PCB內(nèi)層AOI檢測(cè)PFMEA分析范例

PotentialFailureModeandEffectAnalysis,,,,,,,,,,,,,,,,,

過程潛在失效模式及后果分析,,,,,,,,,,,,,,,,,

（PFMEA）,,,,,,,,,,,,,,,,,

項(xiàng)目Item：,雙面板/多層板double-side/multi-layersPCB,,,,FMEA編號(hào)FMEANo.：,,FMEA-D/F(I)-04,,"編制日期Peparedate：

2015-07-07",,,,"編制

Prepareby：",,,,

類型Type：,PCB,,,,關(guān)鍵日期KeyDate：,,,,"內(nèi)容版本

contentVersion：B1",,,,"審批

Approvalby：",,,,

過程責(zé)任Responsibility,內(nèi)層AOIinnerlayerAOI,,,,"修訂日期

ModifyDate：",,2019/7/1,,工廠批準(zhǔn)plantapproval：,,,,,,,,

核心小組coreteam：,,,,,,,,,,,,,,,,,

"1.如果客戶有指定產(chǎn)品及過程特性符號(hào)，按客戶要求標(biāo)識(shí)；2.客戶沒有指定，則按如公司規(guī)定標(biāo)識(shí)。產(chǎn)品特性符號(hào)表示:“◆”,過程特性符號(hào)表示:“▲”。classificationsymboldescription：1.marksymbolpercustomer'sspecificsymbol;2.ifnospecificsymbolfromcustomer，marksymbolasbelow:“◆”forproductspecialcharacteristic,and“▲”forprocessspec",,,,,,,,,,,,,,,,,

"過程

功能processfunction

要求

requirement","潛在失

效模式potentialfailuremode","潛在失

效后果potentialfailureeffect",嚴(yán)重度S,級(jí)別classification,"潛在失效

起因/機(jī)理potentialfailurecause/mechanism",頻度O,"現(xiàn)行過程

控制預(yù)防currentprocesscontrolmethod","現(xiàn)行過程

控制探測(cè)

currentprocessdetection",探測(cè)度D,"R

P

N",建議措施adviceaction,責(zé)任及目標(biāo)完成日期responsibility&duedate,措施結(jié)果actionresult,,,,

,,,,,,,,,,,,,采取的措施actionadopted,S,O,D,"R

P

N"

調(diào)取資料：對(duì)型號(hào)、版本號(hào)核實(shí)inputdata:verifythepartnumberandversion,型號(hào)、版本與實(shí)測(cè)板不符合partnumberandversionisnotconsistantwiththewaitingAOIboards,"無法測(cè)試、效率低failtoAOI,lowefficiency",3,,操作員調(diào)錯(cuò)工程資料operatorinputthewrongengineeringdata,3,調(diào)工程資料按工卡版本號(hào)inputtheengineeringdataaccordingtoMI,調(diào)出資料后再核對(duì)工卡和資料的型號(hào)、版本號(hào)是否一致verifytheP/NandversionofinputdatawiththeonesinMI,6,54,無none,,,,,,

,,,,,工程部資料未更新操作員未核對(duì)engineeringdataisnotupdatedandisnotverifiedbyoperator,,,,,,無none,,,,,,

機(jī)器驗(yàn)證,設(shè)備異常無法確認(rèn),無法測(cè)試failtoAOI,3,,AOI室內(nèi)參溫濕度異常,2,按照WI要求管控溫濕度,每4小時(shí)檢查一次checkonceevery4hours,6,36,無none,,,,,,

,,,,,參數(shù)、設(shè)備異常,5,標(biāo)準(zhǔn)板掃描,每天均需用標(biāo)準(zhǔn)板對(duì)機(jī)器進(jìn)行校驗(yàn),5,75,無none,,,,,,

"參數(shù)設(shè)定：按工卡要求的補(bǔ)償系數(shù)，最小線寬線距，板厚等設(shè)置分辨率及其它測(cè)試條件parametersetup:setparameterslikecompensatecoefficient,min.tracewidth/clearance,boardthickness,resolutionandothertestingconditionetc.",公差太大deviationistoolarge,缺口和線突漏掃skipscanthedefectofnickandtraceprotruding,5,,未按工卡公差計(jì)算notcompensateaccordingtothemanufacturinginstruction,2,計(jì)算補(bǔ)償前核對(duì)工卡要求的公差值checkcompensatevalueonMIrequirementbeforecalculateitscompensation,領(lǐng)班復(fù)核資料foremanreviewthedata,7,70,無none,,,,,,

,公差太小deviationistoosmall,效率低lowefficiency,3,,,,,,,42,無none,,,,,,

,分辨率過大resolutionistoohigh,"缺口、線突、開短路漏掃描skipscanthedefectofnick,traceprotruding,openandshort",5,,未按WI要求設(shè)置分辨率notsetresolutionaccordingtoWI,2,培訓(xùn)操作員按WI要求設(shè)置分辨率trainoperatortosetresolutionaccordingtoWI,領(lǐng)班復(fù)核分辨率foremanreviewtheresolution,7,70,無none,,,,,,

,分辨率過小resolutionistoolow,效率低lowefficiency,3,,未按WI要求設(shè)置分辨率notsetresolutionaccordingtoWI,3,培訓(xùn)操作員按WI要求設(shè)置分辨率trainoperatortosetresolutionaccordingtoWI,領(lǐng)班復(fù)核分辨率foremanreviewtheresolution,7,42,無none,,,,,,

,設(shè)定錯(cuò)誤wrongsetting,假點(diǎn)多、無法掃描toomanyfakeandfailtoscan,3,,未按工卡設(shè)定notsetaccordingtoMI,3,培訓(xùn)員工按工卡作業(yè)trainoperatortooperateaccordingtoMI,領(lǐng)班復(fù)核板厚設(shè)定foremanreviewtheboardthicknesssetting,7,63,無none,,,,,,

,材質(zhì)設(shè)定錯(cuò)誤wrongmaterialsetting,"無法掃描、漏掃描failtoscan,skipscan",5,,操作員疏忽設(shè)定錯(cuò)誤operatorwrongsettingbymistake,2,"①、培訓(xùn)員工按要求設(shè)定材質(zhì)；②、定專人做測(cè)試資料及參數(shù)調(diào)整領(lǐng)班負(fù)責(zé)審核

①、trainoperatortosetmaterialperrequirement②、dedicateoperatortomaketestingdataandparameteradjustment,thenforemanre-check",領(lǐng)班復(fù)核材質(zhì)設(shè)定foremanreviewthematerialsetting,7,70,無none,,,,,,

掃描：使用計(jì)算機(jī)分析CAD數(shù)據(jù)與實(shí)際掃描數(shù)據(jù)之間的差異，以找出缺陷Scan:analysethediscrepancybetweentheCADdataandtheactualscandatabyusingcomputertodetectdefects,缺點(diǎn)面積過大defectareaistoolarge,漏掃描skipscan,5,,更換料號(hào)或新料號(hào)時(shí)缺點(diǎn)面積初始化，員工未發(fā)現(xiàn)operatordon’tfindoutthedefectareainitializationwhenpartnumberchangeornewpartnumber,3,培訓(xùn)員工在更新料號(hào)時(shí)必須確認(rèn)面積值trainoperatortoverifytheareavaluewhenchangepartnumber,領(lǐng)班復(fù)核缺點(diǎn)面積設(shè)定foremanreviewthesettingofdefectarea,7,105,指定專人做資料dedicateoperatortomakedata,生產(chǎn)部prod.Dept.2016.6.30,指定專人做資料dedicateoperatortomakedata,5,2,7,70

,缺點(diǎn)面積過小defectareaistoosmall,假點(diǎn)多掃描效率低lowefficiencyduetotoomanyfake,3,,,,,,,63,無none,,,,,,

,定位問題未及時(shí)反饋notfeedbacktimelyaboutfixedlocationproblem,批量不良產(chǎn)生poorqualityoccursbybatches,5,,操作員未按要求及時(shí)反饋operatordon'tfeedbackproblemtimelyasrequired,2,要求員工必須及時(shí)反饋定位問題requireoperatortofeedbackfixedlocationproblemtimely,首件檢驗(yàn)記錄firstarticleinspectionrecord,5,50,"首件掃描做記錄，操作員看到記錄才可批量生產(chǎn)scanthefirstarticleandrecordit,onlyoperatorhavetherecordcanheputboardsintobatchproduction",生產(chǎn)部prod.Dept.2016.6.30,"首件掃描做記錄，操作員看到記錄才可批量生產(chǎn)scanthefirstarticleandrecordit,onlyoperatorhavetherecordcanheputboardsintobatchproduction",5,2,5,50

掃描：使用計(jì)算機(jī)分析CAD數(shù)據(jù)與實(shí)際掃描數(shù)據(jù)之間的差異，以找出缺陷Scan:analysethediscrepancybetweentheCADdataandtheactualscandatabyusingcomputertodetectdefects,漏做標(biāo)識(shí)missinglabel,"重復(fù)掃描，影響效率scanrepeatly,affectefficiency",5,,操作員疏忽漏做或錯(cuò)做標(biāo)識(shí)missinglabelduetooperator'smistakeorwronglabel,2,嚴(yán)格根據(jù)掃描編號(hào)在板邊做相應(yīng)的標(biāo)識(shí)markscanningnumberonboardedge,QC檢修時(shí)復(fù)核編號(hào)QCreviewthenumberwhenrepair,7,70,無none,,,,,,

,標(biāo)識(shí)錯(cuò)誤wronglabel,漏修理missingrepair,5,,,,,,,70,無none,,,,,,

,假點(diǎn)多toomanyfake,"測(cè)試時(shí)間長(zhǎng)，漏掃testtimeistoolong,missingscan",3,,板面垃圾sundriesonsurface,3,測(cè)試掃描前用粘塵轆清潔板面cleanboardsurfacewithstickyrollerspriortoscanning,目視自檢self-inspectionbyvisual,7,63,無none,,,,,,

,,,,,板面氧化oxideonsurface,3,測(cè)試掃描前先處理板面氧化treatsurfaceoxidepriortoscan,目視自檢self-inspectionbyvisual,7,63,無none,,,,,,

,,,,,參數(shù)設(shè)置不當(dāng)wrongparametersetting,2,根據(jù)最小線寬線距設(shè)定檢板分辨率（詳見WI）setinspectionresolutionbasedonmin.tracewidthandspace(refertoWIformoredetails),"操作員測(cè)試時(shí)自檢,領(lǐng)班審核operatorself-inspect,andforemanreviewit",7,42,無none,,,,,,

,漏掃描skipscan,"影響電性功能,嚴(yán)重造成報(bào)廢affectelectricityperformance,evenleadstoscrap",5,,掃描過程混板boardmixingduringscanning,3,已測(cè)試板和待測(cè)試板必須區(qū)分放置separatefinishedAOIboardsandwaitingforAOIboardsindifferentarea,每班檢查標(biāo)識(shí)與板是否對(duì)應(yīng)區(qū)分checkwhetherlabelsarerightforboardsseparationeveryshift,7,105,"已掃描的板用油性筆在板邊注明測(cè)試序號(hào)區(qū)分

marktestingserialnumberonthescannedboardedgewithgreasypen",生產(chǎn)部prod.Dept.2016.6.30,"已掃描的板用油性筆在板邊注明測(cè)試序號(hào)區(qū)分

marktestingserialnumberonthescannedboardedgewithgreasypen",5,2,7,70

,,,,,機(jī)器異常machineisabnormal,1,"①、同批板機(jī)臺(tái)相互進(jìn)行對(duì)比測(cè)試②、維修和廠商定期保養(yǎng)機(jī)器

①、comparisontestingforAOImachinewiththesamelotboards②、maintainingdepartmentandsuppliermaintainAOImachineperiodically",測(cè)試記錄testingrecord,6,30,無none,,,,,,

,,"影響做板品質(zhì)及電性能,嚴(yán)重造成報(bào)廢affectPCBqualityandelectricity,evenleadstoscrap",5,,參數(shù)不當(dāng)或工程資料和操作補(bǔ)償有誤unproperparameterorwrongengineeringdataandwrongoperatingcompensation,2,"定專人做測(cè)試資料及參數(shù)調(diào)整。領(lǐng)班負(fù)責(zé)審核dedicateoperatortomaketestingdataandparameteradjustment,thenforemanre-check",操作員測(cè)試時(shí)自檢operatorself-inspectionwhentesting,6,60,無none,,,,,,

"檢修：對(duì)AOI機(jī)掃描曝出的缺陷進(jìn)行分析和確認(rèn)，將OK板和待檢修板嚴(yán)格分開repair:analyseandverifythedefectsthatscannedbyAOI,andseparatetheOKboardsandwaitingrepairboardindifferentarea","檢修：對(duì)AOI機(jī)掃描曝出的缺陷進(jìn)行分析和確認(rèn)，將OK板和待檢修板嚴(yán)格分開repair:analyseandverifythedefectsthatscannedbyAOI,andseparatetheOKboardsandwaitingrepairboardindifferentarea",漏修理missingrepair,4,,操作員疏忽漏批號(hào)及時(shí)間標(biāo)識(shí)lotnumberandtimelabelmissingduetooperatormistake,2,在批量掃描之前先寫好批號(hào)及時(shí)間標(biāo)識(shí)recordthelotnumberandtimelabelpriortobatchscanning,QC檢修時(shí)復(fù)核QCreviewpriortorepair,7,56,無none,,,,,,

,未檢查板面序號(hào)notinspecttheboardserialnumber,漏修理missingrepair,5,,操作員未按要求檢查operatordon'thandleaccordingtorequirement,2,要求員工修理前先確認(rèn)板面序號(hào)requireoperatortochecktheserialnumberpriortorepair,操作員自檢、領(lǐng)班抽檢operatorself-inspectandforemanspot-check,7,70,無none,,,,,,

,判斷錯(cuò)誤wrongjudgement,漏修理造成報(bào)廢missingrepairleadstoscrap,5,,操作員對(duì)線路半成品檢驗(yàn)標(biāo)準(zhǔn)把握不準(zhǔn)確operatorisnotfamiliarwiththeinspectionstandardofPCB,2,"培訓(xùn)半成品標(biāo)準(zhǔn),對(duì)操作員進(jìn)行理論與實(shí)際操作的考核trainoperatoraboutPCBstandard,andassessthemwiththetheoryknowledgeandactualoperation",操作員自檢、領(lǐng)班抽檢operatorself-inspectandforemanspot-check,7,70,無none,,,,,,

,漏檢missinginspection,"做板品質(zhì)及電性能,嚴(yán)重造成報(bào)廢affectPCBqualityandelectricityperformance,evenleadstoscrap",5,,檢修過程混板boardmixingduringrepair,2,合格板和不合格測(cè)試必須區(qū)分放置separatetheOKboardsandnonconformityboardsindifferentarea,每班檢查標(biāo)識(shí)與板是否對(duì)應(yīng)區(qū)分checkwhetherlabelsarerightforboardsseparationeveryshift,7,70,無none,,,,,,

,,,,,操作技能和判定標(biāo)準(zhǔn)不熟悉operatorisnotskilledandisnotfamiliarwiththeacceptancestandard,2,AOI操作員培訓(xùn)上崗on-jobtrainingforAOIoperators,檢查是否有合格上崗證,6,60,無none,,,,,,

蝕檢inspection,擦花scratch,"開路,銅面劃傷open,scratchoncoppersurface",5,,板間沒有隔膠片notplasticfilmseparatedbetweenbo