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Accelerate Your DFMEA with Sherlock!
DfR Solutions Webinar
Cheryl Tulkoff
November 20, 2012
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Review of Design Failure Mode & Effects
Analysis (DFMEA) Concepts
o What Sherlock Is
o How Sherlock Can Help
o How Sherlock DFMEA Works
o Summary
o Questions
Agenda
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Introduction
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o DFMEA is just one of many tools in your tool box.
o It is not the only tool or best tool for every problem or every situation.
o It can be used across a wide range of fields and disciplines
o Not limited to “hardware”
o Manufacturing
o Software
o Business Processes
o Healthcare
o Service Industries
o Regulated industries – automotive, medical devices, NASA..
o Any place where you need to reduce risk and prevent failure!
What DFMEA is NOT… the only tool to use!
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What DFMEA is….
o DFMEA
o A systematic group of
activities designed to:
o Recognize and evaluate
potential failures of systems,
products, or processes
o Identify the effects and
outcomes of the failures
o Identify actions that could
eliminate or mitigate the
failures
o Provide a historical written
record of the work performed
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Why perform a DFMEA?
o Purpose of an DFMEA Study is to analyze:
o What might go wrong?
o How bad might the effect be?
o How might it be prevented, mitigated or detected at the earliest possible moment?
o With lowest cost, impact, safety risk….
o Develop a DFMEA process for use in future designs
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FMEA in the News
Japan’s Fukushima Daiichi
nuclear plant
Industry watchers contend a
manufacturing error was likely the
culprit. "It means the assembly was
wrong, it means the wrong tools were
used, it means they were careless in
drilling the holes, and maybe the drill
was dull,"
Tear in Boeing Jet
A study has found that fatal
medication errors spiked by
10 percent in July, the month
that graduates fresh out of
medical school report to
residencies, in counties with
a high number of teaching
hospitals, but stayed the
same in areas without
teaching hospitals Medication Errors
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o Japan Quake & Tsunami points out both strengths and limitations of FMEAo Key issues were detailed and identified
o The plants were built to withstand an earthquake of 7.0.
o There was a seawall around the facility in case of a tsunami.
o In an earthquake, the plants had a SCRAM procedure, which executed an emergency shutdown of the nuclear reactors.
o Electrical pumps were designed to pump cool water to the container to keep the rods submerged (the rods are hotter AFTER the shut down than during regular operation of the plant).
o There were back-up batteries for running the pumps in an emergency that were designed to last about an hour or so.
o There were diesel fuel pumps that were available to take over the pumping when the batteries ran out of juice.
o There are vents built into the system to release steam from the reactors if the pressure inside got too high
o But many were considered low probability and/or excessively expensive to consider or the risk was underestimated
FMEA in the News……
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o Boeing engineers underestimated the risk of cracks in
the aluminum, they assumed it would be fine for
60,000 flights (pressure cycles) but have now reduced
the expected life to 30,000 with inspections
recommended every 500 flights after reaching
30,000….
o http://online.wsj.com/article/SB100014240527487038063
04576244782850491122.html
o FMEA: The Cure for Medical Errors
o http://www.medicalhealthcarefmea.com/guides/qp0803reili
ng.pdf
o http://asq.org/sixsigma/green/pdf/preventing_medication_
errors.pdf
FMEA in the News
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o DFMEA is a widely used and powerful analysis & design review
technique.
o Extremely comprehensive element by element review of:
o What can go wrong
o What will happen
o How the situation can be improved
o For improving a design
o For each design component or element:
o List how failures can occur (Failure Mode, what can go
wrong, how the failure manifests itself)
o List what could happen (Failure Effect, consequences of the
mode).
o List how processes or the system itself can detect & prevent
the problem
o Generate Recommendations for Improvements.
DFMEA Basics - Failure Mode And Effect Analysis
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o Failure: The loss of expected or intended function under stated conditions
o Failure mode: The way in which a failure is observed;generally describes the way the failure occurs.
o Failure effect: The immediate consequences of a failure on operation, function or functionality
o Failure cause: Defects in design, system, process, quality, or part application, the underlying cause of the failure or things which initiate a process which leads to failure.
o Severity: The consequences of a failure mode. Severity considers the worst case outcome of a failure as determined by the degree of injury, property damage, or harm that could ultimately occur.
Some Key DFMEA Terms
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o Calculate a Risk Priority Number (RPN) for Each Line Item using
3 Criteria,
o Severity of the Failure Effect “S” (Scale of 1 (Low) - 10 (High)).
o Frequency of Failure Occurrence “O” (Scale of 1(Infrequent) -
10 (Frequent)).
o Detectability/Preventability/Warning “D” (Scale or 1(Very
Detectable) - 10 (Not Detectable)).
o RPN = S x O x D, range (1 (good) to 1000 High Risk).
o An unacceptable range is defined.
o Example: RPN’s > 150 are unacceptable and require a
corrective action redesign.
o Often a Pareto Ranking of the RPN is performed and used
to prioritize corrective action efforts.
DFMEA Basics - Failure Mode And Effect Analysis
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© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o “Fill in the blanks” only.
o Don’t understand the scope and objective of FMEA
o Day dreaming
o Didn’t go through the self-challenge process of design control
o Couldn’t separate Failure Mode, Cause, Effect
o Mixed everything together. Argument for the sake of
argument.
Common DFMEA Mistakes and Traps
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o Repeated itself
o Dog chases its own tail.
o Mitigation is not truly challenged
o Ranking criteria too loose
o Only identifying the problems but not the solutions. Or, couldn’t control it, even if there is a solution. Control plan not in place.
o Do once, then keep in file
o Leaving Document rather than Living Document
o Lack of consistency
Common DFMEA Mistakes and Traps
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o So, how can Sherlock help?
DFMEA’s and Sherlock
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o An automated design analysis tool to bring insight and
prediction earlier in product development process
Sherlock
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Old Strategies…
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The Solution
The Future
Will be
Modeled
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o PCB Design
o Temp Cycling
o Vibration
o Shock
o Bending
o In Circuit Test
o DFMEA
o Thermal Derating
o Failure Rate
o etc.
Requirement: Solve Everyone’s Problem
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o Demonstrated to avionics customer that transition to Pb-free
would have a detrimental impact to product performance
o Driven by severe use environment
Case Study C: Pb-Free Transition
SnPb Assembly SAC305 Assembly
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o Automated to Save Time and Money
o Sherlock Automated Design Analysis™ Software automates most of the time consuming DFMEA process, potentially saving you and your organization up to thousands of hours every year.
o Standards Compliance:
o AIAG
o SAEJ1739
o Complies with ISO S26262
o Pre-populate Your DFMEA Spreadsheet
o Takes your standard design files
o Bill of materials, net lists, Gerber, etc.
o Automatically prepopulates DFMEA reports with reference designators, component technology (capacitor, resistor, etc.), and failure mode (open, short).
Sherlock DFMEA Module
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o Sherlock is Fast and Smart
o Specializes in electronics design reliability
o Automatically performs a comprehensive review of pin location and net
o Automatically removes non-relevant shorting events, such as electrical shorts within the same circuit net.
o Occurs within a matter of seconds
o Not limited by the size of the design or the number of components.
o Complex Boards Simplified
o Unique nesting capability allows designers to more easily analyze complex boards.
o Nests DFMEA worksheets for ease of organization and visibility
o Allows designers to view the overall circuit as well as sub circuits and components.
Sherlock DFMEA Module – Tailored for Electronics
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o So, how does Sherlock DFMEA work?
DFMEA’s and Sherlock
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o Sherlock automatically imports Net List data for
ODB++ or Eagle CAD files.
o For other projects, users must supply a standard IPC-D-
356 formatted file containing the Net List data.
o Once the file has been added to the “Files” list for a
given circuit card, select the “Net List (IPC)” file type &
Sherlock will load the net list data found in the file.
o Net List data associated with a given circuit card can
be viewed by doubleclicking the “Inputs >> Net List”
entry in the project tree.
Importing Net List Data
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Sherlock – Imported Net List
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o Sherlock maintains DFMEA data as a hierarchical
collection of the following types of data:
o One or more Subcircuits per Circuit Card
o One or more Parts per Subcircuit
o One or more Failure Modes per Part
o For maximum usability, DFMEA data is displayed and
managed as a graphical data tree, allowing users to
easily expand, collapse, browse and edit the data.
Managing DFMEA Data
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Updating DFMEA Data from a Parts List in Sherlock
o To view the DFMEA
data tree, simply
double-click the
“DFMEA” entry located
in the Circuit Card
“Inputs” folder of the
Project Tree. At that
point, the DFMEA
Viewer will appear as
a separate window.
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Updating DFMEA Data from Parts List
o For each new circuit card,
the DFMEA Viewer will
initially contain no data
o Easily add default
DFMEA data entries by
right-clicking the circuit
card name in the
“Navigation” panel &
selecting the “Update
From Parts List” menu
option
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Updating DFMEA Data from Parts List
o Dialog box appears allowing various processing options.
o Can create:o Default failures based on
part types
o Default “open” failures for all part pins
o Default “short” failures for all pairs of pins
o Select “Update From Parts List” button to create default DFMEA data entries for all parts in the Parts List.
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Updating DFMEA Data from Parts List
o The Navigation panel is used to quickly find the data associated with any Subcircuit, Part or Failure Mode.
o As each entry is selected, data corresponding to that entry, and all higher-level entries, is displayed in the property panels located on the right-side of the main panel.
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Manually Organizing DFMEA Data
o In addition to using the
“Subcircuit Name(s)”
property to organize
parts in the DFMEA
tree, it is easy to assign
one or more parts to a
specific subcircuit
After any DFMEA data changes are made, press the “Save Changes” button
to save all changes.
Press the “Reset Changes” to reset the DFMEA viewer to show the
previously saved data.
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Adding Default Part Failures
o Use Sherlock to help create the failure modes
associated with each part
o Right click the entry just and select “Add Default
Failures” from the pop-up menu.
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Manually Adding Failure Modes
o Create a Failure Mode
item manually by right-
clicking the part and
selecting “Add Failure
Mode”
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Exporting DFMEA Data
o Flexible, user-customizable way to export all or part
of the DFMEA data to one or more spreadsheet files
using a collection of spreadsheet “templates”.
o To export DFMEA data, select the desired DFMEA
data and an appropriate template file
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o 00-Backup-Template.xls
o 01-CCA-Summary-Template.xls
o 02-CCA-Details-Template.xls
o 03-Subcircuit-Summary-Template.xls
o 04-Subcircuit-Details-Template.xls
o 05-Part-Template.xls
o 06-Failure-Mode-Template.xls
Templates List
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Importing DFMEA Data
o Same template used to export DFMEA data
from Sherlock can be used to import DFMEA
data from a spreadsheet into Sherlock
o Defaults to display last template used
o Press the “Load DFMEA Data” button to parse
the input file and begin the import process.
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DFMEA Analysis Options
o DFMEA results are
generated by right-
clicking the Analysis >>
DFMEA entry in the
Sherlock project tree
for a given circuit card
& selecting the “Edit
Properties
o Save & Run
RPN values >/= or the “Error Cutoff Value”
are colored as errors (e.g., red)
RPN values greater >/= to the “Warning
Cutoff Value” are colored as warnings (e.g.,
yellow).
All other results are colored green.
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DFMEA Results
o After the analysis has
completed, double-click
the “Analysis >>
DFMEA” entry in the
project tree to view the
DFMEA results
o Summary Results
o RPN Distribution Chart
o DFMEA Ratings Table
o Processing Issues
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DFMEA Results
The “RPN Dist” tab shows a graphical distribution of the maximum RPN
values assigned to each part in the DFMEA data.
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DFMEA Results
The “Table” tab shows a list of all parts defined in the DFMEA tree and the
maximum ratings assigned to the failure modes associated with those
parts.
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DFMEA Layers
DFMEA module also generates graphical layers that display color-coded parts
based on the maximum RPN value assigned in the DFMEA data.
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Design Failure Mode and Effects Analysis (DFMEA) is
o Critical process in electronics design.
o Allows design engineers to identify and correct potential failure
modes early in the design process
o Improves overall product reliability
o Decreases cost
o Enhances customer satisfaction.
o But with increasingly complex electronics components, the time
required to complete a DFMEA can take weeks, adding to costs
and product delays!
o Let Sherlock accelerate your DFMEA efforts!
Sherlock DFMEA Module Summary
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Questions & Discussion
Please feel free to contact us anytime for
questions!
www.dfrsolutions.com