Prof G.R.C.

Nair
FMEA




Prof GRC Nair
What is FMEA?
Prof G.R.C.Nair


Failure
Modes
Effects
Analysis
Prof G.R.C.Nair
Reasons to do FMEA
Define and guide a logical design
process
Identify, quantify, and reduce
design risk
Provide a traceable document for
design and development
Justify design activities
Provide a means for continuous
product improvement
Prof G.R.C.Nair
Scope of FMEA
The FMEA is a team function
All team members must participate
Multi-disciplinary expertise and input is
beneficial
Input from all engineering fields is desirable
Representatives from all areas (not just
technical disciplines) are generally included as
team members
The DFMEA will be refined and evolve with the
product
Numerous revisions are required to obtain the
full benefit of the DFMEA
The DFMEA should include all systems, sub-
systems, and components in the product design
Measure of Availability

MTR MTBF
MTBF
A
+
=
MTBF = mean time between failures
MTR = mean time to repair
MTTF = mean time to fail
MTBF or MTTF= (T1+T2+--+--+TN)/N
MTR = (t1+t2+t3+---+---+tN)/ N
Prof G.R.C.Nair
Availability is also called UTR
UTR = Up time ratio
DTR = down time ratio
UTR + DTR = 1
System availability can be
increased by
Increasing MTBF
Decreasing MTR
Or any favourable combination
Prof G.R.C.Nair
Generally defined as the ability
of a product to perform as
expected, over a period of time
Formally defined as the
probability that a product, piece
of equipment, or system
performs its intended function
adequately for a stated period of
time, under specified operating
conditions.
Prof G.R.C.Nair
Inherent reliability
predicted by product design.
Achieved reliability
observed during use.
Prof G.R.C.Nair
Prof G.R.C.Nair
Prof G.R.C.Nair
Infant mortality
period/ Debug
period
Prof G.R.C.Nair
To take care of Infant Mortality
phase, consider debugging team,
Warrantee,free service, free
replacement, pre testing for that
period before release to market
etc
Prof G.R.C.Nair

Failure rate (l) number of
failures of break downs per
unit time.
Alternative measures
Mean time to fail (MTTF)
Mean time between
failures(MTBF)
l = 1 / MTBF or 1 / MTTF

Prof G.R.C.Nair
Reliability Function

1


R(t)

R(t)



Time t
Prof G.R.C.Nair
Reliability for a period of
t
r(t) = e
-lt


Probability of failure
within time t
f(t) = 1 e
-lt


Prof G.R.C.Nair
Exercises
MTBF = 500 hrs
Find l

,

Also find r (50, 400, 800,
1000,2000)
Prof G.R.C.Nair
System Reliability
Depends on ,
Component Reliability
Number of Components
The Configuration
Prof G.R.C.Nair
R = r
1
* r
2
*

r
3
*... r
n

1 2 n
Prof G.R.C.Nair
R = 1 [(1 - r
1
) (1 - r
2
) (1 r
n
)]
1
2
n
Prof G.R.C.Nair
Optimum Reliability



Reliability







cost
Prof G.R.C.Nair
Prof G.R.C.Nair
Frequency Ranking
Severity Rankings
Prof G.R.C.Nair
RPN (Risk Priority Number) 1 to
1000
Higher the number higher the risk
RPN= SxOxD each 1 to 10
increasing
S= Severity of failure - 1 to 10
O= Prob of Occurrence- 1 to 10
D= Difficulty in identifying 1 to 10
Prof G.R.C.Nair
Prof G.R.C.Nair
Classification of Risk
Possibility
Of
Occurrence
Severity of Outcome
High Risk
Moderate Risk
Low Risk