Greg Baker 2004 MQM_RY_S6

Failure Modes Effects and Criticality Analysis (FMEA/FMECA) Part-2

Reliability and Quality Principles MQM_RY_S6
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Dr. O. Alsahli

Greg Baker 2004 MQM_RY_S6

FMEA & FMECA Standards

(BS 5760-part5) Guide to Failure Modes, Effects and Criticality

Analysis .

(MIL-STD-1629A) Procedures for performing a Failure Modes,

Effects and Criticality Analysis .

IEC 60812 Procedures for failure mode and effect analysis (FMEA) (NHB 5300) Failure Modes and Effects Analysis (FMEA), and Critical
Item List (CIL), requirements for NASA programs .

SAE J-1739 Potential Failure Mode and Effects Analysis in Design

(Design FMEA) and Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA) and Effects Analysis for Machinery (Machinery FMEA)

O. Alsahli

Greg Baker 2004 MQM_RY_S6

FMEA Info Centre

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O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

SubFunction Function SubFunction SubFunction

Sub-SubFunction Sub-SubFunction Sub-SubFunction

1. A unique reference to an element (subsystem or component) is given. It may be a reference to an id. 2. The functions of the element are listed. It is important to list all functions. 3. The various operational modes for the element are listed.

O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

Description of failure (4) Failure Mode (O.C., S.C., No Power,..) (5) Failure Cause (Temp., Load, Aging ..) (6) Failure Detection (Testing, Alarm, Detection Probability: 1-2 Very high, 3-4 High, 5-7 Moderate, 8-9 Low, 10 Very low

O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

Failure Effect (7) On the Subsystem (Local effect) (8) On the System function (Global effect ) Are the consequences of each failure mode on item operation, function or status. Can be described in terms of what the users experience or what would be drawn to their attention.

O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

Failure Rate (Occurrence) 1-2 Very unlikely Once per 1000 years . 3-4 Remote Once per 100 years 5-6 Occasional Once per 10 years 7-8 Probable Once per year 9-10 Frequent Once per month or more often

O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

p X Q X E X A...... b p Pr edicted failure rate Base failure rate

b X Quality factor Q X Environment factor E X Application stress factor A

O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

Severity ranking 10 Catastrophic Failure 7-9 Critical Failure 4-6 Major Failure 1-3 Minor Failure

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O. Alsahli

Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

Severity 1 2-3 4-6 7-9 10

System/Mission No or Negligible effect

People/Enterprise

No injury/ No or negligible production loss. Less than 10% loss of Minor injury/ capability Minor production loss. 10% to 40% loss of capability 40% to 80% loss of capability 100% loss of capability Moderate injury with full recovery/ Significant production loss. Severe injury and long term damage/ Moderate plant and production loss. Loss of life / Major plant and production loss .

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Greg Baker 2004 MQM_RY_S6

Criticality Analysis
Criticality Assessment (Risk Ranking)

The objective of the criticality assessment is to determine priorities the failure modes discovered during the system analysis on the basis of their effects and occurrence likelihood.

Risk ranking (Criticality Analysis) The risk related to the various failure modes is often presented either by a: Criticality Matrix (Military Standard technique), or Risk Priority Number (RPN):

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Greg Baker 2004 MQM_RY_S6

Criticality Analysis
Criticality Matrix

Criticality is a combinations of the Severity of an effect and the probability or expected frequency of its Occurrence

5 4

A A A A A 1

C B B A A 2

C C B B A 3

D C C B A 4

D D C C A 5

Occurrence
13

3 2 1

Severity
O. Alsahli

Greg Baker 2004 MQM_RY_S6

Criticality Analysis
Risk Priority Number (RPN)

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O. Alsahli

Greg Baker 2004 MQM_RY_S6

Criticality Analysis
Risk Priority Number (RPN)

This method calculates the risk priority number for a part failure mode using three factors: (1) Failure effect severity, (2) Failure mode occurrence probability, and (3) Failure detection probability.

More specifically, the risk priority number is computed by multiplying the rankings (i.e., 110) assigned to each of these three factors.

RPN = O * S * D where RPN is the risk priority number. O is the occurrence ranking. S is the severity ranking. D is the detection ranking.

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Greg Baker 2004 MQM_RY_S6

Criticality Analysis
Critical Items List

The Critical Items List is prepared to facilitate communication of important analysis results to management.

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Greg Baker 2004 MQM_RY_S6

Criticality Analysis
Team review

Design engineer (hardware/software/systems) Test engineer Reliability engineer Quality engineer Maintenance engineer Field service engineer Manufacturing/process engineer Safety engineer
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Failure analysis and preparation of FMECA worksheets

Greg Baker 2004 MQM_RY_S6

Risk reducing measures

Possible actions to correct the failure and restore the function or prevent serious consequences are listed. Actions that are likely to reduce the frequency of the failure modes should also be recorded.

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Greg Baker 2004 MQM_RY_S6

Advantages of FMEA
There are many benefits of performing FMEA, Including a systematic approach to classify hardware failures, reduces development time and cost, reduces engineering changes, easy to understand, serves as a useful tool for more efficient test planning, highlights safety concerns to be focused on, an effective tool to analyze small, large, and complex systems, useful in the development of cost-effective preventive maintenance systems, provides safeguard against repeating the same mistakes in the future, improves customer satisfaction, useful to compare designs, a visibility tool for manager, and useful to improve communication among design interface personnel.

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Greg Baker 2004 MQM_RY_S6

FMEA example
FMEA Pressure Cooker

1. 2. 3.

Safety valve relieves pressure before it reaches dangerous levels. Thermostat opens circuit through heating coil when the temperature rises above 250 C. Pressure gage is divided into green and red sections. "Danger" is indicated when the pointer is in the red section.

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Greg Baker 2004 MQM_RY_S6

FMEA example
FMEA Pressure Cooker

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O. Alsahli

Greg Baker 2004 MQM_RY_S6

FMEA example
FMEA Pressure Cooker

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O. Alsahli

Greg Baker 2004 MQM_RY_S6

FMEA example
FMECA - RPN

D=5 , S=7
A=0.60

D=6 , S=8
B=0.85

D=9 , S=3
C=0.91

D=1 , S=5
D=0.79

D=2 , S=9
E=0.83

D=7 , S=7
K=0.52

D=3 , S=4
F=0.94

D=6 , S=2
G=0.97

D=4 , S=8
H=0.70

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Greg Baker 2004 MQM_RY_S6

FMEA example
FMECA RPN

RPN (O) Occurrence .

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Greg Baker 2004 MQM_RY_S6

FMEA example
FMECA RPN

ITEM A B C D E

S 5 6 9 1 2

O 7 8 3 5 9

D 5 2 1 3 2

RPN 175 96 27 15 36

F
G H K

3
6 4 7

4
2 8 7

1
1 4 5

12
12 128 245

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Greg Baker 2004 MQM_RY_S6

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