corrected or controlled.
Occurrence: The likelihood that a specific failure mode is projected to
occur.
Detection: The effectiveness of current process controls to identify the
failure mode (or the failure effect) prior to occurring, prior to release to
production, or prior to shipment to the customer.
RPN -- Risk Priority Number: The product of Severity, Occurrence &
Detection
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
FMEA & CP Form.xls
capability?
improved?
operations, another division or impacts the failure mode, i.e., root number. actions only on high RPN's or
severity?
the end user. causes. easy fixes.
occur?
0 0
0 0
0 0
0 0
0 0
0 0
After completing the initial assessment, the team then generates a list
of actions to reduce the occurrence or increase the detection.
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
FMEA Examples
Plating Example
An aerospace plating company was shipping product to its
customers with nickel plating that was too thin. Parts were failing
corrosion testing at the customer.
Shipping Example
The shipping department of an electronics company is unable to
ship an assembly without its clam shell protective packaging. This
causes occasional late shipments to the customer.
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Part I: Initial Assessment
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
The highest In what ways What is the How can the What are the
to the cusotmer?
cause or FM?
requirements and/or customer can be corrected test) that either
and/or design requirements? or controlled. Be prevent or detect
intent? specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Process Function
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
The highest In what ways What is the How can the What are the
to the cusotmer?
cause or FM?
requirements four and/or
that customer
were identified in corrected
can be in the C&E test) that either
and/or design requirements? or controlled. Be prevent or detect
intent?
Matrix. specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Potential Failure Mode
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
The highest In what ways What is the How can the What are the
to the cusotmer?
cause or FM?
requirements and/or customer can be corrected
can have more than one failure test)
mode.that either
and/or design requirements? or controlled. Be prevent or detect
intent? specific. occurrence?
?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Potential Effects of Failure
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
to the cusotmer?
as the top the C&E
cause or FM?
requirements and/or customer can be corrected test) that either
and/or design requirements? or controlled. Be
matrix.prevent or detect
intent? specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Severity
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V
Severity
of Failure
is aC ranking ona
Controls
1-10
T
scale,
N
10 being the most severe. Low
The highest In what ways What is the How can theseverities What are the that are
are those
to the cusotmer?
reserved
corrected for safety oreither
liability issues.
cause or FM?
requirements and/or customer can be test) that
and/or design requirements? or controlled. Be prevent or detect
intent? specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Severity Scale
Severity of Effect Rating
May endanger machine or operator.
Extreme
10
Hazardous without warning
May endanger machine or operator.
9
Hazardous with warning
Major disruption to production line.
8
High
No effect 1
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Potential Causes of Failure
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
To theInextent
The highest what wayspossible,
What islist
theevery How can the What are the
to the cusotmer?
man, machine,and/or method,
cause or FM?
requirements customer can be corrected test) that either
measurement,
and/or designmaterials, mother
requirements? or controlled. Be prevent or detect
intent? nature. specific. occurrence?
?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Occurrence
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
Occurrence is the likelihood that aVspecific
of Failure C Controls T N
cause will occur andWhat
The highest In what ways
willisresult
the
in a specific
How can the What are the
to the cusotmer?
cause or FM?
requirements and/or customer can be corrected test) that either
failure
and/or design
mode.
requirements? or controlled. Be prevent or detect
intent? specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Occurrence Scale
Failure Capability
Likelihood of Occurrence Rate (Cpk) Rating
1 in 2 < .33 10
High
Very
1 in 8 > .51 8
High
1 in 80 > .83 6
Moderate
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Current Process Controls
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
The highest In what ways What is the How can the What are the
to the cusotmer?
from occurring or detectcanthe
be a
cause or FM?
requirements and/or customer corrected test) that either
failurerequirements?
and/or design mode when it occurs. or controlled. Be prevent or detect
intent? specific. occurrence?
?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Detection
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
The highest In what ways What is the How can the What are the
to the cusotmer?
cause or FM?
requirements and/or customer can be corrected test) that either
the manufacturing operation.
and/or design requirements? or controlled. Be prevent or detect
intent? specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Detection Scale
Very Likelihood that control will detect failure DPPM Probability Rating
Low
No known control(s) available to detect failure mode. 100,000 1 in 10 10
50,000 1 in 20 9
Low
10,000 1 in 100 7
Moderate
2,000 1 in 500 5
1,000 1 in 1,000 4
High
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Risk Priority Number
S Potential O Current D R
Process Potential Failure Potential Effects
E Cause(s) C Process E P
Function Mode of Failure
V of Failure C Controls T N
to the cusotmer?
cause or FM?
requirements and/or customer can be corrected test) that either
and/or design requirements? RPN SEV
or controlled. Be OCC DETor detect
prevent
intent? specific. occurrence?
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Shortcomings of the RPN
The Risk Priority Number is only a guideline and must be
combined with common sense, intuition and logic.
Consider: Two RPNs rated 160 and 200.
Failure Mode Severity Occurrence Detection RPN
A 10 4 4 160
B 4 10 5 200
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Rating Summary
Rating Severity of Effect Likelihood of Occurrence Detection Ability
10 Hazardous without warning Cannot detect
Very High:
Very remote chance
9 Hazardous without warning Failure is almost inevitable
of detection
Remote chance
8 Loss of primary function
High: of detection
Reduced primary Repeated Failures Very low chance
7
function performance of detection
Loss of secondary Low chance
6
function performance of detection
Reduced secondary Moderate: Moderate chance
5
function performance Occasional Failures of detection
Minor defect noticed Moderately high chance
4
by most customers of detection
Minor defect noticed
3 High chance of detection
by some customers Low:
Minor defect noticed Relatively few failures Very high chance
2
by observant customers or detection
Remote:
1 No effect Almost certain detection
Failure is unlikely
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Part II: Actions and History
Action Results
Responsibility
Recommended S O D R
and Completion
Action(s) Actions Taken E C E P
Date
V C T N
What are the actions for Who is List the completed
capability?
improved?
unknown? Should have implementation date
actions only on high for any changes.
RPN's or easy fixes.
Add auto-sensor for B. Carlson Sensor Added,
voltage/current 6/8/99 Software upgraded 5 3 5 75
7/7/99
Establish Forecast and C.S. Soo Auto-ship system
7 2 3 42
Auto-ship w/ supplier 9/2/99 in-place 10/1/99
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Recommended Actions
Action Results
Responsibility
Recommended S O D R
and Completion
Action(s) Actions Taken E C E P
Date
V C T N
What are the actions for WhoCorrective
is actions
List are the point of the
the completed
capability?
improved?
unknown? Should have
actions only on high for any changes.
RPN's or easy fixes.
Add auto-sensor for B. Carlson Sensor Added,
voltage/current 6/8/99 Software upgraded 5 3 5 75
7/7/99
Establish Forecast and C.S. Soo Auto-ship system
7 2 3 42
Auto-ship w/ supplier 9/2/99 in-place 10/1/99
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Responsibility
Action Results
Responsibility
Recommended S O D R
and Completion
Action(s) Actions Taken E C E P
Date
V C T N
What are the actions for Who is List the completed
capability?
improved?
unknown? Should have implementation date
completion of the action.
actions only on high for any changes.
RPN's or easy fixes.
Add auto-sensor for B. Carlson Sensor Added,
voltage/current 6/8/99 Software upgraded 5 3 5 75
7/7/99
Establish Forecast and C.S. Soo Auto-ship system
7 2 3 42
Auto-ship w/ supplier 9/2/99 in-place 10/1/99
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Actions Taken
Action Results
Responsibility
Recommended S O D R
and Completion
Action(s) Actions Taken E C E P
Date
V C T N
Include
Whata brief
are thedescription of the
actions for Who is List the completed
capability?
improved?
unknown? Should have implementation date
actions only on high for any changes.
RPN's or easy fixes.
Add auto-sensor for B. Carlson Sensor Added,
voltage/current 6/8/99 Software upgraded 5 3 5 75
7/7/99
Establish Forecast and C.S. Soo Auto-ship system
7 2 3 42
Auto-ship w/ supplier 9/2/99 in-place 10/1/99
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
The Form Recalculation
Action Results
Responsibility
Recommended S O D R
and Completion
Action(s) Actions Taken E C E P
Date
V C T N
WhatGenerate new
are the actions for ratings
Who is for severity,
List the completed
capability?
improved?
unknown? Should have implementation date
causes
actions only on high for any changes.
RPN's or easy fixes.
Add auto-sensor for B. Carlson Sensor Added,
voltage/current 6/8/99 Software upgraded 5 3 5 75
7/7/99
Establish Forecast and C.S. Soo Auto-ship system
7 2 3 42
Auto-ship w/ supplier 9/2/99 in-place 10/1/99
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Introduction to Control Plans
Process What's Input or Spec. Limits / Measurement Who/What Where Decision Rule/
Sample Size Frequency SOP's
Step Controlled? Output? Requirements Method Measures? Recorded Corrective Action
Coat/Bake Bake Plate Omega T/C Maintenance
X 112 .3 C n/a Weekly ASI Adjust to spec. 9785-123
PMGI Temp. Meter Technician
PMGI 1 wafer/
Y 195 45 nm SP 3 sites/ wafer Operator Oracle None 9785-369
Thickness lot
PMGI 36 sites- all
Y 14 xx m KLA 100% Operator Oracle Rework wafer 9785-411
Width wafers
36 sites- all
Undercut Y 2.0 0.5 m KLA 100% Operator Oracle 9785-615
wafers
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001
Exercise
Apply the FMEA to the same process identified in the
mapping & C&E exercises.
Analyze the top three input variables using the FMEA.
Establish the action priorities based on the RPN and other
experience.
Report results on a flip chart, or Excel.
Report on any problems during the team presentation.
Mar 9, 2017, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. October 23, 2001