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FMEA is a logical, structured process that can help identify potential causes of system failure before the failures actually occur. It is used to determine the frequency of top events for which historic data is not available or applicable. FMEA - focus on each system component, and examines before-the-fact all things that could go wrong with that component.
FMEA is a logical, structured process that can help identify potential causes of system failure before the failures actually occur. It is used to determine the frequency of top events for which historic data is not available or applicable. FMEA - focus on each system component, and examines before-the-fact all things that could go wrong with that component.
FMEA is a logical, structured process that can help identify potential causes of system failure before the failures actually occur. It is used to determine the frequency of top events for which historic data is not available or applicable. FMEA - focus on each system component, and examines before-the-fact all things that could go wrong with that component.
Lecture 2-2 Fault Tree Analysis Reliability System, Concept FMEA 2 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 2 3 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 4 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 3 5 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 6 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. 4 7 FMEA Example 8 FMEA What is Reliability? PERCEIVED RISK Competition Market Pressure Management Emphasis Customer Requirements Legal, Statutory Safety Warranty and Service Costs Public Liability Development Risks 5 9 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. 10 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 6 11 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) 12 FMEA Quantification of Reliability Establishing reliability requirements or objectives Apportionment (budgeting) Prediction Analysis 7 13 FMEA Design Testing Performance Environmental Stress Reliability Maintainability Life Pilot Run 14 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 8 15 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 16 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 9 17 FMEA 1. Develop a Strategy ST91260A DRIVE BASESUB SYSTEM& FIRMWARE COVER MEDIA DISC PACK FINALARM ARM SUB ARMCOIL BOBBIN ROT. ARM SP. FLEX SPINDLE STATOR ROTOR HDA ASSEMBLY BASEDECK RECIRFILTER BREATH. FILTER LABELS PCB ASSEMBLY DISC CLAMP BAL. WT SPACERS MAG ASSY LATCH ARM SUB ARMSUB BASEDECK DAMPER SEAL MOTORPOLES, POLESPACER 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 18 FMEA Planning APPLICATION NEW TECHNOLOGIES COMPLEXITY RESOURCES It would very costly to apply FMEA to every part. When planning for FMEA, consider: 10 19 FMEA 1. Develop a Strategy 2. Review the design /process EFFECT CAUSES Basic Steps 20 FMEA Review the Process Design Drawings Specifications Bill of material Process Flow process chart Operator work instructions 11 21 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 22 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 12 23 FMEA Functions/Features - Example 24 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 13 25 FMEA Failure to perform a defined function Something occurring that you don't expect, or want Wrong application A Failure Mode is . . . 26 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 14 27 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 28 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 15 29 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 30 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 16 31 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 32 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 17 33 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