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dFMEA 2014Re-shaping Design

M. Shneide!-She"e!# $. A%e!mann# S. Sa!%i&ov-2014

$1.1'(nteg!it") http)**s%o+de-m%s.%o+de.t!,.om)001*si*vie,!evision

p!o/et&ame*SS*S"sE*1'3Method3and

3Too5s*03FMEA*p!o/et.p/6se5etionFMEA2014.ppt7

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References (TBD)

Deductive Analysis ref ISO18

C_044_BR_!_001_"8#_$% &S'#000 *$A + e,ler'*-.lic,/eits' und '$influss'Analyse

DA DA'Band 4 Sicherung der Qualität vor Serieneinsatz -

Produkt- und Prozess-FMEA "2 Aufla.e "003

DI% $% 3081"

D& Band 1!+11 FMEA – Fehlermöglichkeits- und

Einflussanalse !2 Aufl2 "004

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 AtionsFai5u!esFuntions

d*$A in BR $lectr5nics

*$A is an integ!ated method o! syste6atic ris/ analysis du!ing the

p!odut deve5opment. (t is used to identi" ,ea%nesses in the design and to ad!ess !is%

!edution measu!es to avoid o! !edue those potentia5 ai5u!es and au5ts

in an ea!5" p!o/et phase.

(t is a 7reventive 6et,5d f5r syste6atic desi.n ai5u!e !is% mitigation.

(t sha55 +e integ!ated in the design phase and ad!esses a55 a!eas)

 8 Speiiation ,ea%nesses and omp5eteness

 8 Susepti+i5it" to envi!nomenta5 onditions

 8 (nte!ae ,ea%nesses

 8  A!hitetu!e ,ea%nesses 8 Seve!it" and impat to ustome! untions

 8 omponent and mate!ia5s se5etion

 8 Test ove!age

 8 and man" mo!e9

St!utu!e

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d*$A and S*9:* Inte.rati5n

$C; Re<uire6ents

$C; Arc,itecture

$C; Sc,e6atics = :ay5ut

S*9:*

d*$A

Syste6 Desi.n (SCS)

RA%DO* :M;:&E&T

FA(<=RE R(S>

RED=T(:&

S>ST$*ATIC DES(?& FA(<=RE

R(S> RED=T(:&

See a5so s5ide 23 . o! mo!e ino!mation9

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d*$A and S*9:* Analysis

 8 D-FMEA sha55 !edue the !is% o!

s"stemati ai5u!es @design ai5u!es#

e.g. ,!ong omponent se5eted#

to5e!anes not onside!ed#

tempe!atu!e in5uene not onside!ed

 8 (ts &:T !eBui!ed to use the D-FMEA

o! !andom ai5u!es# e.g. !esisto! opendue to !andom ai5u!es. =se the S;FM-

<FM ana5"sis to !edue the !is% o!

!andom ai5u!es and to ensu!e that the

Diagnosti ove!age is high enough.

Risk Priority Number (RPSeverity (s)

Occurrence (O)Detection(D)

Experience

Worst case analysis

simulationtests

Si

ngle Point Fault etric (S

Open ! S"ort ! Dri#t

F$%&R'%E

Pin&to&Pin #ailures

atent Fault etric (F )FR riteria D

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$le6ent Structure

$le6ents are structure in t,e f5ll5?in. @asic layers

 8 Funtion ao!ding to Speiiation(SEVERITY is inherited from sFMEA)

 8 Main A!hitetu!a5 E5ements =sed to ahieve the untionThis 5a"e! an +e e7tended i it ma%es sense to g!oup e5ements u!the! @see e7amp5es +e5o,

 8 omponent o5de! to suppo!t 5in%ing to pFMEA @not neessa!" o! omp5etion o dFMEA

1

"

!

!

"

"

1

E7amp5e 2

1

" !

""

E7amp5e 1

!

 AtionsFai5u!esFuntions

St!utu!e

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Structure uncti5ns acc5rdin. S7ecificati5n

T,e first $le6ent lists t,e functi5ns re<uired 8 Deines the What-To-Do

 8 Deines ,hih au5ts to detet

 A55 (no!mation sha55 +e !et!ieved !om the Speiiation

 8 ?aps in the speiiation get visi+5e

 8 onsisten" +et,een Design and FMEA is gene!ated

E7amp5e 1

1

1

The !eBui!ed ai5u!es to +e

deteted a!e 5isted as sing5e

F=&T(:&s

a This d!ives the design

+ This a55o,s di!et 5 in%ing

to the Fau5t D

 AtionsFai5u!esFuntionsSt!utu!e

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Structure C5675nent r5u7s

T,e C5675nents are t,e lin/ t5 t,e 7*$A @not neessa!" o! omp5etion o dFMEA

 8 Sho,s WHI#H  omponents ;R:$(DE the untion

 8  A ai5u!e o the omponents 5eads to a ai5u!e in the untion.•  A u!the! +!ea% do,n to sing5e omponent ai5u!es is not neessa!" as the Enginee!ing detetion ations ve!i" the

f"n$tion

• Mission !itia5 e5ements @shunts# p!oesso!s sha55 +e t!eated as Main A!hitetu!e e5ements

• 100 omponent ai5u!e +!ea% do,n is ana5"sed du!ing the S;FM*<FM

 A55 (no!mation sha55 +e ta%en !om the !e5eased E<

 8 onsisten" +et,een Design and FMEA is gene!ated 8  Automated update o E< and eas" g!ouping a55o,s Bui% update o hanges

E7amp5e 2

Mission !itia5 omponents a!e main

 A!hitetu!e e5ements and the!eo!e

sing5e entities in the E5ements

The a!hitetu!e +5o%s a!e u!the!

sp5itted to ahieve +ette! g!anu5a!it"

to the design @omponents and

ations to +e assigned.

!

!!

 AtionsFai5u!esFuntionsSt!utu!e

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uncti5n and ailures

T,e first $le6ent lists t,e functi5ns re<uired 8 <ist o untions as des!i+ed in p!evious s5ides

Fai5u!e a!e a negation o the untion

E7amp5e 1

1

1

1

 AtionsFai5u!esFuntionsSt!utu!e

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ailure %ets

T,e Arc,itecture $le6ents are t,e 6ain as7ect 5f t,e analysis 8 Funtion o the A!hitetu!e E5ements as des!i+ed in p!evious s5ides

Fai5u!es a!e negation o the untion

7lus additiona5 !is%s out o team disussion * +!ain sto!ming 8 (t is a55o,ed to pu55 the ai5u!e nets on the same 5eve5

@see e7amp5e +e5o,) a wron% dimensionin% 5eads to a false dete$tion# +ut +oth a!e sing5e va5id au5ts

 8  Ations an +e g!ouped +" the au5ts and ai5u!es

E7amp5e 1

"

"

 AtionsFai5u!esFuntionsSt!utu!e

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ailure %ets t5 C5675nents

T,e C5675nents are t,e lin/ t5 t,e 7*$A 8 as des!i+ed in p!evious s5ides

 A ai5u!e o the omponents 5eads to a ai5u!e in the untion 8 Top Do,n App!oah o the design FMEA ends he!e

 8 Detai5ed ottom =p App!oah is given +" S;FM*<FM

 8 Highest Seve!" out o Design ana5"sis is given to the omponent

E7amp5e 1

!

!

 AtionsFai5u!esFuntionsSt!utu!e

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Acti5ns

Acti5ns are assi.ned t5 Arc,itecture $le6ents 9 r5u7s 8 Testing st!ateg" to ahiev high va5idation ove!age +" standa!d tests

 Ations a!e assigned on o!e and speii App5iations 8 S"m+o5i Teams) < Team# (nteg!ation Team# App5iation Team

 8 S"m+o5i Dates) ?e!+e! !e5ease# D$ Test Sta!t# App5iation ;$ omp5eted

E7amp5e 1

 AtionsFai5u!esFuntionsSt!utu!e

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Severity Ratin.

Ran/ $ffect Criteria

10 ailure t5 6eet safety and9 5r

re.ulat5ry re<uire6ents

;otentia5 ai5u!e mode aets sae vehi5e ope!ations ,ithout ,a!ning.

&on-omp5iane ,ith gove!nment !egu5ations.

# Same as !ite!ia o! 10 +ut ,ith ,a!ning

8 :5ss 5r de.radati5n 5f7ri6ary functi5n

<oss o p!ima!" untion @$ehi5e inope!a+5e IStoppe!J# does not aet saevehi5e ope!ation# vehi5e needs di!et se!vie.

Deg!adation o p!ima!" untion @$ehi5e ope!a+5e# +ut at a !edued 5eve5 o

pe!o!mane.End-use! ve!" dissatisied.=na+5e to assem+5e o! pa!amet!i !e/et at $ehi5e Manuatu!e! @$M o! $MKsmodu5e su+-ont!ato!.

3 :5ss 5r de.radati5n 5fSec5ndary functi5n

<oss o seonda!" untion @vehi5e ope!a+5e# +ut omo!t*onveniene untioninope!a+5e. Appea!ane o! Audi+5e &oise @SBuea% and Ratt5eEnd-use! dissatisied.

Deg!adation o seonda!" untion

4 Ann5yance some deets# $ehi5e ope!a+5e @Fit and Finish Appea!ane o! Audi+5e &oise @SBuea% and Ratt5eDeet notied +" most ustome!s @g!eate! than 3.

! Deet notied +" most ustome!s @g!eate! than 30.

" Deet notied +" most ustome!s @g!eate! than 23.

1 %5 effect &o dise!ni+5e eet

 AtionsFai5u!esFuntionsSt!utu!e

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Occurrence ratin. 10'

Ran/ :i/eli,55d Descri7ti5n $a67le

10 ery ersistentfailures (Al65st) Histo!" o man" ai5u!es ,ith p!evious# simi5a!design and used envi!onment e7t!eme5"ha!sh o! un%no,n :R &e, onepts ,ith nopast design e7pe!iene and no ana5"tia5methods avai5a+5e to eva5uate.

omp5e7it") Fo! e7amp5e the ne, design <Ai!uit @3G'21G04LM.00 ,ith no ana5"tia5methods used.

# ery ersistentfailures (i.,)

Design is !adia5 ,ith man" un%no,n !is%sand envi!onment is ha!sh*un%no,n :R &e,onept eva5uated on5" via ana5"tia5tehniBues o! mode5ing.

omp5e7it") Fo! e7amp5e the ne, design <Ai!uit @3G'21G04LM.00

8 re<uent failures(i.,)

Design is signiiant5" die!ent !om p!eviouso! envi!onment is ha!sh*un%no,n :R &e,onept ,ith some p!otot"pe e7pe!iene onsimi5a! app5iations ,ith good !esu5ts.&o e7p5iit HW !eBui!ements deined.

omp5e7it") Fo! e7amp5e the ne, u!!entont!o5 so5enoid i!uit @3G'2222LM.00

Mode!ate5" hanged design ,ith on5" ai!!e5ia+i5it" !eo!d used in s5ight5" ha!she!envi!onment :R onept e7ists ,ide5" inothe! indust!ies in simi5a! app5iations ,ith

un%no,n !esu5ts.E7p5iit HW !eBui!ements deined @e.g.ope!ationa5 p!oi5es

omp5e7it") Fo! e7amp5e the digita5 5uthsenso! inte!ae @3G'2'004L00

ReBui!ements deined o! a i!uit +ut no

doumented t!aea+i5it" to ve!iiation andtest.

 AtionsFai5u!esFuntionsSt!utu!e

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Occurrence ratin. 3'1

Ran/ :i/eli,55d Descri7ti5n $a67le

3 Occasi5nal failures

(65derate)

E5et!oni ,o!st ase ana5"sis o! simu5ation

is pe!o!med ,hih onside!s supp5" vo5tageand tempe!atu!e va!iation as ,e55 as e7petedomponent d!itsHa!d,a!e design ,a5%-t!ough @o! AS(< A#i!uits Ha!d,a!e design inspetion @o! AS(< #Di!uitsonside!ation o design guide5ine*!eommended omponent usageDesign ao!ding HW !eBui!ements

Des!iption o speii setion in (D

Mode!ate5" hanged design ,ith good

!e5ia+i5it" !eo!d used in u!!ent envi!onment

;a!t*assem+5" simi5a! to p!evious design ,ithon5" ai! !e5ia+i5it" !eo!d used in s5ight5"ha!she! envi!onment

4 ;a!t*assem+5" simi5a! to p!evious design ,ithon5" ai! !e5ia+i5it" !eo!d used in u!!entenvi!onment

! Relatively fe? (l5?) ( the !esu5ts o the-,o!st ase ana5"sis A&D simu5ation o! -,o!st ase ana5"sis A&D Deve5opment testa!e ompa!a+5e:R A55 HW ReBui!ement t!aea+5e to !e5eased(D:Ra!!"-ove! in5uding same omponent +ut

va5ue hange

a!!"-ove! e7amp5e o! va5ue hange) Digita5S,ith inputs @3G'1324LM.00

 A55 Ha!d,a!e ReBui!ements# eithe! !omustome! o! !om TRW @e.g. senso! supp5"au!a" 0#3$# !e5ated to the ana5"Nedi!uit 5i+!a!" needs to +e t!aed to the!e5eased (D.

" Simu5ation +ased on !e5ated omponentmode5s and ; impedane onside!ation.:RD$*;$ samp5es @statistia5 testing passed the!e5ated tests

Design ana5"sis*detetion ont!o5s have a st!ongdetetion apa+i5it". $i!tua5 Ana5"sis @e.g. AE#FEA# et. is high5" o!!e5ated ,ith atua5 and*o!e7peted ope!ating onditions p!io! to design!eeNe.

1 ;nli/ely a!!"-ove! pa!t*assem+5" ,ith good !e5ia+i5it"!eo!d  ppm O1

 AtionsFai5u!esFuntionsSt!utu!e

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Detecti5n ratin. 10'3

Ran/ :i/eli,55d Descri7ti5n $a67le

10 A@s5lute;ncertainty

Fai5u!e ma" +e deteted du!ing 5ong te!m vehi5eope!ation.

Fai5u!e ,i55 not +e deteted +eo!e end-use! detetion@in5uding 5eet use!s.&o test method avai5a+5e.

# eryRe65te

Fai5u!e ma" +e deteted du!ing vehi5e p!odution. Fai5u!e ,i55 not +e deteted +eo!e automotive ustome!p!oess @p5ant o! p!oving g!ounds.=np!oven o! un!e5ia+5e method avai5a+5e.

8 Re65te Fai5u!e ma" +e deteted on5" du!ing vehi5e o!ope!ationa5 testing.

$ehi5e ;!odut ve!iiation*va5idation ate! design phase andp!io! to 5aunh ,ith pass*ai5 testing @e.g. Su+-s"stem o!s"stem testing ,ith aeptane !ite!ia suh as !ide 6hand5ing# shipping eva5uation# et.

ery :5? Fai5u!e 5i%e5" to +e deteted on5" du!ing vehi5e o!ope!ationa5 testing.

;!odut ve!iiation*va5idation ate! design phase and p!io! to5aunh ,ith test to ai5u!e testing @e.g. Su+-s"stem o! s"stemtesting unti5 ai5u!e ou!s# testing o s"stem inte!ations# et.

3 :5? Fai5u!e ma" +e deteted on5" du!ing E= assem+5". ;!odut ve!iiation*va5idation ate! design phase and p!io! to5aunh ,ith deg!adation testing @e.g. Su+-s"stem o! s"stemtesting ate! du!a+i5it" testP untion he%

 AtionsFai5u!esFuntionsSt!utu!e

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Detecti5n ratin. '1

Ran/ :i/eli,55d Descri7ti5n $a67le

*5derate Fai5u!e deteted on5" ,hen a speii

measu!ement is made o! on5" unde! 5a+ t"peonditionsP Fai5u!e on5" deteted du!ingassem+5".

Design $e!iiation @!e5ia+i5it" testing# 5a+ testing# envi!onmenta5 testing#

et. using pass*ai5 testing @e.g. aeptane !ite!ia o! pe!o!mane#untion he%s# et.

4 *5deratelyi.,

Fai5u!e deteted +" diagnostis on5" unde!some ope!ationa5 onditions the ne7t timethe i!uit is ativatedP E!!ati ope!ation o!!eset that is not automatia55" deteted +utma%es a s5ight hange in the ope!ation o theunit suh that it ma" not +e easi5" deteted.

Design $e!iiation @!e5ia+i5it" testing# 5a+ testing# envi!onmenta5 testing#et. using test to ai5u!e testing @e.g. unti5 5ea%s# "ie5ds# !a%s# et.

! i., Fai5u!e deteted +" diagnostis on5" unde!some ope!ation onditions ,hen it happensPE!!ati ope!ation o! !eset that is notautomatia55" deteted +ut ma%es anotiea+5e hange in the ope!ation o theunitP Fai5u!e deteted +" automati teste!+eo!e and ate! testing.

Design $e!iiation @!e5ia+i5it" testing# 5a+ testing# envi!onmenta5 testing#et. using deg!adation testing @e.g. data t!ends# +eo!e*ate! va5ues#et.

" ery i., Fai5u!e deteted +" diagnostis the ne7t timethe i!uit is ativatedP ;a!tia5 5oss o

ope!ation

Test in !e5ated ope!ating modes and tempe!atu!e to i!uit ous ,ithpass*ai5 !ite!ia o! mu5tip5e samp5es.

1 Certain Fai5u!e deteted +" diagnostis ,hen ithappensP Tota5 5oss o ope!ationP Fai5u!edeteted +" automati testing du!ing testing.

Fai5u!e ause o! ai5u!e mode an not ou! +eause it is u55"p!evented th!ough design so5utions @e.g. p!oven design standa!d*+estp!atie o! ommon mate!ia5# et.

 AtionsFai5u!esFuntionsSt!utu!e

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inaliEati5n 5f 7reventive and detecti5n acti5ns

T,e acti5n .r5u7s s,all @e finaliEed after eac, 5t,er 

S5 start ?it, t,e 5ccurrence reducti5n (e2.2 re<uire6entsdefiniti5n and revie?)

T,en cl5se t,e detecti5n related ris/ reducti5n (e2.2 tests)

Only if t,e related ris/ reducti5n 6easure is 7erf5r6ed

d5cu6ented and d5es %OT c5ntain any n5t Fustified deviati5n

t,e 6easure can @e 6ar/ed as c567leted in t,e D*$A2

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Gal/t,ru., vs2 Ins7ecti5n

ISO"3"3" art 9 Ta@le ! re<uires t,at f5r ASI: A9B a G desi.n ?al/'

t,r5u., is 7erf5r6ed and f5r ASI: C9D a ins7ecti5n2

Gal/'t,r5u., is defined as

 8 s"stemati e7amination o ,o!% p!oduts in o!de! to detet anoma5ies

 8 EQAM;<E Du!ing a ,a5%-th!ough# the deve5ope! e7p5ains the ,o!% p!odut

step-+"-step to one o! mo!e assesso!s. The o+/etive is to !eate a ommon

unde!standing o the ,o!% p!odut and to identi" an" anoma5ies ,ithin the

,o!% p!odut. Ins7ecti5n is defined as

 8 e7amination o ,o!% p!oduts# o55o,ing a o!ma5 p!oedu!e# in o!de! to detet

anoma5ies

 8 &:TE) A o!ma5 p!oedu!e no!ma55" in5udes a p!evious5" deined p!oedu!e#

he%5ist# mode!ato! and !evie, o the !esu5ts.

%5te B5t, ins7ecti5ns and ?al/'t,r5u.,s are ty7es 5f 7eer revie? ?,ere

a ?al/'t,r5u., is a less strin.ent f5r6 5f 7eer revie? t,an an ins7ecti5n2

G,at d5es t,at 6ean f5r t,e desi.n tea6  See net 7a.e

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Gal/t,r5u., vs2 Ins7ecti5n

G,at d5es t,at 6ean f5r t,e electr5nics desi.n

1. Revie,s have to +e doumented# shematis id# pa!tiipants#

indings @see !evie, temp5ate1

2. Revie, doumentation sha55 a5so des!i+e ,hih points have +een

he%ed du!ing the !evie,# e.g. its not suiient to he% i the o!ma5

points a!e ove!ed suiient5" @shematis (D# date# !ee!ene

designato!s et.# the main ta!get o the !evie, is to ind design and

5a"out ai5u!es @is the pa!tiu5a! i!uit u5i55ing the !eBui!ements.

'. Revie,s sha55 +e +ased on a he%-5ist o! potentia5 design ai5u!es.

TD add 5in%

1 http)**s%o+de-m%s.%o+de.t!,.om)001*si*vie,!evision

p!o/et&ame*i!uit<i+!a!"Reposito!ies*3G'22G123i!uit<i+!a!"Deve5opmentF!am

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Wo!st ase Ana5"sis

Repo!t

Simu5ation Repo!t

Revie, Repo!t

E= E5et!onis

Design FMEA

Shemati

SW (nte!ae ont!o5

Doument @(D

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Tests

< Fau5t in/etion test

< Design Spe.

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 App5iation

D$*;$

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< inte!ae deinition *

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@TRD

E= Fau5t (n/etion Tests

o! E= inte!na5 ai5u!es

i!uit <i+!a!"

Tests

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o! E= e7te!na5 ai5u!esI;!ove :ut TestingJ

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Des!iption in5. Saet"

reventive vs2 Detecti5n Acti5ns AtionsFai5u!esFuntionsSt!utu!e

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Statistics

5r6s,eets and Ris/ *atri is .enerated 5n uncti5nal level

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 AtionsFai5u!esFuntionsSt!utu!e

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Re'use 9 ariant *ana.e6ent

ariant *atri used t5 s?itc, O 9 O% full structures

E7amp5e 1

 AtionsFai5u!esFuntionsSt!utu!e

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Attac,6ent

D'*$A vs2 S*9:*

44et

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D'*$A vs2 S*9:*

- oi5 d!ive! @FET damage# due t5

electrical 5verstress (device n5t

suita@le f5r t,e s7ecified current)

:pen# due t5 rand56 failures

DE$I)4 "AI5.E, Ciruitdesign, wron% selectiono- co+ponents 6electronic parts7 !arts notsuitable -or this purpose7

.A4DO "AI5.E whichdepends on thetechnolo%*, load, sel-heatin%, etc7 o- individualcomponents

E7amp5e ai5u!e modeE7amp5e ai5u!e mode

-Wo!st ase ana5"sis sho,s that

devie is suita+5e o! the speii

pu!pose-E5et!ia5 au5t in/etion test sho,s

that devie does not ai5 unde!

ove!st!ess onditions.

E7amp5e o! !is% mitigationE7amp5e o! !is% mitigation

- Safety *ec,anis6 detets the

ai5u!e and +!ings the s"stem in a

sae state

 I n e , J  4 o ! 

 4 i e 5 d  e 4 4 e  t 

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D'*$A S*9:*

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D'*$A vs2 S*9:*

( the D-FMEA is +ased on s"stemati

ai5u!es its &:T !eBui!ed to app5" a

o!ma5 ai5u!e mode dist!i+ution. D-

FMEA is a +!ainsto!ming method so the

D-FMEA team has to deide ,hih

ai5u!e modes a!e onside!ed o! a

omponent in the D-FMEA. D-FMEAp5an is used as he%5ist ,hih is

suppo!ting the onsisten" and

omp5eteness o the D-FMEA.

E7amp5e ai5u!e mode dist!i+ution ao!ding to M(< H> ''Fai5u!e mode dist!i+ution

 8ransistor,"E8

$hort 9(,22:Output ow &&,22:

!ara+eter#han%e (;,22:Open 9,22:

Output 'i%h 9,22:

S;FM-<FM is ousing on !andom ai5u!es

so the dist!i+ution has to +e deined. At

TRW ,e a!e using M(< H>'' to deine

the ai5u!e mode dist!i+ution.

D'*$A S*9:*

D<"EA!lan

I 'B011=B

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D-MEA vs" SPM#$M

D'*$A S*9:*

 A;(S ( FMEATRW

.75s Temp5ate