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uk

Successful Failure Mode and Effect Analysis (FMEA)

Simon Mills
Director of Training Services AV Technology Ltd

AV Technology Ltd

02.2012

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Introduction
FMEAs and other maintenance optimisation
processes can generate huge amounts of data Its important to keep these processes manageable, for example:
Ask questions which can easily be answered Use engineering approximations where possible Limit the depth of investigations

This module outlines how to carry out FMEAs

and achieve successful results and real benefits
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Objectives

Contents

Pre-Requirements

What youre responsible for, & what your deliverables are What information you need up front Keep it Simple (KISS) How to make approximations Easy and hard ways Best Practice & Key References Outputs & Deliverables E.g. Optimised Maintenance Plan Examples

Simplified Methodology

Practical Processes

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Objectives
Review design and operation of chosen
equipment Review failure history & failure modes Review current maintenance Agree failure mode criticalities Assign optimised maintenance tasks / frequencies & owners Produce a revised maintenance plan for the selected asset(s)
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Pre-Requirements
To assist in the FMEA, examples of the following
information are useful to support the review on the selected Pilot Area/Equipment:
General layout and schematics O&M Manuals for the selected equipment Any operator checks for the selected equipment List of current maintenance inspections (with history) Latest listing of plant breakdown history O&M logbooks referring to plant operation Listings of spares usage
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Simplified FMEA Best Practice

ISO 17359:2011 Condition monitoring and
diagnostics of machines General guidelines. New 2nd Edition
Incorporates ISO 13380 Condition Monitoring and Diagnostics of Machines using performance parameters Adds 9 tables of different machine type FMEAs

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ISO 17359:2011 CM Procedure

The latest issue now has 8 key steps for bestpractice implementation of CM:
Cost benefit analysis Equipment audit Reliability and criticality audit Select appropriate maintenance strategy Select monitoring method Data acquisition and analysis Determine maintenance action Review
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Additional Machine Type Examples

ISO 17359:2011 now includes nine different machine types Examples of fault and symptom diagrams are now
included for the following machine types:
Electric motor Steam turbine Aero gas turbine Industrial gas turbine Pump Compressor Electric generator Rotary internal combustion engine Fan
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with typical examples of fault and failure modes with associated symptoms and measurement parameters.

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For each of the machine

types, the revised ISO 17359 gives a matrix of 27 applicable CM & Performance measurement parameters
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For each machine type there

is a table with:
A selection of faults and A range of measureable symptoms / parameters
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Practical FMEA
A full reliability-centred maintenance process
can generate huge amounts of data Its important to keep the process manageable
Ask questions which can easily be answered Use engineering approximations Use simple understandable models

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KISS Tips
FMEAs should be kept as simple as possible. FMEAs should be easily carried out. FMEAs should be quantifiable.
Over complication is rarely a good idea so FMEAs should be kept as simple as possible to both evaluate and understand. The easier it is to do, the more likelihood of the FMEA data being available at timely intervals and on an on-going basis Both Objective and Subjective data must always be quantified. FMEAs should always be completed in a relatively short time so as to limit the load on personnel.

FMEAs should be done in a short time.

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KISS Tips
FMEAs should be understandable by the whole
maintenance team
This ensures engagement of all team members, and encourages participation

FMEAs should be reviewed or subject to

continuous improvement

FMEAs should be communicated in an

As business needs and techniques change then so should the FMEAs which support them

appropriate manner to all sections of the workforce

A key to driving improvement is the effective communication of progress to the very people who are making it happen

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Typical FMECA Tools

Identify process Itemise components and connections Produce system level block diagrams Process Flow Diagram Reliability Block Diagram Asset Criticality Pareto Asset MTTR / Events / MTBF Availability
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Limiting the depth of an FMEA

Keep choices simple at every level
Asset Type Asset Configuration Asset Local Performance Requirements Top 10 faults and failure modes Preferred maintenance/CM technique Match frequency to LTTF Technique fault detectability & confidence Output is maintenance plan
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Making FMEAs Manageable

We should concentrate on:

known facts about the asset expected failure modes
Examples of Easy Facts
Motor Driven Pump Open Drive with Coupling Rolling element bearings Motor label Speed / Power
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Examples of Difficult Facts

No. of rotor bars Coupling No. of teeth or bolts Bearing make, size and number of balls Pump impeller number of vanes
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Example
Estimate of How Many Maintainable Assets? Number of Key Asset Types (Variants) First Estimate Criticality [A, B, C]
A: Important B: Routine C: Ad Hoc (As and when)
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E.g. Total 2500

Rotating, Static, Electrical Typically Max 30 per site

Simple Criticality Review

Use consequence cards or
spreadsheet Include relevant factors
Operational Availability Maintainability Quality Health and Safety Environment

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Example Asset Types (Typically Max 30)

Motor Driven Fan Motor Driven Pump Compressors Conveyor Mixer/Blender Chillers Tanks etc
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Example Asset Components

Ref 1 2 3 4 5 6 7 8 9 10 Component Bearing Cable Coupling Drive Belt Electric Motor Fan Rotor Filter Gearbox Mount Pulley
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Ref 11 12 13 14 15 16 17 18 19 20

Component Pump Impeller Seal Valve etc

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Example
Asset Type Configuration
Pump 1430 rpm 18kW Open drive coupled

Local Performance
Requirements

Cooling Water 5 Deg C Downtime < 5%

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Example of Top 10 Faults

Top faults and failure modes
Unbalance Misalignment Looseness Lack of Lubrication Bearing Damage Leaks Motor overload Impeller erosion/damage Seal Leaks Corrosion
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Workshop Examples of FMEAs

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Importance of Local History

Sources
Operator Log Books Fault Reporting Work Orders CMMS Local Staff

Actual failure rates, MTBF, MTTR Actual Lead Time to Failure (LTTF)
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Assemble FMEA Data

Assemble the following for the selected asset
type
Asset Components Failure Modes Warning Effects Root Causes Task, Periodicity, Skill

For example:AV Technology Ltd 02.2012

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Maintenance Planning & Management

Most tasks can have estimated time & skill Needs to be managed and scheduled
Schedule inspections CBM / PdM Measurements Dont just say Completed
Better to add Completed no faults found Or Completed following faults found
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FMEA sets requirements for techniques CBM / PdM, PPM, Lube, Casual Inspections etc

Feedback needs to be short but useful

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Create the Maintenance Plan

Assemble Tasks Allocate Resources Carry out Maintenance Feedback History

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Key Points
Important to keep process
manageable Ask questions which can easily be answered Focus on known failure modes Use approximations Use simple understandable models

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References
ISO 17359:2011, Condition monitoring and diagnostics of machines Developing a Maintenance Strategy and Setting Performance Targets,
Simon Mills
Presented at Maintec 2008 Published in ME Maintenance & Asset Management, Vol 23 no 5, Sept/Oct 2008 Presented at Maintec 2010 Presented at Maintec 2011 British Standards web site www.bsigroup.com ISO web site www.iso.org AV Technology Ltd www.avtechnology.co.uk

General guidelines

Understanding Maintenance Key Performance Indicators, Simon Mills Key Steps to Implementing Condition-Based Maintenance, Simon Mills Websites

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