creative tool
System Functional Model, also known as Function Modeling, is a popular problem-solving tool that helps us to model a problem using functional language and identify problematic and functional components. Functional modeling helps us to think within the scope of components and their functions instead of the system as a whole.
As part of many problem-solving projects, it is extremely important to understand the functional interactions between different components of the systems that you are analyzing. Functional modeling allows us to quickly describe and map the functionality of all components contributing to the final product or service of that system. The functional modeling tool is applicable to both sudden unpredictable deviations (also known as excursions) and solving chronic problems for consistent improvements.
Among many cases when Functional Modeling is useful for us as problem solvers and innovators, we want to highlight just a few:
Functional modeling offers several distinct advantages for problem solvers and innovators. By breaking down complex systems into manageable components, it allows for a more granular analysis of each part’s role and effectiveness. This methodical approach makes it easier to identify inefficiencies and opportunities for improvement. Additionally, functional modeling promotes a deeper understanding of the interplay between various system components, which is crucial for developing robust solutions.
Functional modeling is versatile and can be applied across various industries. For instance, in manufacturing, it can help identify which machinery or processes are most critical to production and where bottlenecks occur. In software development, functional modeling can pinpoint which modules or features are causing performance issues. By addressing these specific areas, organizations can streamline operations, reduce costs, and enhance overall product quality.
To dive deeper into the principles and applications of functional modeling, visit our comprehensive guide on functional modeling. This resource provides detailed insights, practical examples, and expert tips to help you master this powerful problem-solving tool. Whether you’re dealing with sudden deviations or chronic issues, functional modeling can equip you with the strategies needed for effective analysis and resolution.
By understanding and leveraging the capabilities of functional modeling, you can transform the way you approach problem-solving, leading to more innovative and efficient solutions.
Wet cleaning is widely used in microchip manufacturing. Single wafer equipment is working as follows. A wafer rotates, and chemistry is poured from a movable nozzle. Water rinsing is performed at the end of the process. Loading of a new batch of the chemistry resulted in excursion - a strongly increased amount of defects was observed on the wafer after the processing. The project is dedicated to the failure analysis and creation of innovative solutions.
The process is related to microelectronics - microchip manufacturing.The purpose of the process is to create a SiO2 layer on the surface of a Si wafer. Equipment: Vertical furnace to heat the wafers in the Q2 atmosphere and perform oxidation on the wafer surface. Process: The oxidation occurs on the front side and on the back side of the wafer Requirements: Create a SiO2 thin layer with a certain thickness and low sigma - low standard deviation of the thickness between the wafers and within the waferFailure: Wafers from the lower zone have higher thickness and significantly higher within wafer sigma (standard deviation of the thickness within the wafer)
An example of how to make task prioritization with Urgency - Important Matrix (UMI) using the PRIZ Innovation Platform
The vacuum cleaner problem is an excellent example showing how to manage and resolve excursion - unexpected deviation from normal operation. Read, learn and use the platform for resolving of your excursions.
The vacuum furnace is used for sintering parts made of metal powder. To keep the shape of the parts, a binder is used. The main problem is that the vacuum furnace becomes dirty and needs a very long cleaning. Regular washing was not successful. We investigated the process and found that washing should be dedicated to the conversion of the material into a form that results in the formation of gases having low temperature of the condensation
Chilled water is used for production equipment cooling. Suddenly pH of the water started to drop. The aim of the project is to analyze the issue, understand the root cause, and propose solutions to the problem.
To reduce high turnover at the plant the managers propose different ideas, but it does not help. All proposed solutions are good, but there are some of them that are blocking the effectiveness of the rest of the solutions. The purpose of the project is to analyze the proposed solutions (perceptions) and define the blocked. The solutions with high blocking rank should be completed first to ensure the effectiveness of the rest of the ideas. The Perception Mapping (PMap) creative thinking tool was used for the blockers definition.
Flash heating of a wafer is widely used in microchip manufacturing. The purpose of the process is to prevent the diffusion of ions and atoms. During the flash process, a wafer breakage occurs. The project's purpose is to learn and understand the mechanism of the wafer breakage and propose the solutions to prevent the wafer breakage
