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FMECA
What is FMECA? Why to perform FMECA? How to perform FMECA? Conclusions
FMECA Definition
Failure Modes = Incorrect behavior of a subsystem or component due to a physical or procedural malfunction. Effects = Incorrect behavior of the system caused by a failure. Criticality = The combined impact of
The probability that a failure will occur
The severity of its effect
Failure Modes Effects and Criticality Analysis (FMECA) = a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service.
Evolution of FMECA
FMEA was originally developed by NASA to improve and verify the reliability of space program hardware. MIL-STD-1629 establishes requirements and procedures for performing FMECA
Purpose of FMECA
Select the most suitable design with high reliability and high safety potential in the design phases. List potential failures and identify the severity of their effects in the early design phases. Develop criteria for test planning and requirements. Provide necessary documentation for future design and consideration of design changes. Provide a basis for maintenance management. Provide a basis for reliability and availability analyses.
Benefits of FMECA
FMECA is one of the most important and most widely used tools of reliability analysis. The FMECA facilitates identification of potential design reliability problems
Identify possible failure modes and their effects Determine severity of each failure effect
FMECA helps
removing causes of failures developing systems that can mitigate the effects of failures.
Benefits of FMECA
It provides detailed insight about the systems interrelationships and potentials of failures. Information gained by performing FMECA can be used as a basis for
troubleshooting activities maintenance manual development design of effective built-in test techniques.
FMECA Techniques
The FMEA can be implemented using a hardware (bottom-up) or functional (topdown) approach Due to system complexity, it isperformed as a combination of the two methods.
FMECA Techniques
Hardware Approach :
The bottom-up approach is used when a system design has been decided already. Each component in the system on the lowest level is studied one-byone. Evaluates risks that the component incorrectly implements its functional specification.
FMECA Techniques
Functional Approach :
Considers the function of each item. Each function can be classified and described in terms of having any number of associated output failure modes. The functional method is used when hardware items cannot uniquely identified This method should be applied to when the design process has developed a functional block diagram of the system, but not yet identified specific hardware to be used.
FMECA Procedure
FMECA pre-requirements System structure and failure analysis Preparation of FMECA worksheets Team review Corrective actions to remove failure modes
FMECA Prerequisites
Define the system to be analyzed
System boundaries. Main system missions and functions. Operational or/and environmental conditions.
Collect available information that describes the system functions to be analyzed. Collect necessary information about previous and similar designs.
Severity Classification
A qualitative measure of the worst potential consequences resulting from a function failure. It is rated relatively scaled from 1-10.
Severity Classification
1 Failure would cause no effect.
2
3 4 5 6 7 8 9 10
Probability of Occurrence
Probability that an identified potential failure mode will occur over the item operating time. It is rated relatively scaled from 1-10.
Occurrence Classification
10 9 8 7 6 5 4 3 2 1 >= 50% (1 in two) >= 25% (1 in four) >= 10% (1 in ten) >= 5% (1 in 20) >= 2% (1 in 50) >= 1% (1 in 100) >= 0.1% (1 in 1,000) >= 0.01% (1 in 10,000) >= 0.001% (1 in 100,000) Almost Never
Detection rating
A numerical ranking based on an assessment of the probability that the failure mode will be detected given the controls that are in place. It is rated relatively scaled from 1-10.
Detection rating
1 Detected by self test.
2 Easily detected by standard visual inspection or ATE. 3 Symptom can be detected. The technician would know exactly what the source of the failure is. 4 Symptom can be detected at test bench. There are more than 2-4 possible candidates for the technician to find out the sources of failure mode. 5 Symptom can be detected at test bench. There are more than 5-10 possible candidates for the technician to find out the sources of failure mode. 6 Symptom can be detected at test bench. There are more than 10 possible candidates for the technician to find out the sources of failure mode. 7 The symptom can be detected, and it required considerable engineering knowledge/resource to determine the source / cause. 8 The symptom can be detected by the design control, but no way to determine the source / cause of failure mode. 9 Very Remote. Very remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. Theoretically the defect can be detected, but high chance would be ignored by the operators. 10 Absolute uncertainty. Design Control will not and /or cannot detect a potential cause/mechanism and subsequent failure mode; or there is no Design Control.
FMECA Worksheet
Recommendation Occurrence Component D1 R41 U10 detection Function Severity 7 7 7 Failure Cause Effect RPN
315
short
Reverse current
no current limit high current draw
10
280
short
FPGA
10
280
short
Corrective Actions
RPN reduction: the risk reduction related to a corrective action.
FMECA Checklist
System description/specification Ground rules Functional Block Diagram Identify failure modes Failure effect analysis Worksheet (RPN ranking) Recommendations (Corrective action) Reporting
Summary
References
MIL-P-1629 Procedures for performing a failure mode, effects and criticality analysis http://www.fmeca.com/