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Failure Mode and Effect Analysis

Lecture 2-2
Fault Tree Analysis
Reliability
System, Concept FMEA
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FMEA
Fault Tree Analysis
Same basic approach as the Root Cause
Analysis
Allows a backward approach to
systematically identify potential causes of
failures
Provides an overview of interrelationships
between causes and effects
Breaks down failures into more detail
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FMEA
Fault Tree Analysis
A logical, structured process that can help
identify potential causes of system failure
before the failures actually occur
Benefits
Identify possible system reliability or safety problems
at design time,
Assess system reliability or safety during operation
identify components that may need testing or more
rigorous quality assurance scrutiny,
Identify root causes of system failures
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FMEA
When to Apply FTA
Applied any time during the life of a
plant, system, subsystem, or equipment
item
Primarily used to examine incidents or
accidents whose consequences would
be classified as catastrophic
Often initiated after a major hazard has
been recognized for the first time
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FMEA
How FTA is Used
Fault trees are used to determine the
frequency of top events for which
historic data is not available or
applicable
Once the top event is defined, the fauslt
tree is constructed by working
downwards through the system, one
level at a time, to determine what
failures could occur which could lead to
the top event
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FMEA
FTA and FMEA Compared
Different basic purpose, or focus
FTA focus on failure outcome
Examines the applicable components, processes
and conditions retroactively to identify all possible
contributing factors that could have worked alone
or in combination to cause the outcome
FMEA focus on each system component,
and examines before-the-fact all things that
could possible go wrong with that component.
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FMEA
Example
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FMEA
What is Reliability?
PERCEIVED
RISK
Competition
Market Pressure
Management Emphasis
Customer
Requirements
Legal,
Statutory
Safety
Warranty and
Service Costs
Public
Liability
Development
Risks
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FMEA
Definition of Reliability
The probability that a system or
product will perform in a satisfactory
manner for a given period of time
when used under specified operating
conditions.
elements of reliability,
satisfactory performance,
time,
specified operating conditions.
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FMEA Reliability - Tasks
Reliability program plan
monitor and control of
subcontractors & suppliers
Program reviews
Failure reporting, analysis, corrective
action system (FRACAS)
Reliability modeling, allocations,
prediction
source: MIL-STD-785B, 1980
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FMEA Reliability - Tasks
Failure Mode Effect & Criticality
Analysis (FMECA)
Tolerance analysis
Effects of functional testing, handling,
packaging, transportation, and
maintenance
Environmental stress screening (ESS)
Reliability Qualification Test (RQT)
Production Reliability Acceptance Test
(PRAT)
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FMEA
Quantification of Reliability
Establishing reliability
requirements or objectives
Apportionment (budgeting)
Prediction
Analysis
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FMEA
Design Testing
Performance
Environmental
Stress
Reliability
Maintainability
Life
Pilot Run
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FMEA
Reliability Program Issues
Define a reliability program
Develop goals and requirements
Design for Reliabilty
Assess reliability Progress
Measure product reliability
Ensure reliable performance
source: RAC Blueprint
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FMEA
Product Life
During the life of a product, failure occur in a
predictable pattern known as a bathtub
curve.
The curve can be divided into three regions:
Wearout
(End of Life)
Early Life Failure
(Infant Mortality)
Useful Life
(Constant Failure Rate)
Time
F
a
i
l
u
r
e
s
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FMEA
FMEA and Product Life
By eliminating failure modes, FMEA
Improves the reliability of the product
Reduces the number of product failures
experienced by the customer
Wearout
(End of Life)
Early Life Failure
(Infant Mortality)
Useful Life
(Constant Failure Rate)
Time
F
a
i
l
u
r
e
s
FMEA improves product
performance
in all three areas
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FMEA
1. Develop a Strategy
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Teams will be establishedto evaluatethe applicationof FMEA inareas shownbythe
shadingonthe followingdiagram. Each" FMEA" Teamunder thedirectionof the FMEA
Facilitator will:
- ESTABLISHa strategyfocusingonnewtechnology, pastissues, newor redesigned
components, bothfromthe product(design) andprocess perspectives..
- PREPARE a DesignandaProcess FMEA for the selectedcomponents or
subassemblies..
- DETERMINE functions, potential failure modes, effects, causes, andverification
activities plannedor in-place..
- RECOMMEND correctiveactions to theproductteam..
FIRST PRIORITY
SECOND PRIORITY
THIRD PRIORITY
Basic Steps
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FMEA
Planning
APPLICATION
NEW TECHNOLOGIES
COMPLEXITY
RESOURCES
It would very costly to apply FMEA to
every part. When planning for FMEA, consider:
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FMEA
1. Develop a Strategy
2. Review the design
/process
EFFECT
CAUSES
Basic Steps
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FMEA
Review the Process
Design
Drawings
Specifications
Bill of material
Process
Flow process chart
Operator work instructions
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
Basic Steps
The task that the system, process,
component subsystem or service must
perform
Very important in understanding the
entire FMEA process
Must be communicated in a concise and
easily understood manner
Use active verbs to describe the function
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FMEA
FMEA is Function-driven
FMEA begins with a definition of the FUNCTIONS an
item or process step is supposed to perform. The
inputs must come from several sources to be
effective:
Manufacturing
Engineer
Supplier
Quality
Reliability
Engineer
Design
Engineer
Project
Manager
Production
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FMEA
Functions/Features - Example
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential
failure modes
functions
failure modes
Basic Steps
The inability of the system, design,
process or service to perform based on
design intent.
Failures that do not meet customer
requirements
Consider both known and potential
failures
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FMEA
Failure to perform a defined
function
Something occurring that you
don't expect, or want
Wrong application
A Failure Mode is . . .
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential failure modes
5. Organize potential failure
modes
topic topic
Affinity Diagram
Basic Steps
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential failure modes
5. Organize potential failure modes
6. Analyze potential failure modes
PRODUCT: FMEA NO.
PROCESS/OPERATION: PAGE OF
DESIGN (OR PROCESS) FMEA
PLANNINGREFERENCE: DATE: BY:
OklahomaCity
POTENTIAL POTENTIAL S POTENTIAL O CURRENT D RPN ACTION CORRECTIVE RESPONSIBILITY ACTION RESULTING
FUNCTION FAILURE MODE EFFECTSOF CAUSE(S) OF CONTROLS PRIORITY ACTION & DATE DUE TAKEN
FAILURE FAILURE S O D RPN
DETECTION OCCURRENCE SEVERITY RPN =SxOxD
Basic Steps
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential failure modes
5. Organize potential failure modes
6. Analyze potential failure modes
7. Establish risk priority
VITAL
FEW
TRIVIAL
MANY
Basic Steps
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential failure modes
5. Organize potential failure modes
6. Analyze potential failure modes
7. Establish risk priority
8. Take action to reduce risk
Basic Steps
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential failure modes
5. Organize potential failure modes
6. Analyze potential failure modes
7. Establish risk priority
8. Take action to reduce risk
9. Calculate resulting risk
Basic Steps
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FMEA
1. Develop a Strategy
2. Review the design /process
3. List functions
4. Brainstorm potential failure modes
5. Organize potential failure modes
6. Analyze potential failure modes
7. Establish risk priority
8. Take action to reduce risk
9. Calculate resulting RPNs
10. Follow up
Basic Steps
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FMEA
System FMEA
1. Transform an operational need into a
description of system performance
parameters
2. Integrate related technical parameters
and assure compatibility of:
Physical
Functional Interfaces
Program
To optimize the total system design and
definition
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FMEA
System (Concept) FMEA
Goal: define and demonstrate a proper
balance among operational and
economic factors
Must be based on solid needs, wants and
expectations of the customer (internal and
external)
Outcome: preliminary design with
baseline configuration, functional
specifications