FMEA

Failure Mode and Effect

Analysis
PT. MTS Indonesia
https://mts-indonesia.com
Tata Kelola Aset
Tata Kelola Aset Manajemen
Pertahanan
Inventory
Pertahanan
Service Level
Service Level

Manajemen Operasi
Pertahanan
Pertahanan
Manajemen Efisiensi dan Produksi
Efisiensi dan Produksi Work Planning &
Pertahanan
Kehandalan Pertahanan
Pertahanan Control
Pertahanan
Pertahanan Failure Mitigasi Failure
Pertahanan Failure Manajemen Kondisi
Pertahanan Manajemen Resiko
Pertahanan Mitigasi Failure
Pertahanan Pertahanan
Mendeteksi Failure Resiko Failure Terdeteksi
Manajemen Aging Mendeteksi Failure Resiko Failure Terdeteksi
Pertahanan Manajemen Outage
Pertahanan
Asset
Pertahanan Pertahanan
End of Life Mitigasi Failure
End of Life Mitigasi Failure

Continuous
Pertahanan Manajemen Kinerja
Pertahanan
Improvement
Pertahanan Pertahanan
Analisa Opportunity Maturity Mapping
Analisa Opportunity Maturity Mapping
FMEA, defines implemented maintenance
strategy
Function and Failure
ENGINEERING
KKS 1. SERP 2. FMEA 3. RCFA
PLANNER
Wher Wher Why?
Task EKSEKUTOR
e? e?
Identificatio CR/PD/PM/OH
4. Baseline 5. FDT n
Continuous Improvement

FMEA:Failure Modes Effects

Analysis
PdM SERP:System Equipment
Reliability Prioritization
PM

Design Out Plan Schedule Implement Task

Run To Measurement
Failure
What & Who &
Overhaul How? When?
Task Execution
 FMEA = RCM?

FMEA RCM
Was at design phase, to develop an ongoing
optimize product design. maintenance plan,
addresses risk, operations, and
Choose lowest Risk Priority cost and attempts to remove all
Number. failures
Why every asset owners should do FMEA?

Identification of functions

Identification of functional failure

Identification of potential failure mode

Identification of required reliability tasks to mitigate failure mode/scauses

Failure Probabilities
• Failure isn’t usually related to age or
usage (first 3 mechanism account
for only 11%)
• Restorative or replacement
maintenance based on time or
usage won’t normally help to
improve failure odds
• Major overhaul might be a bad idea,
since you might end up at higher
failure probability in some cases.
• Age –related replacement might be
too costly for the same reason
Failure Analytical Tools and
Method
• Qualitative Analysis Technique
• Expert Analysis
• Failure Mode and Effect Analysis (FMEA)
• Failure Mode, Effect, and Criticality Analysis
• Failure Mode, Effect, and Diagnostics Analysis
• Hazard and Operability Study (HAZOP)
• Quantitative Analysis Technique
• Reliability Block Diagram
• Fault Tree Analysis
• Markov Models
FMEA
• Technique involving a bottom-up analysis of a system, by examining
all possible component failures and determining the effect of these
failures on the entire system.
 Procedure / Steps
1. to define the system to be analyzed;
2. to illustrate the interrelationships of functional elements of the system by
means of block diagrams;
3. to identify all potential failure modes and their causes and to evaluate the
effects on the system of each failure mode;
4. to identify failure detection methods;
5. to identify corrective measures for failure modes;
6. to assess the probability of failures causing hazardous or catastrophic effects,
where applicable:
7. to document the analysis;
1. System Definition
General description of system operation and
structure;

Functional relationship among the system

elements;

Acceptable functional performance limits of

the system and its constituent elements in each
of the typical operational modes: and

System constraints.
1. System Defenition
Defining Function and Functional
Failure
Function

Function
A Verb Deliver

An Object Water

A desired performance 1000

standard Litres/minute
Performance Standard
P-F Curve

P : Potensial Failure F : Functional Failure

Failure Classification
• Potential Failure
Potential failure, or PF, indicates a detectable state of failure, or the
point at which degradation begins.

• Functional Failure
A Functional Failure is defined as the inability of any asset to fulfill a
function to a standard of performance which is acceptable to the user
2. To illustrate the interrelationships of functional
elements Development of System Block Diagram

General breakdown of the system into

major sub-systems or equipment;

all appropriate labelled inputs and outputs

and identification numbers by which each
sub-system is consistently referenced; and

all redundancies, alternative signal paths

and other engineering features which
provide "fail-safe" measures.
Example of Block Diagram
 3. Identification of failure mode, cause and effect

Failure mode is the manner by which a failure is observed. It generally describes the way the failure occurs and its
impact on the equipment or system.
• ISO 14424: effect by which a failure is observed on the failed item
3. Identification of failure mode, cause and effect

FAILURE
Failure Mode Failure Effect Failure Cause
Maintainable Consequence An event
Item + Failure of a failure initiates a
Symptom mode failure mode
HOW CONSEQUENCE INDICATOR
Likelihood Severity Detecability
3. Identification of failure mode, cause and effect

• Occurrence (O) - Occurrence or sometimes termed

LIKELIHOOD, is a numerical subjective estimate of the
LIKELIHOOD that the cause of a failure mode will occur during
the design life, or during production in the case of a Process
FMEA.
3. Identification of failure mode, cause and effect

• The consequence of a failure mode on the operation, function, or status of an equipment

or a system is called a "failure effect". Failure effects on a specific sub-system or
equipment under consideration are called "local failure effects". The evaluation of local
failure effects will help to determine the effectiveness of any redundant equipment or
corrective action at that system level. In certain instances, there may not be a local effect
beyond the failure mode itself.
• The impact of an equipment or sub-system failure on the system output (system function)
is called an "end effect". End effects severity should be evaluated.
• Severity (S) -  Severity is a numerical subjective estimate of how severe the customer
(next user) or end user will perceive the EFFECT of a failure
FMEA idea
Failures Outputs
Failure Mode List of actions to prevent
causes or detect failure
Failure Cause modes
FMEA (Failure Defence Plans)
Failure Effect History of actions taken
Failure Defence Plans
4. Failure Detection
• The FMEA study in general only analyses failure effects based
on a single failure in the system and therefore a failure
detection means, such as visual or audible warning devices,
automatic sensing devices, sensing instrumentation or other
unique indications should be identified.
• Detection (D) - Detection is sometimes termed
EFFECTIVENESS. It is a numerical subjective estimate of the
effectiveness of the controls to prevent
or detect the cause or failure mode before the failure reaches
the customer. The assumption is that the cause has occurred.
Assessing Risk
• Risk Priority Number (RPN) is a measure used when assessing risk to
help identify critical failure modes associated with your design or
process.

RPN = Severity x Occurrence x Detection

Severity: Example of subjective estimate
SEV (Severity)
Criteria Simplified
Ranking
No effect 1
Very slight effect on component or system performance 2
Slight effect on component or system performance 3
Minor effect on component or system performance 4
Moderate effect on component or system performance 5
Component or system performance degraded but still safe and operable 6
Component or system performance severely affected but still safe and 7
functionable. System impaired.
Component or system inoperable. 8
Component or system inoperabel, potential hazardous effect. 9
Hazardous related, safety related. Non-compliance with government regulation. 10
Occurrence: Example of subjective estimate

OCC (Occurence)
Kriteria Simplified Ranking
Failure unlikely. History shows no failure 1
Rare number of failures likely 2
Very few failures likely 3
Few failures likely 4
Occasional number of failures likely 5
Medium number of failures likely 6
Moderately high number of failures likely 7
High number of failures likely 8
Very high number of failures likely 9
Failure almost certain. History of failures exists from previous or similar 10
designs
 Detection: Example of subjective
estimate
DET (Failure Mode Detection)
Criteria Simplified
Ranking
Proven detection methods available 1
Computer analysis 2
Simluation and/or modeling 3
Test on prototype 4
Test on Preproduction 5
Test on similar system 6
Test on product with prototypes with system components installed 7
Proving durability test o products with system components installed 8
Theorytical approach only 9
No known techniques available 10
 5. Corrective Measures
1. The response of any back-up equipment, or any corrective action initiated at a given system
level to prevent or reduce the effect of the failure mode of a system element or equipment,
should also be identified and evaluated.
2. Provisions which are features of the design at any system level to nullify the effects of a
malfunction or failure, such as controlling or deactivating system elements to halt
generation or propagation of failure effects, or activating back-up or standby items or
systems, should be described. Corrective design provisions include: redundancies that allow
continued and safe operation; safety devices, monitoring or alarm provisions, which permit
restricted operation or limit damage; and alternative modes of operation.
5. Corrective Measures
• Provisions which require operator action to circumvent or mitigate the
effects of the postulated failure should be described. The possibility and
effect of operator error should be considered, if the corrective action or
the initiation of the redundancy requires operator input, when
evaluating the means to eliminate the local failure effects.
• It should be noted that corrective responses acceptable in one
operational mode may not be acceptable at another, e.g., a redundant
system element with considerable time lag to be brought into line,
while meeting the operational needs.
6. Use of Probability Concept
Reference:
• Workshop test
• History of reliability used in other areas under similar operating
condition; e.g. OREDA
• Mathematical model if applicable
Potential unavailability of a
system
Potential unavailability a of
system
7. Documentation
Another documentation
alternative
Relationship between FMEA Elements
FMEA Template
FMEA Template
FMEA Template
Deliverables  Reliability
Library
• Description Function of equipment
• Description of performance standard and functional failure
• List of failure mode, failure effect and cause
• List of reliability strategy
• List strategic spare part
Next: Asset Wellness Table
Condition Indicators (Technologies)
Critical Equipment
Review FMEA

WO CM 2020 FMEA v.1

FMEA (v.0) FM baru? 2020
2019 Failure masih FM, FC, Frek,
terjadi.! Strategy
Thank You
PT. MTS Indonesia