Failure modes and effects analysis (FMEA)

Project:

MAE 156A: Robot Competition

A02 - Monday Afternoon

Date:

10/19/2008
Andy Luo

FMEA Team:

Prepared by:

SEV = How severe is effect on the customer? OCC = How frequent is the cause likely to occur? DET = How probable is detection of cause? RPN = Risk priority number in order to rank concerns; calculated as SEV x OCC x DET N e w S E V N e w O C C N e w D E T N e w R P N

Process step

Potential failure mode

Potential failure effects

S E V

Potential causes

O C C

Current process controls

D E T

R P N

Actions recommended

Responsibility (target date)

Actions taken

In what ways can the step go wrong?

What is the impact on the customer if the failure mode is not prevented or corrected?

10

What causes the step to go wrong? (i.e., How could the failure mode occur?)

10

What are the existing controls that either prevent the failure mode from occurring or detect it should it occur?

10

1000

What are the actions for reducing the occurrence of the cause or for improving its detection? You should provide actions on all high RPNs and on severity ratings of 9 or 10.

Who is responsible for the recommended action? What date should it be completed by?

What were the actions implemented? Include completion month/year (then recalculate resulting RPN).

10

10

10

1000

Screws Stripping

Causes part to be difficult to Loose parts (flanges,etc) that make it come out. slide around the shaft.

Too much torque inflicted on screw.

Visual image.

16

Take out misshapen screws with pliers.

Team

Replaced screws

16

Second Robot Arm

Motor brakes not strong enough to completely stop robot arm causing it to read a different value then the desired one.

Incorrect reading when motor driver tells motor to stop but momentum causes arm to continute swinging for a little bit.

Not enough dampeners (washers) on second robot arm.

10

What are the existing controls that either prevent the failure mode from occurring or detect it should it occur?

10

800

More washers. Implement some kind of brake system.

Team (Implemented by Increased washers. 10/22/2008 Wed)

10

10

800

Coding Errors

Causes the robot to behave Cause our process to "randomly" to the operator. activate in a incorrect order Incorrect data attained.

Wrong syntax. Incorrect usage of keywords in BASIC. Incorrect logical steps.

Complier check. Operators and associates cross checking the code.

10

200

Crosschecking the code.

Andy Luo

Crosschecking the code. Increasing the code efficency. Added stopper code to skip reading results if a result have already been stored.

30

Devices blowing up. Possible Shortages. Circuits blowing destruction of microprocessor Incorrect circuitry up. Incorrect values being and motor drivers. Fuses read. blown. Wires being pulled out.

10

Resistors crossing. Leads that are touching each other without the operator realizing it.

Black electrical tape covering leads. Cutting the resistors short and taping it down with electrical tape.

10

600

Tape up leads with electrical tape. Shorten resistors and make Kevin Chui sure circuit is clean and easily identifable.

Clean up circuit diagram. Made sure there are no loose ends.

60

62021477.xls

Printed 12:43:32,07/01/2011

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Failure modes and effects analysis (FMEA)

Project:

MAE 156A: Robot Competition

A02 - Monday Afternoon

Date:

10/19/2008
Andy Luo

FMEA Team:

Prepared by:

SEV = How severe is effect on the customer? OCC = How frequent is the cause likely to occur? DET = How probable is detection of cause? RPN = Risk priority number in order to rank concerns; calculated as SEV x OCC x DET N e w S E V N e w O C C N e w D E T N e w R P N

Process step

Potential failure mode

Potential failure effects

S E V

Potential causes

O C C

Current process controls

D E T

R P N

Actions recommended

Responsibility (target date)

Actions taken

Sensor Not Reading

Incorrect values read. Causes Reads potentiometer values premature exit condition for too early or too late causing first while loop under coding. incorrect values to be read Sensors not working and hard to detected.

Incorrect use of schematics. Faultly device.

Hyperterminal to locate voltage anomaly.

180

Check circuity of sensors. Replace circuits.

David Tasker

Replacement of sensors.

10

Friction Drive on Potentiometer not turning Potentiometers giving us invalid data

Skewed final values. Wrong location for LED to shine on.

Too much friction between plastic flange and potentiometer.

Visual imagery of the potentiometer not moving although the motor belt is moving.

40

Ream the plastic Andy Luo (Will flange. Add bearings to implemented by plastic flange. Reduce 10/22/2008 Wed) tension on friction drive.

None at this moment

40

Gear Ratio (39:5) Slipping of the timing belt

Slow completition speed. Too much excess torque. Reduced performability.

Given ineffective gear ratio

Visual imagery of the timing belt slipping. Motor running but belt not moving.

Increase the gear ratio. Erick Barrientos (Will Increase the gear Implemented by located on 5VDC 10/22/2008 Wed) motor. 45

None as of this moment

45

62021477.xls

Printed 12:43:32,07/01/2011

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