製程失效模式與效應分析(Process Failure Mode and Effects Analysis, PFMEA)是屬於失效模式與效應分析(Failure Mode and Effects Analysis, FMEA)中專門用來分析產品在生產過程中潛在的失效模式,並且對所造成的失效效應,提出適當的製程改善活動,預先防止問題發生及不良現像再現,目前國內專業電子製造服務(Electronics Manufacturing Services, EMS)產業面對客戶品質要求愈來愈高,非常需要了解如何降低產品在生產各階段的不良率。 國內目前對於研究PFMEA推行過程的相關文獻不多,很少有詳細的作業流程說明,本研究匯整PFMEA的要求及配合EMS產業的作業模式,發展出一套PFMEA作業模型,並透過實際案例解說如何運用此模型,經由研究結果顯示,本研究的個案廠商在運用後,可明顯降低製程風險優先指數至可控制範圍,並增進人員的製程控制能力,縮短產品開發時間及節省成本,提昇產品的品質及可靠度。
Process Failure Mode and Effects Analysis (PFMEA) is one of the critical Failure Mode and Effects Analysis techniques specifically focus on the potential failure mode analysis of producing a product and provides appropriate process improvement and prevents the occurrence of possible defects and problems. Electronics Manufacturing Services (EMS) industry needs to understand on how to resolve the defect rate generating from various manufacturing phases in order to meet and fulfill the customers on the high-quality demand. There are only few relevant studies in regard to the PFMEA and none of them have a brief and detailed description of how the processes/procedures are worked. This study is focused on developing a PFMEA operational model which complied and aligned with the spirit of PFMEA standards/guidelines and uses the real industrial cases to explain how the model works. The research results show that case study does not only reduce the risk priority number to a certain controllable level, but also prove a significant improvement/enhancement in both manufacturing process control and product quality especially in shorten product development life cycle and cost savings.