Failure Mode And Effects Analysis In Reliability

Centred Maintenance

SUBMIT TED TO
AMIT PHOGAT
MAINTENANCE MANAGEMENT
ASSIGNMENT 1
 FAILURE MODE & EFFECT ANALYSIS (FMEA) [6]

FMEA defines the term “failure mode” to identify defects or errors, potential or actual, in a product design or
process, with emphasis on those affecting the customer or end user.

A “failure effect” is the result of a failure mode on the product or system function as perceived by the user.
Failure effects can be described in terms of what the end user may see or experience.

The study of consequences of identified failures is called effects analysis.

 FAILURE MODE & EFFECT ANALYSIS (FMEA) [3]
FMEA is a systematic, proactive method designed to:
• Identify and fully understand potential failures modes and their causes, and the effects of failures on the
system or end users ,for a given process or product.
• Assess the risk associated with the identified failure modes ,effects , and causes , and prioritize issues for
corrective action.
• Identify and carry out corrective actions to address the most serious concerns.

An FMEA should be the guide to the development of a complete set of actions that will reduce risk associated
with the system, subsystem, and component or manufacturing/assembly process to an acceptable level.
FMEA can be employed from the earliest design and conceptual stages onward through development and
testing processes, during ongoing operations throughout the life of the product or system.
OBJECTIVES Recognize and evaluate the potential failure of a product/process and its
effects

OF Develop Preventive Maintenance plans for in-service machinery and

equipment
FMEA [4]
Identify significant product or process characteristics

Consider changes to the product design or manufacturing process

Identify and prevent safety hazards

Minimize loss of product performance degradation


FMEA was formalized in 1949
by the US Armed Forces by the
introduction of Mil-P 1629
Procedure
First used in the 1960’s in the
Aerospace industry during the
Apollo missions
Timeline of FMEA [4]
In the late 1970s the Ford
Motor Company introduced
FMEA to the automotive
industry
In 1974, the Navy developed
MIL-STD-1629 regarding the
use of FMEA
In the 1980s, the automotive industry began
implementing FMEA by standardizing the structure
and methods through the Automotive Industry Action
Group.
FMEA method is now extensively used in a variety
of industries including semiconductor processing,
foodservice, plastics, software, aeronautics,
automotive, and healthcare, to name a few
TYPES OF FMEA [4]
FMEA

SYSTEM FMEA DESIGN FMEA PROCESS FMEA

• The objective is to
• The objective is to • The objective is to improve
improve the design of
improve the design of the design of the
the manufacturing
the system. subsystem or component.
process.

• The focus is on system • The focus is on design

• It emphasizes on how
related deficiencies, related deficiencies,
the manufacturing
that could cause the ensuring product is safe to
process can be improved
overall system not to use and reliable during the
to ensure that a product
work as intended. useful life of the
is built in a safe manner,
equipment
with minimal downtime,
scrap and rework.
 FMEA: A Team Tool [9]
The FMEA is a team function and cannot be done on an individual basis.

• The team must defined as appropriate for a specific project and cannot serve as the universal or
company FMEA team.

• The optimal number of members in the team is 6-10.

• The FMEA team is a cross-functional team of people with diverse knowledge about the process, product
or service and customer needs.

• FMEA teams often include design engineers, analysts, process control engineers, manufacturing
engineers, customer service personnel, as well as managers and other product team members.

• The FMEA team is led by a process owner who is the responsible manufacturing engineer or technical
person, or other similar individual familiar with FMEA.
PREREQUISITES
Trained personnel

FOR
FMEA form template of equivalent tool
FMEA [6]
Past statistical data or records about failures

Selected process description

Special team combined of key users of the process or experienced personnel

related to methods and techniques used in the chosen process
FMEA Standards [4]
Some of the standards are :

• SAE (Society of Automotive Engineers) J1739, Potential Failure Mode and Effects Analysis in Design (Design
FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)
[2009]

• AIAG (Automotive Industry Action Group), Potential Failure Mode and Effects Analysis (FMEA) Reference
Manual Fourth Edition [2008]

• SAE ARP5580 (Society of Automotive Engineers), Recommended Failure Modes and Effects Analysis (FMEA)
Practices for Non Automobile Applications [2001]

• IEC 60812 (International Electrotechnical Commission), Analysis techniques for system reliability – Procedure
for failure mode and effects analysis (FMEA) [2006]

These standards cover the scope and general procedure for doing FMEAs or FMECAs.
 Severity, Occurrence and Detection [7]
Using data and knowledge of the process or product, each potential failure mode and effect is rated in each of the
following 3 factors:

Rating Meaning Rating Meaning

1 No effect, no danger 1 No documented failures on similar products/processes

2 Very minor – usually noticed only by discriminating or very

observant users 2-3 Low – relatively few failures

3 Minor – only minor part of the system affected; noticed by 4-6 Moderate – some occasional failures
average users
7-8 High – repeated failures
4-6 Moderate – most users are inconvenienced and/or annoyed
9-10 Very high – failure is almost certain
7-8 High – loss of primary function; users are dissatisfied
9-10 Very high – hazardous. Product becomes inoperative, 9-10 Very high – hazardous. Product becomes inoperative,
customers angered. Failure constitutes a safety hazard and can customers angered. Failure constitutes a safety hazard and can
cause injury or death. cause injury or death.

Severity(S): Severity is the seriousness of failure Occurrence(O): The probability or frequency

consequences of failure effects. of the failure occurring

Identifying known and potential failure modes is an important task in FMEA .

Severity, Occurrence and Detection [7]

Rating Meaning

1 Fault is certain to be caught by testing

2 Fault almost certain to be caught by testing

3 High probability that tests will catch fault

4-6 Moderate probability that tests will catch fault

7-8 Low probability that tests will catch fault

9-10 Fault will be passed undetected to user/customer

Detection(D): The probability of the failure being

detected before the impact of effect is realized.
 Risk Priority Number (RPN) [8]
Risk Priority Number(RPN)
• The three factors(severity, occurrence and detection) are combined in one number called the
Risk Priority Number(RPN) to reflect the priority of the failure modes identified.
• RPN is the product of the severity, occurrence, and detection scores.
RPN = S * D * O
• RPN should be calculated for the entire design and/or process and documented in the FMEA.
• Results should reveal the most problematic areas.
• The highest RPNs should get highest priority for corrective measures.
• When corrective measures are implemented, RPN is calculated again and the results
documented in the FMEA.

Corrective measures can include a variety of actions: new inspections, tests or procedures, design
changes, different components, added redundancy, modified limits, etc.
FMEA Process [7]
A typical FMEA process is a proactive methodology that follows the following steps:

1. Select the process: The first thing the user has to do is to select the process to analyze. The importance of the process in terms of
the impact of potential failures is a parameter that has to be taken into account as selection criteria.

2. Review the process: This step usually involves a carefully selected team that includes people with various job responsibilities and
levels of experiences. The purpose of a FMEA team is to bring a variety of perspectives and experiences to the project.

3. Brainstorm potential failure modes: Look at each stage of the process and identify ways it could potentially fail, things that might
go wrong.

4. Identify root causes of failure modes

5. List potential effects of each failure mode

6. Assign a severity rating for each effect: Give each effect its own severity rating (from 1 to 10, with 10 being the most severe). If
the team can't agree on a rating, hold a vote. To quantify or prioritize the effects someone can use Pareto analysis.
FMEA Process Contd. [7]
7. Assign an occurrence rating for each failure mode: Collect data on the failures of the product's competition. Using this
information, determine how likely it is for a failure to occur and assign an appropriate rating (from 1 to 10, with 10 being the most
likely).

8. Assign a detection rating for each failure mode and effect: List all controls currently in place to prevent each effect of a failure
from occurring and assign a detection rating for each item (from 1 to 10, with 10 being a low likelihood of detection).

9. Calculate the risk priority number (RPN) for each effect: Multiply the severity rating by the occurrence rating by the detection
rating.

10. Prioritize the failure modes for action: Decide which items need to be worked on right away. Give priority to high RPNs, must
look at severities rated a 10.

11. Take action to eliminate or reduce the high-risk failure modes

12. Calculate the resulting RPN as the failure modes are reduced or eliminated

13. Use and update the FMEA form

 Generic FMEA Worksheet [4]

Determine and
Identify failure modes Identify causes of the Prioritize
assess actions
and their effects failure modes
and controls
What is Reliability Centred Maintenance (RCM)? [1]

Reliability-Centered Maintenance (RCM) is the process of determining the most effective

maintenance approach. Reliability-centered maintenance (RCM) is the optimum mix of reactive,
time or interval-based, condition-based, and proactive maintenance practices. These principal
maintenance strategies, rather than being applied independently, are integrated to take
advantage of their respective strengths in order to maximize facility and equipment reliability
while minimizing life-cycle costs.
 7 Questions For Comprehensive Approach [7]
The SAE standard defines the RCM process as asking seven basic questions from which a comprehensive
maintenance approach can be defined:

1. What are the functions and associated desired standards of performance of the asset in its present
operating context (functions)?
2. In what ways can it fail to fulfill its functions (functional failures)?
3. What causes each functional failure (failure modes)?
4. What happens when each failure occurs (failure effects)?
5. In what way does each failure matter (failure consequences)?
6. What should be done to predict or prevent each failure (proactive tasks and task intervals)?
7. What should be done if a suitable proactive task cannot be found (default actions)?

From these 7 questions emerges a systematic process to determine the maintenance requirements for any
physical asset in its operating context, called the Reliability Centered Maintenance.
Components of RCM Program [1]
Timeline of RCM [5]
1974: The United States Department of Defence commissioned United Airlines to prepare a report on
the processes used by the civil aviation industry to prepare maintenance programs for aircraft. The
resulting report was entitled Reliability-Centred Maintenance.

1975-1990: After being created by the commercial aviation industry, RCM was adopted by the U.S.
military (beginning in the mid-1970s) and by the U.S. commercial nuclear power industry (in the 1980s)

1997: Disney introduced RCM to its parks.

1999: The International Society of Automotive Engineers (SAE) established the Technical Committee
which in 1999 developed the JA1011 standard: Evaluation Criteria for Reliability-Centered Maintenance
(RCM) Process.

2002: SAE issued SAE JA1012, “A Guide to the RCM Standard” - amplifies and clarifies key concepts and
terms from SAE JA1011
 Primary Principles of RCM [5]
1. Function Oriented – It seeks to preserve system or equipment function, not just operability for operability's sake.
Redundancy of function, through multiple equipment, improves functional reliability, but increases life cycle cost in terms
of procurement and operating costs.

2. System Focused – It is more concerned with maintaining system function than individual component function.

3. Reliability Centered – It treats failure statistics in an actuarial manner. The relationship between operating age and the
failures experienced is important. RCM is not overly concerned with simple failure rate; it seeks to know the conditional
probability of failure at specific ages (the probability that failure will occur in each given operating age bracket).

4. Acknowledges Design Limitations – Its objective is to maintain the inherent reliability of the equipment design,
recognizing that changes in inherent reliability are the province of design rather than maintenance.

5. Driven by Safety and Economics – Safety must be ensured at any cost; thereafter, cost-effectiveness becomes the
criterion.
Primary Principles of RCM [5]
6. Defines Failure as Any Unsatisfactory Condition – Therefore, failure may be either a loss of function
(operation ceases) or a loss of acceptable quality (operation continues).

7. Uses a Logic Tree to Screen Maintenance Tasks – This provides a consistent approach to the maintenance of
all kinds of equipment.

8. Tasks Must Be Applicable – The tasks must address the failure mode and consider the failure mode
characteristics.

9. Tasks Must Be Effective – The tasks must reduce the probability of failure and be cost effective.

10. RCM is a Living System – It gathers data from the results achieved and feeds this data back to improve
design and future maintenance. This feedback is an important part of the Proactive Maintenance element of the
RCM program
RCM Methodology [10]
RCM has a seven step methodology which is as follows:

1. Selection of the system and collection of information - The level at which RCM analysis is performed can be
selected as part of a large system or plant. Documents such as the scheme of the system and/or block diagram,
history of failures of similar equipment or operating instructions should serve as the basis for collecting
information about the system.

2. Definition of system boundaries - The main equipment included in the system is identified with primary
physical boundaries. Precise definition of boundaries makes sure that the potentially important functions are
not neglected and the boundary represents a link between the entrance to the system and the exit from the
system.

3. Description of the system and the functional block diagram - It should provide certain important information
that relate to: a) functional description of the system and its functions, excess functions, protective functions,
etc. b) representative functions of the system c) input/output interface d) a list of equipment and functional
subsystems e) history of failures of equipment during the past 2 - 3 years.
RCM Methodology [10]
4. Functions and functional failures - The equipment belongs to a system that performs a crucial function. The
system can be large or small, but the function of the system, and its inputs and outputs, should be known. The
objective of this step is to list all of the ways that the function of the system can fail.

5. FMEA analysis - It is the basic procedure for qualitative estimation of technical system reliability.

6. Logic tree analysis (LTA) - When the lists of failure modes are formed for each component of the system and when
the functional dependence among all failure modes of components are found, it is necessary to establish the
influence of each failure mode at the local level as well as at the levels of system and plant. Such decisions are not at
all simple and drawing a logic tree simplifies the process.
RCM Methodology [10]
7. Classification of maintenance tasks based on the RCM analysis - The aim is to find such a maintenance task
which has the highest performance regarding prevention of failure occurrence. Potential maintenance tasks belong
to one of the 4 possible categories
TD – Time – Directed (Preventive Maintenance)
CD – Condition – Directed (Predictive Maintenance)
FF – Failure Finding (A routine maintenance task, normally an inspection or testing task, designed to determine
whether an item or component has failed.)
RTF – Run to Failure (Reactive Maintenance)

It is necessary to assign a maintenance activity to every failure mode.

Using FMEA in RCM [9]
• The most important component in a successful reliability-centered maintenance(RCM) program is the ability to
anticipate and prevent serious failure.
• FMEA is a proven and effective tool which helps to identify potential failures of system failure on the plant floor.
• The FMEA can offer, with bigger facility and objectivity, answers to the following questions which refer to the
equipment failures. The questions are as follows:
• Which are the functions to preserve? Which are the functional failures? Which are the failure modes? Which are
the failure effects? Which are the failure consequences? Which are the applicable and effective tasks? Which are
the remaining alternatives?
• The phases of RCM implementation depend on the answers to such questions.
• Understanding the consequences of failure would drive the maintenance planning. An effective and affordable
maintenance plan focuses on preventing the critical and costly consequences
Author-B. Devaraj
Naik, Pradeep Kumar CASE STUDY [2]
Soni Application of Reliability Centered
Maintenance on Horizontal Boring Machine
International Journal of
Advanced Engineering Research
and Science (IJAERS)
[Vol-3, Issue-7 , July- 2016]
Abstract [2]
A case study has been developed by analyzing the RCM effectiveness on the balancing system of horizontal
boring machine in private sector Madhya Pradesh , by using tools such as FMEA (Failure Modes and Effects
Analysis), FTA (Fault Tree Analysis), MTBF (Mean time between failure) and MTTR (Mean time to repair). The
failure characteristics of system components (cylinder, direction control valve and pump) have been compared
in terms of RPN.
Introduction [2]
• Maintenance is an essential part of the hydraulic system today.
• A reliable hydraulic system is required to ensure progress in the horizontal boring machine operation.
• When the hydraulic system stops functioning, the industry has to declare downtime which increases the expenses
further.
• This highlights the importance of a maintenance strategy to avoid break down.
• The implementation of reliability centered maintenance (RCM) can help decide what equipment that needs different
maintenance strategies to ensure a high reliability at a reasonable cost.
RCM Methodology in the case study [2]
The objective of this work is to improve the reliability of the hydraulic system and perform a maintenance cost
analysis of these tools. It is accomplished by using tools like FMEA, FTA, MTBF (Mean Time between Failures)and
MTTR (Mean Time to Repair) on the system components such as cylinder, dc valve and pump.

1. Hydraulic circuit preparation of the balancing circuit.

2. Fault tree analysis of the system.

3. FMEA of cylinder, Direction valve and pump.

4. Calculation of MTBF and MTTR.

4. Preparation of Logic Tree diagram for each component.

5. Proposing the optimized maintenance strategy.

Hydraulic Boring Machine [2]
The horizontal boring machine is installed in steam turbine
workshop of private sector Madhya Pradesh. The horizontal
boring machine is used in boring operation of steam turbines. It
consists of two beds, one of which is horizontal (300m) and
other is vertical. The travel lengths of beds are 27m and 5m.
The travel length of head is 1250mm and that of spindle is
1750mm.

Source - B. Devaraj Naik, P. K. (2016)

[2]
Criteria For Failure Mode Evaluation [2]

Source - B. Devaraj Naik, P. K. (2016)

[2]
FMEA Procedures [2]
• Reviewing design details, illustrating equipment block diagram and recognizing all potential failures,
respectively.
• Following recognition, all possible causes and effects are classified to the related failure modes.
• After this practice, failures are according to ranking based on Number (RPN).

RPN = Severity*Occurrence*Detection
FMEA Analysis of Major Components of Hydraulic Circuit [2]

No. Item/ Failure Mode Potential S Potential O Current D RPN

Function Effect Causes Control
1 Cylinder 1. Rod failure 1.Machine stops 5 1. High operating temp., 5 1.Working under prescribed limit 5 125
2. Oil Leakage 2.System Pressure overload 2.Painting the surface
3. 3.Cylinder lowers 2. Erosion 3.Improper lubrication
Noise 3.Unpleasant 3. High speed, excessive 4.Proper alignment of
4. Rod vibration working condition friction components
4. Noise
4. High speed, misalignment

2 Direction Valve 1. Failure of valve 1. Flow stops 6 1. High fluctuation 10 1. Cleaning, Fitting and 6 360
ports 2. Improper oil flow pressure Tightening
2. Failure of spool 3. Improper shifting 2. High wear , improper 2. Cleaning and fitting
3. Defective spring 4.Pressure lowers spool adjustment 3. Work under permissible
4. Valve leakage 3. High fluctuation load, 4. Periodically checking
over load
4. High fluid temperature,
erosion
3 Pump 1. Leakage of pump 1. System pressure 9 1. Contaminated high 9 1.Proper fitting 4 324
2. Leakage in suction lowers pressure of fluid 2.Check hydraulic hoses and
3. Pipe 2. System press 2. Erosion fitting
Pump shaft broken lowers 3. Excessive loading 3. Check flow rate ,visual
4. blockage in 3. System stops 4. Contamination of oils inspection
suction 4 Flow of oil stops 4.Visual inspection
side

Source - B. Devaraj Naik, P. K. (2016)

[2]
Result Of FMEA [2]
• The frequency of the high priority maintenance activities
should be increased or new maintenance activities should
be implemented.
• FMEA analysis in this case ranks the valve as the highest
priority.
• While the pump has the second highest priority and cylinder
is the last highest RPN.
• The valve, pump and cylinder should be prioritized in the Source - B. Devaraj Naik, P. K. (2016)
[2]
maintenance plan.
 Maintenance Strategy [2]
• With the help of logic tree diagrams, the required preventive maintenance activities need to be
determined.
• This was used to evaluate the proposed strategies.
• Most of the parts on the hydraulic machine needed a periodic maintenance strategy.
• Activities like cylinder pump and direction valve fitted into a periodic schedule.
• The maintenance activities were therefore be divided into groups.
• Group A of maintenance is done every 3 months.
• Group B is done every 6 months.
• Group C is done annual.
• Group D is done every five years.
 Conclusion [2]
• After conducting Reliability Centered Maintenance strategy to the hydraulic
balancing circuit of horizontal boring machine and FMEA analysis, a check
list of preventive maintenance tasks for the hydraulic component was
proposed.
• With the help of RCM, FMEA and Logic Diagrams, appropriate maintenance
task has been determined for each component failure that should be
executed in a timely manner as decided.
• It was suggested that by the proper monitoring of the mentioned PM tasks,
the system functionality could be maintained efficiently at low cost and low
safety risk.

Source - B. Devaraj Naik, P. K. (2016)

[2]
Benefits of FMEA [2]
•Increase customer satisfaction by improving safety and reliability and mitigating the adverse effect of problems before
they reach the customer.

•Improve development efficiency in terms of time and cost by solving reliability and manufacturing problems during
design stages.

•Document, prioritize, and communicate potential risks by making issues explicit to FMEA team members, management,
and customers.

•Help reduce the chances of catastrophic failure that can result in injuries and/or adverse effect on the environment

•Optimize maintenance efforts by suggesting applicable and effective preventive maintenance tasks for potential failure
modes
References
1. Afefy, I. H. (2010). Reliability-Centered Maintenance Methodology and. Industrial Engineering Department, Faculty of
Engineering, Fayoum University, Al Fayyum, Egypt, Retrieved from
http://file.scirp.org/pdf/Engineering20101100003_85096465.pdf

2. B. Devaraj Naik, P. K. (2016). Application of Reliability Centered Maintenance on Horizontal Boring Machine - A Case
Study. International Journal of Advanced Engineering Research and Science (IJAERS), Retrieved from
http://ijaers.com/detail/application-of-reliability-centered-maintenance-on-horizontal-boring-machine-a-case-
study/

3. Carlson, C. (2012). Effective FMEAs: Achieving Safe, Reliable, and Economical Products and Processes Using Failure
Mode and Effects Analysis. Hoboken, New Jersey: John Wiley & Sons. Retrieved from
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nepage&q&f=false
References
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Symposium: ReliaSoft Consultant. Retrieved from
https://www.weibull.com/pubs/2016_RAMS_fundamentals_of_fmeas.pdf

5. Corporation, C. (2000). What is Reliability Centered Maintenance? High Technology Solutions for the Producers,
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6. FAILURE MODES AND EFFECTS ANALYSIS (FMEA). (2007). Institute for Healthcare Improvement, Retrieved from
http://www.improhealth.org/fileadmin/Documents/Improvement_Tools/FMEA.pdf
References
7. Mohamed Ben-Daya, S. O.-K. (2009). FMEA Defined. In S. O.-K. Mohamed Ben-Daya, Handbook of Maintenance
Management and Engineering (p. 76). New York: Springer. Retrieved from
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a=X&ved=2ahUKEwjRtsvajKPhAhWabysKHYhzC7gQ6AEwAHoECAkQAQ#v=onepage&q=Increase%20custome
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rse%20effect%20of%20problems%20before%20they%20reach%20the%20customer.&f=false

8. Siemens PLM Software. (2016). How to conduct a failure modes and effect analysis. Siemens PLM Software, 8.
Retrieved from https://polarion.plm.automation.siemens.com/hubfs/Docs/Guides_and_Manuals/Siemens-
PLM-Polarion-How-to-conduct-a-failure-modes-and-effects-analysis-FMEA-wp-60071-A3.pdf
References

9. Stamatis, D. H. (2003). Failure Mode and Effect Analysis: FMEA from Theory to Execution. Milwaukee: ASQ.
Retrieved from
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wjsg6GkiKDhAhXbZSsKHZ0AAZYQ6AEIKDAA#v=onepage&q=fmea&f=false

10. Zoran Petrovi, Z. C. (2014). Implementation of the RCM Methodology on the Example of City. VIII International
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