8/14/2009

PRESENTATION FLOW
Definitions for FMEA
FAILURE MODES What is FMEA
& Why FMEA

EFFECTS ANALYSIS Basic failure modes

What causes for failure
(FMEA)
Failure effects
Sources of information about FMEA
RCM information sheet
JAYASEKARA H.M.C.R.
E/04/125 RPN Calculation

DEFINITIONS FOR FMEA

DEFINITIONS FOR FMEA
Function

Failure - State or condition of not meeting a desirable or System Transfer water

intended objective. from X tank
Water pump to Y tank Failure
Failure mode- Event that causes a functional failure.
Unable to
transfer water
Failure effects- Describe What happened when a failure mode
pump
occurs.

Reactive maintenance - Dealing with failures after it happened Failure mode

Failure effect
Proactive maintenance - Dealing with failures before it happened Bearing
seize
Couldn't supply
water for 3
hours to Y tank

WHAT IS FMEA BASIC FAILURE MODES

FMEA is a technique utilized to define, identify, and
eliminate known or potential failures or errors from a There are three main types of failure modes
product or a process.
1. Falling capability

WHY FMEA 2 Increasing desired performance

2.
3. Initial incapability
To keep proactive maintenance process & eliminate or
reduce the future failure occurrence.

Provides a methodology for documenting this analysis for

future use and continuous process improvement.

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FALLING CAPABILITY WHAT CAUSES FOR FALLING

CAPABILITY
This means capability or ability to give desired output Deterioration
reduces with time Due to erosion, corrosion, etc..
Lubrication failures
Due to lack of lubrication
Due to lubrication it self fails
Example
Dirt
Water pump is having a initial delivery rate of 1000 Due to depletion of dirt particles block, stuck happens

liters/minute, it supplies to a tank which is having 900 Disassembly

litters/ minute. After sometimes pump delivery rate reduces Due to fails of welded or jointed area -
Human errors
to 800 litters/ minute Due to not proper operates

INCREASING DESIRED WHAT CAUSES FOR INCREASING

PERFORMANCE DESIRED PERFORMANCE
Deliberate overloading
This means desired performance is increases until it To increase the output of the process overloading is done instead
of increasing capability of the system .
reaches to
Unintentional
U i t ti l overloading
l di
outside of the capability.
Overloading of systems without an intention
1. Desired performance increases until the system can no
incorrect process material
longer deliver it Due to the out of quality raw material use, system is unable to
2. unnecessary force stress is apply to system to get more perform so this can be considered as palling of a extra stress on

than its capability the system

INITIAL INCAPABILITY FAILURE EFFECTS

Failure effects should includes the information about failure by
describing the every effect of failure
This is mainly occur due to the wrong designing Following points should be recorders in failure effects recording

Due to wrong designing process the designed Evidence of failure

y
system mayy not enough
g to pperform desired Whether it gave any evidence when it fails such as smell
smoke fire etc.
performance.
Safety & environmental hazardous
This types of failures really occurred Damages occur in phesically

Secondary damage & production effects

Process down time, MTBF,MTTR etc.

Corrective action
What are the steps taken to repair it etc.

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INFORMATION SOURCES ABOUT FORMAT OF RCM INFORMATION

FAILURE MODES & EFFECTS SHEET
Manufacturer of the equipment.
Energetic lists of failure modes.
Other
Oth users off the
th same equipment
i t use.
People who operate & maintain the same equipment.

RISK PRIORITY NUMBER ANALYSIS

Severity Rating (S)
Severity is the numerical rating of the impact on customers.. Identify each candidate Part or Process, list likely failure mode, causes,
and current controls
Occurrence Rating (R) Prioritize risk by using a ranking scale for severity, occurrence, and
detection
Is an estimate number of frequencies or cumulative number of failures
(based on experience) that will occur (in our design concept) for a given Characteristics with high Risk Priority Numbers should be selected for
Improvement and Action Plans Created
cause over the intended life of the design.
Recalculate RPN After Completion of Action Plans to Validate
Improvements
Detection Rating (D)
A numerical rating of the probability that a given set of controls will
discover a specific Cause of Failure Mode to Product S O D R
Resp. & p p p p
Failure Failure Actions Target S O D R
prevent bad parts leaving the facility or getting to the ultimate customer or E Causes C Controls E P
Mode Effects / Plans Complete E C E P
Process V C T N
Date V C T N

Risk Priority Number (RPN)

Is the product of Severity, Occurrence, & Detection.

Risk= RPN= S x O x D

GOAL OF THE FMEA

Why does it always
seem we have plenty
of time to fix our
problems, but never
enough time to
prevent the
p
problems by y doingg it
right the first time? QUESTIONS ?