08 Mar 2025 Physical Function Analysis for manufacturing processes
Background
In recent years a lot of production issues happend, as the process engineers did not have resources to fully dig down into the physics and understand all interactions going on within the production line. Therefore we developed a concept known as Physical Function Analysis – PFA. It helps to understand the physics behind each process and thereby create robust processes. In case of issues, troubleshooting can be done much faster with a solid understanding of the phyiscs going on.
Physical Function Analysis (PFA): Definition
Physical Function Analysis is a structured method used to systematically break down technical systems or processes into fundamental physical phenomena and principles (e.g., energy transfers, material flows, physical interactions). This analysis decrypts how a system operates at a physical level. This fundamental understand is the base to develop and improve manufacutring procesess. Phenomena such as the sudden appearance of manufacturing defects and their equally sudden disappearance without any changes being made to the process can be explained in this method.
Objectives of Physical Function Analysis:
- Understand technical processes or systems at a fundamental physical level.
- Visualize and quantify physical phenomena (energy transfer, heat conduction, fluid dynamics, etc.).
- Identify critical points for optimization and improvement based on physical laws.
- Provide an objective basis for decision-making and process improvements.
Physical Function Analysis focuses on the laws of physics:
- Energy types and transfers: (thermal, mechanical, electrical, chemical, hydraulic, pneumatic)
- Material flows: (mass transfer, chemical reactions, phase changes)
- Physical effects: (conduction, convection, radiation, friction, diffusion, electromagnetic effects, etc.)
Step-by-step approach of Physical Function Analysis:
1. Define the system
Define system boundaries, inputs (e.g., energy, material) and outputs (product, waste, heat).
2. Identify physical phenomena
Break down each step into it’s fundamental physics (e.g., conduction, convection, melting, etc.).
3. Create functional diagrams
Visualize the energy and material flows clearly, using diagrams to show relationships between physical effects.
4. Quantify relevant physical parameters
Use physical equations and laws (e.g., Fourier’s law, Newton’s law of cooling, energy balance equations) to quantify system behavior.
5. Analyze and interpret
Identification of critical process parameters and their progression or setting (e.g. temperature curve).
Practical Example: Soldering Process
| Process Step | Physical Effects | Relevant Physical Parameters |
|---|---|---|
| Heat application | Heat transfer by convection | Convection coefficient, heat flux, temperature |
| Heat conduction in part | Heat conduction | Thermal conductivity, thermal mass, temperature gradient within the part |
| Solder melting | Phase change (solid to liquid) | Melting point, latent heat |
| Cooling & solidification | Heat loss (convection, radiation) | Heat transfer coefficients, thermal mass, environment temperature |
Advantages of Physical Function Analysis:
- Clear and systematic understanding of physical processes within a production process
- Identification of critical process parameters and their charateristics
- Quantitative, traceable, and objective basis for process, machine or system optimization
- Structured documentation for issue prevention and faster trouble shooting
Understanding the physics behind a process is a game changer! It improves the adoption to other processes, lines and factories. Troubleshooting will be acellerated and a lot of issues will be gone forever.
Ideal Applications:
- Manufacturing and industrial processes (e.g., sintering, soldering, molding, welding, wire bonding)
- Process optimization and efficiency improvements
- Product development & quality management
- Troubleshooting and root-cause analysis of production issues
Comparision to other methods such as TRIZ:
TRIZ (Theory of Inventive Problem Solving) is a method to guide developers at solving problems, primarily in technical and engineering fields. It is based on the principle that problems and their solutions follow certain universal patterns. TRIZ provides tools such as contradiction matrices, 40 inventive principles, and algorithms (e.g., ARIZ) to solve technical challenging tasks and generate creative solutions. The knowledge was drawn from analyzing a lot of patents and inventions.
While TRIZ is primarily aimed at resolving technical contradictions through creative and universal principles, Physical Function Analysis (PFA) focuses on breaking down a process or system into fundamental physical phenomena (such as heat transfer, fluid dynamics, energy transformations).
In contrast to the inventive nature of TRIZ, PFA is analytical, quantitative, and aims for a deeper physical understanding and optimization of system performance. It does not inherently provide creative solutions but rather identifies critical physical interactions and parameters that can be optimized.
In short:
- TRIZ: Creative, contradiction-focused, qualitative, innovative problem-solving.
- PFA: Analytical, physics-based, quantitative, detailed process understanding and optimization.
Comparison: TRIZ vs. Physical Function Analysis (PFA)
| Feature | TRIZ (Theory of Inventive Problem Solving) | Physical Function Analysis (PFA) |
|---|---|---|
| Core Idea | Systematic innovation methodology that solves technical problems by applying universal principles and strategies. | Methodical decomposition of systems/processes into fundamental physical principles and phenomena. |
| Primary Objective | Generation of innovative ideas, resolving contradictions, and improving technical systems. | Understanding and optimization of technical systems based on physical interactions and principles. |
| Focus | Resolving technical contradictions using established inventive principles. | Structured analysis of physical functions, energy flows, and material exchanges within systems. |
| Typical Approach | Define problem → Identify contradictions → Apply TRIZ matrix → Generate innovative solutions | Define system boundaries → Identify physical effects → Develop energy/material flow diagrams → Quantitative analysis |
| Tools & Elements |
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| Type of Solution Approach | Qualitative, innovative, often intuitive, leveraging general inventive principles | Quantitative, analytical, structured, based firmly on physical laws |
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| Limitations & Disadvantages |
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| Optimal Application Situation | Ideal for scenarios prioritizing innovation, creativity, and quick generation of breakthrough ideas. | Ideal when precise physical understanding, quantitative analysis, and optimization are required. |
Summary in Short:
Physical Function Analysis (PFA) breaks down technical systems or processes into fundamental pyhsics. It enables quantitative and objective analysis that supports optimization and decision-making.
Ideal for engineers aiming for detailed analysis, systematic improvement, and deep understanding of manufacturing processes or technical systems.