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Dr. Attia Hussien Gomaa Maintenance Engineering Consultant Engineering service - American University in Cairo (AUC)
2007
FMEA
Step 6: Critical failures (Top 5 failures) Step 7: RCFA Step 8: Remedy (best policy selection) Step 9: Policy description and program Step 10: Policy plan and implementation
FMEA
A functional failure is the inability of an item to fulfill a function to a standard of performance acceptable to the user
Functional failures can either be: Full loss of function or Partial loss of function Example: Function: To transfer water from tank 1 to tank 2 at 800 LPM Functional failure: Unable to transfer any water at all Transfers less than 800 LPM
FMEA
Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007
Example: Function: A hydraulic pump provides 3000 psi +/- 200 psi. Functional failures might be: Pump provides more than 3200 psi Pump provides less than 2800 psi
Example: Function: Keep system temperature between 50 C and 70 C, Functional failures might be: Unable to raise temperature above ambient Unable to keep system temperature above 50 C Unable to keep system temperature below 70 C
FMEA
Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007
Example
Function: The function of a hydraulic pump is to provide 3000 psi +/- 200 psi. Once the hydraulic pressure drops below 1000 psi a certain critical component ceases function.
Functional failures: Pump provides more than 3200 psi Pump provides between 1000 psi and 2800 psi Pump provides less than 1000 psi
FMEA
Failure Modes:
A failure mode is any event which causes a functional failure
Two step Process: Identify failure modes which are likely to cause functional failure Ascertain failure effects associated with each failure mode
FMEA
FMEA
Failure Modes:
Bearing seizes Impeller comes loose Impeller jammed Coupling broken Motor burns out Inlet valve jammed Partially blocked suction line
- Knocking:
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Overheating:
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- Others
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Discharge pressure low: Air leaks Leaking valves Restricted air intake Slipping belts Unloading mechanism not operating properly Blown gaskets Worn compressor rings Defective gauge Compressor too small for load
- Knocking: Loose motor pulley or compressor flywheel Loose belts Lack of oil in crankcase Oil pump not functioning Worn connecting rod bearings Worn piston pin bearing Worn main bearing Excessive crankshaft end play Excessive motor shaft end play Loose valve assemblies Loose piston Piston hitting the head, due to foreign matter Piston hitting the head, due to carbon deposits. 10
FMEA
- Excessive belt wear: Motor pulley or flywheel out of alignment Belt too loose or too tight Belt slipping Flywheel wobble
- Oil in the discharge air: Worn piston rings Compressor air intake restricted Restricted crankcase breather Excessive oil in compressor Wrong oil viscosity
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- Pump bearing overload: The wrong interference fit between the bearing and the shaft ( the shaft was out of tolerance). Misalignment between the pump and its' driver. Bent shafts. An unbalanced rotating element. Pushing the bearing too far up a tapered sleeve. Operating the pump off of its best efficiency point (B.E.P.). Shaft radial thermal expansion. Cavitation. Water hammer. Axial thrust. The bearing housing is out of round. A futile attempt to cool the bearings by cooling the bearing housing with a water hose or some other similar system. Cooling the outside diameter of a bearing causes it to shrink, increasing the interference and causing additional stress. Pulley driven designs. High vibration. The impeller is located too far away from the bearing. (common problem in many mixer/ agitator applications) A bad bearing was supplied counterfeit part FMEA
Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007
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Brainstorming:
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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
Is the manner by which a failure is observed and is defined as non-fulfillment of one of the equipment functions .
Example: valve the failure mode is open,partially open,closed partially closed and wobble
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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007
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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
For each failure cause there is one or several failure mechanisms examples of failure mechanism are Fatigue ,corrosion and wear
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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
Effect of failure is described in terms of the worst case outcome with respect to safety and environmental impacts ,production availability and direct economic cost and all that in numerical measure which are defined from ranking criteria
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
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HSE severity ranking criteria
RANK 10 79 46
SEVERITY LEVEL
DESCRIPTION A failure results in the major injury or death of personnel. A failure results in minor injury to personnel, personnel exposure to harmful chemicals or radiation, a fire or a release of chemicals in to the environment. A failure results in a low level exposure to personnel, or activates facility alarm system. A failure results in minor system damage but does not cause injury to Personnel allow any kind of exposure to operational or service personnel or allow any release of chemicals into environment.
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Minor IV
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
The probability that a failure will occur during the expected life of the system can be described in potential occurrence per unit time
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Occurrence ranking criteria
RANK 1 DESCRIPTION An unlikely probability of occurrence during the item operating time interval. Unlikely is defined as a single failure mode (FM) probability < 0.001 of the overall probability of failure during the item operating time interval. A remote probability of occurrence during the item operating time interval (i.e. once every two months). Remote is defined as a single FM probability > 0.001 but < 0.01 of the overall probability of failure during the item operating time interval. An occasional probability of occurrence during the item operating time interval (i.e. once a month). Occasional is defined as a single FM probability > 0.01 but < 0.10 of the overall probability of failure during the item operating time interval. A moderate probability of occurrence during the item operating time interval (i.e. once every two weeks). Probable is defined as a single FM probability > 0.10 but < 0.20 of the overall probability of failure during the item operating time interval. A high probability of occurrence during the item operating time interval (i.e. once a week). High probability is defined as a single FM probability > 0.20 of the overall probability of failure during the item operating interval.
Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
This section provides a ranking based on an assessment of the probability that a failure of mode will be detected given the controls that are in place . The probability of detection is ranked in reverse order
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Detection ranking criteria
RANK 12 34 57 8-9 10 DESCRIPTION Very high probability that the defect will be detected. Verification and/or controls will almost certainly detect the existence of a deficiency or defect. High probability that the defect will be detected. Verification and/or controls have a good chance of detecting the existence of a deficiency or defect. Moderate probability that the defect will be detected. Verification and/or controls are likely to detect the existence of a deficiency or defect. Low probability that the defect will be detected. Verification and/or controls not likely to detect the existence of a deficiency or defect. Very low (or zero) probability that the defect will be detected. Verification and/or controls will not or cannot detect the existence of a deficiency or defect.
Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007
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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
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Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval
An appropriate maintenance action may hopefully be found by the decision logic in step 7
The identified maintenance action is performed at intervals of fixed length.the length of the intervals is found in step 8
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