FMEAMI.docx
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FMEAMI
1.0ProcessFMEA（Manualinsertofthethroughholecomponent）
ProcessStepRiskAssessment
ComponentpreparationfortheleadlengthLow
PlacementofthegoldfingerprotectorLow
ManualinsertoftheMedium
Platedthroughholecomponent
WavesolderingMedium
RemovalofthegoldfingerprotectorLow
TouchuponthesoldersideLow
Depanelizefromthe2uptosinglePCBAHigh*
BracketMountingLow
2.0ProcessFMEARiskpriorityNumber（RPN）tableonde-panelizingfromthe2uptosinglePCBA
Functionalorequipmentidentification
Failuremodes
Failureeffects
Severity
Failuremechanism
Occurrence
Failuredetection
Detection
Correctiveactions
R
P
N
RPN
Process
Chipcomponent
Brokeninto2pieces
ICTtestdetectedfailed
8
Originalcomponentfromsupplierweakintensilestrength
3
IQAsamplingmeasurement
3
72
Solderabilitytestduringpartsqualification
Causedbyboardshittingoneanotherduringinsertionintotheholdingmagazaine
2
Visualforchippedorbrokencomponent
3
40
Operatortrainingtoholdtheboardattheedgeandnotonthetailendwhereitisnotpronetooverhang.
Stressedduringthepassageoftravelontherailguideofdepanelizer
3
Visualinspection
Atposttestvisual
6
144
ClearanceontherailguidedesignofthedepanelizertoallowthePCBAtoexpandasitisbeingpartedfromthev-groove.
Functionalorequipmentidentification
Failuremodes
Failureeffects
Severity
Failuremechanism
Occurrence
Failuredetection
Detection
Correctiveactions
R
P
N
RPN
Process
Chipcomponent
Brokeninto2pieces
ICTtestdetectedfailed
8
3
3
72
2
3
40
3.0Severity（R）
Severityisanassessmentoftheseriousnessoftheeffectofthepotentialfailuremodetothecustomer.Severityappliestotheeffectonly.Ifthecustomeraffectedbyafailuremodeistheassemblyplantortheproductuser,assessingtheseveritymaylieoutsidetheimmediateprocessengineer’steamfieldofexperienceorknowledge.Inthesecases,thedesignFMEAdesignengineer,andorsubsequentmanufacturingorassemblyplantprocessengineershouldbeconsulted.Severityshouldbeona“1”to“10”scale.
Effect
Criteria:
SeverityofEffect
Ranking
Remarks
Hazardouswithoutwarning
Mayendangermachineorassemblyoperator.Failurewilloccurwithoutwarning
10
Hazardouswithwarning
Mayendangermachineorassemblyoperator.Failurewilloccurwithwarning
9
Veryhigh
Majordisruptiontoproductionline.100%oftheproductmayhavetobescrapped.
8
High
Minordisruptiontoproductionline.Productmayhavetobesortedandaportion（lessthan100%）
7
Moderate
Minordisruptiontoproductionline.Aportion（lessthan100%）oftheproductmayhavetobescrapped（nosorting）.
6
Effect
Criteria:
SeverityofEffect
Ranking
Remarks
Low
Minordisruptiontoproductionline.100%ofproductmayhavetobereworked.Customerexperiencesomedissatisfaction
5
VeryLow
Minordisruptiontoproductionline.Theproductmayhavetobesortedandaportion（lessthan100%）reworked.Fit&finish/squeakrattleitemdoesnotconform.Defectnoticedbymostcustomers.
4
Minor
Minordisruptiontoproductionline.Aportion（lessthan100%oftheproductmayhavetobereworkedonlinebutoutofstation.
3
Veryminor
Minordisruptiontoproduction.Aportion（lessthan100%）oftheproductmayhavetobereworkedonlinebutinstation.
2
None
Noeffect
1
4.0Occurrence（O）
ProbabilityofFailure
Possiblefailurerates
Ranking
Veryhigh:
Failureisalmostinevitable
1in2
1in3
10
9
High:
generallyassociatedwithprocessessimilartopreviousprocesseswhichhaveexperiencedoccasionalfailuresbutnotinmajorproportions
1in8
1in20
8
7
Moderate:
Generallyassociatedwithprocessessimilartopreviousprocesseswhichhaveexperiencedoccasionalfailures,butnotinmajorproportions.
1in80
1in400
1in2,000
6
5
4
ProbabilityofFailure
Possiblefailurerates
Ranking
Low:
Onlyisolatedfailuresassociatedwithalmostidenticalprocesses
1in15,000
3
VeryLow:
Onlyisolatedfailuresassociatedalmostidenticalprocesses
1in150,000
2
Remote:
Failureisunlikely.Nofailureseverassociatedwithalmostidenticalprocesses
Lessthan1in1,500,000
1
5.0Detection（D）
Detection
Criteria:
Likelihoodtheexistenceofadefectwillbedetectedbyprocesscontrolbeforeornextsubsequentprocess,orbeforepartofcomponentleavesthemanufacturingorassemblylocation
Ranking
Almostimpossible
Noknowncontrol（s）availabletodetectfailuremode
10
Veryremote
Veryremoteli
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