PCB内层AOI检测PFMEA分析范例

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

过程潜在失效模式及后果分析,,,,,,,,,,,,,,,,,

（PFMEA）,,,,,,,,,,,,,,,,,

项目Item：,双面板/多层板double-side/multi-layersPCB,,,,FMEA编号FMEANo.：,,FMEA-D/F(I)-04,,"编制日期Peparedate：

2015-07-07",,,,"编制

Prepareby：",,,,

类型Type：,PCB,,,,关键日期KeyDate：,,,,"内容版本

contentVersion：B1",,,,"审批

Approvalby：",,,,

过程责任Responsibility,内层AOIinnerlayerAOI,,,,"修订日期

ModifyDate：",,2019/7/1,,工厂批准plantapproval：,,,,,,,,

核心小组coreteam：,,,,,,,,,,,,,,,,,

"1.如果客户有指定产品及过程特性符号，按客户要求标识；2.客户没有指定，则按如公司规定标识。产品特性符号表示:“◆”,过程特性符号表示:“▲”。classificationsymboldescription：1.marksymbolpercustomer'sspecificsymbol;2.ifnospecificsymbolfromcustomer，marksymbolasbelow:“◆”forproductspecialcharacteristic,and“▲”forprocessspec",,,,,,,,,,,,,,,,,

"过程

功能processfunction

要求

requirement","潜在失

效模式potentialfailuremode","潜在失

效后果potentialfailureeffect",严重度S,级别classification,"潜在失效

起因/机理potentialfailurecause/mechanism",频度O,"现行过程

控制预防currentprocesscontrolmethod","现行过程

控制探测

currentprocessdetection",探测度D,"R

P

N",建议措施adviceaction,责任及目标完成日期responsibility&duedate,措施结果actionresult,,,,

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

P

N"

调取资料：对型号、版本号核实inputdata:verifythepartnumberandversion,型号、版本与实测板不符合partnumberandversionisnotconsistantwiththewaitingAOIboards,"无法测试、效率低failtoAOI,lowefficiency",3,,操作员调错工程资料operatorinputthewrongengineeringdata,3,调工程资料按工卡版本号inputtheengineeringdataaccordingtoMI,调出资料后再核对工卡和资料的型号、版本号是否一致verifytheP/NandversionofinputdatawiththeonesinMI,6,54,无none,,,,,,

,,,,,工程部资料未更新操作员未核对engineeringdataisnotupdatedandisnotverifiedbyoperator,,,,,,无none,,,,,,

机器验证,设备异常无法确认,无法测试failtoAOI,3,,AOI室内参温湿度异常,2,按照WI要求管控温湿度,每4小时检查一次checkonceevery4hours,6,36,无none,,,,,,

,,,,,参数、设备异常,5,标准板扫描,每天均需用标准板对机器进行校验,5,75,无none,,,,,,

"参数设定：按工卡要求的补偿系数，最小线宽线距，板厚等设置分辨率及其它测试条件parametersetup:setparameterslikecompensatecoefficient,min.tracewidth/clearance,boardthickness,resolutionandothertestingconditionetc.",公差太大deviationistoolarge,缺口和线突漏扫skipscanthedefectofnickandtraceprotruding,5,,未按工卡公差计算notcompensateaccordingtothemanufacturinginstruction,2,计算补偿前核对工卡要求的公差值checkcompensatevalueonMIrequirementbeforecalculateitscompensation,领班复核资料foremanreviewthedata,7,70,无none,,,,,,

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

,分辨率过大resolutionistoohigh,"缺口、线突、开短路漏扫描skipscanthedefectofnick,traceprotruding,openandshort",5,,未按WI要求设置分辨率notsetresolutionaccordingtoWI,2,培训操作员按WI要求设置分辨率trainoperatortosetresolutionaccordingtoWI,领班复核分辨率foremanreviewtheresolution,7,70,无none,,,,,,

,分辨率过小resolutionistoolow,效率低lowefficiency,3,,未按WI要求设置分辨率notsetresolutionaccordingtoWI,3,培训操作员按WI要求设置分辨率trainoperatortosetresolutionaccordingtoWI,领班复核分辨率foremanreviewtheresolution,7,42,无none,,,,,,

,设定错误wrongsetting,假点多、无法扫描toomanyfakeandfailtoscan,3,,未按工卡设定notsetaccordingtoMI,3,培训员工按工卡作业trainoperatortooperateaccordingtoMI,领班复核板厚设定foremanreviewtheboardthicknesssetting,7,63,无none,,,,,,

,材质设定错误wrongmaterialsetting,"无法扫描、漏扫描failtoscan,skipscan",5,,操作员疏忽设定错误operatorwrongsettingbymistake,2,"①、培训员工按要求设定材质；②、定专人做测试资料及参数调整领班负责审核

①、trainoperatortosetmaterialperrequirement②、dedicateoperatortomaketestingdataandparameteradjustment,thenforemanre-check",领班复核材质设定foremanreviewthematerialsetting,7,70,无none,,,,,,

扫描：使用计算机分析CAD数据与实际扫描数据之间的差异，以找出缺陷Scan:analysethediscrepancybetweentheCADdataandtheactualscandatabyusingcomputertodetectdefects,缺点面积过大defectareaistoolarge,漏扫描skipscan,5,,更换料号或新料号时缺点面积初始化，员工未发现operatordon’tfindoutthedefectareainitializationwhenpartnumberchangeornewpartnumber,3,培训员工在更新料号时必须确认面积值trainoperatortoverifytheareavaluewhenchangepartnumber,领班复核缺点面积设定foremanreviewthesettingofdefectarea,7,105,指定专人做资料dedicateoperatortomakedata,生产部prod.Dept.2016.6.30,指定专人做资料dedicateoperatortomakedata,5,2,7,70

,缺点面积过小defectareaistoosmall,假点多扫描效率低lowefficiencyduetotoomanyfake,3,,,,,,,63,无none,,,,,,

,定位问题未及时反馈notfeedbacktimelyaboutfixedlocationproblem,批量不良产生poorqualityoccursbybatches,5,,操作员未按要求及时反馈operatordon'tfeedbackproblemtimelyasrequired,2,要求员工必须及时反馈定位问题requireoperatortofeedbackfixedlocationproblemtimely,首件检验记录firstarticleinspectionrecord,5,50,"首件扫描做记录，操作员看到记录才可批量生产scanthefirstarticleandrecordit,onlyoperatorhavetherecordcanheputboardsintobatchproduction",生产部prod.Dept.2016.6.30,"首件扫描做记录，操作员看到记录才可批量生产scanthefirstarticleandrecordit,onlyoperatorhavetherecordcanheputboardsintobatchproduction",5,2,5,50

扫描：使用计算机分析CAD数据与实际扫描数据之间的差异，以找出缺陷Scan:analysethediscrepancybetweentheCADdataandtheactualscandatabyusingcomputertodetectdefects,漏做标识missinglabel,"重复扫描，影响效率scanrepeatly,affectefficiency",5,,操作员疏忽漏做或错做标识missinglabelduetooperator'smistakeorwronglabel,2,严格根据扫描编号在板边做相应的标识markscanningnumberonboardedge,QC检修时复核编号QCreviewthenumberwhenrepair,7,70,无none,,,,,,

,标识错误wronglabel,漏修理missingrepair,5,,,,,,,70,无none,,,,,,

,假点多toomanyfake,"测试时间长，漏扫testtimeistoolong,missingscan",3,,板面垃圾sundriesonsurface,3,测试扫描前用粘尘辘清洁板面cleanboardsurfacewithstickyrollerspriortoscanning,目视自检self-inspectionbyvisual,7,63,无none,,,,,,

,,,,,板面氧化oxideonsurface,3,测试扫描前先处理板面氧化treatsurfaceoxidepriortoscan,目视自检self-inspectionbyvisual,7,63,无none,,,,,,

,,,,,参数设置不当wrongparametersetting,2,根据最小线宽线距设定检板分辨率（详见WI）setinspectionresolutionbasedonmin.tracewidthandspace(refertoWIformoredetails),"操作员测试时自检,领班审核operatorself-inspect,andforemanreviewit",7,42,无none,,,,,,

,漏扫描skipscan,"影响电性功能,严重造成报废affectelectricityperformance,evenleadstoscrap",5,,扫描过程混板boardmixingduringscanning,3,已测试板和待测试板必须区分放置separatefinishedAOIboardsandwaitingforAOIboardsindifferentarea,每班检查标识与板是否对应区分checkwhetherlabelsarerightforboardsseparationeveryshift,7,105,"已扫描的板用油性笔在板边注明测试序号区分

marktestingserialnumberonthescannedboardedgewithgreasypen",生产部prod.Dept.2016.6.30,"已扫描的板用油性笔在板边注明测试序号区分

marktestingserialnumberonthescannedboardedgewithgreasypen",5,2,7,70

,,,,,机器异常machineisabnormal,1,"①、同批板机台相互进行对比测试②、维修和厂商定期保养机器

①、comparisontestingforAOImachinewiththesamelotboards②、maintainingdepartmentandsuppliermaintainAOImachineperiodically",测试记录testingrecord,6,30,无none,,,,,,

,,"影响做板品质及电性能,严重造成报废affectPCBqualityandelectricity,evenleadstoscrap",5,,参数不当或工程资料和操作补偿有误unproperparameterorwrongengineeringdataandwrongoperatingcompensation,2,"定专人做测试资料及参数调整。领班负责审核dedicateoperatortomaketestingdataandparameteradjustment,thenforemanre-check",操作员测试时自检operatorself-inspectionwhentesting,6,60,无none,,,,,,

"检修：对AOI机扫描曝出的缺陷进行分析和确认，将OK板和待检修板严格分开repair:analyseandverifythedefectsthatscannedbyAOI,andseparatetheOKboardsandwaitingrepairboardindifferentarea","检修：对AOI机扫描曝出的缺陷进行分析和确认，将OK板和待检修板严格分开repair:analyseandverifythedefectsthatscannedbyAOI,andseparatetheOKboardsandwaitingrepairboardindifferentarea",漏修理missingrepair,4,,操作员疏忽漏批号及时间标识lotnumberandtimelabelmissingduetooperatormistake,2,在批量扫描之前先写好批号及时间标识recordthelotnumberandtimelabelpriortobatchscanning,QC检修时复核QCreviewpriortorepair,7,56,无none,,,,,,

,未检查板面序号notinspecttheboardserialnumber,漏修理missingrepair,5,,操作员未按要求检查operatordon'thandleaccordingtorequirement,2,要求员工修理前先确认板面序号requireoperatortochecktheserialnumberpriortorepair,操作员自检、领班抽检operatorself-inspectandforemanspot-check,7,70,无none,,,,,,

,判断错误wrongjudgement,漏修理造成报废missingrepairleadstoscrap,5,,操作员对线路半成品检验标准把握不准确operatorisnotfamiliarwiththeinspectionstandardofPCB,2,"培训半成品标准,对操作员进行理论与实际操作的考核trainoperatoraboutPCBstandard,andassessthemwiththetheoryknowledgeandactualoperation",操作员自检、领班抽检operatorself-inspectandforemanspot-check,7,70,无none,,,,,,

,漏检missinginspection,"做板品质及电性能,严重造成报废affectPCBqualityandelectricityperformance,evenleadstoscrap",5,,检修过程混板boardmixingduringrepair,2,合格板和不合格测试必须区分放置separatetheOKboardsandnonconformityboardsindifferentarea,每班检查标识与板是否对应区分checkwhetherlabelsarerightforboardsseparationeveryshift,7,70,无none,,,,,,

,,,,,操作技能和判定标准不熟悉operatorisnotskilledandisnotfamiliarwiththeacceptancestandard,2,AOI操作员培训上岗on-jobtrainingforAOIoperators,检查是否有合格上岗证,6,60,无none,,,,,,

蚀检inspection,擦花scratch,"开路,铜面划伤open,scratchoncoppersurface",5,,板间没有隔胶片notplasticfilmseparatedbetweenbo