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    Fmea, RCM

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    Anne Marie Tudor
    1. FMEA is a methodology used to identify potential failure modes and their effects. It is performed during a product's lifecycle to prevent or lower failures and risks. 2. The FMEA identifies failure modes and their effects, while the FMECA (Failure Mode, Effects and Criticality Analysis) adds a criticality analysis and assigns a risk priority number to failure modes based on severity, occurrence, and detectability ratings. 3. The document defines key terms related to failure analysis and provides guidelines for conducting an FMEA/FMECA including identifying failure causes and mechanisms, performing a root cause analysis, defining corrective actions, and measuring the effectiveness of those actions.

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    Fmea, RCM

    Uploaded by

    Anne Marie Tudor
    165 views10 pages
    1. FMEA is a methodology used to identify potential failure modes and their effects. It is performed during a product's lifecycle to prevent or lower failures and risks. 2. The FMEA identifies failure modes and their effects, while the FMECA (Failure Mode, Effects and Criticality Analysis) adds a criticality analysis and assigns a risk priority number to failure modes based on severity, occurrence, and detectability ratings. 3. The document defines key terms related to failure analysis and provides guidelines for conducting an FMEA/FMECA including identifying failure causes and mechanisms, performing a root cause analysis, defining corrective actions, and measuring the effectiveness of those actions.

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    Short summary of RCM and FME(C)A

    Original Title

    FMEA, RCM

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    1. FMEA is a methodology used to identify potential failure modes and their effects. It is performed during a product's lifecycle to prevent or lower failures and risks. 2. The FMEA identifies failure modes and their effects, while the FMECA (Failure Mode, Effects and Criticality Analysis) adds a criticality analysis and assigns a risk priority number to failure modes based on severity, occurrence, and detectability ratings. 3. The document defines key terms related to failure analysis and provides guidelines for conducting an FMEA/FMECA including identifying failure causes and mechanisms, performing a root cause analysis, defining corrective actions, and measuring the effectiveness of those actions.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    165 views10 pages

    Fmea, RCM

    Uploaded by

    Anne Marie Tudor
    1. FMEA is a methodology used to identify potential failure modes and their effects. It is performed during a product's lifecycle to prevent or lower failures and risks. 2. The FMEA identifies failure modes and their effects, while the FMECA (Failure Mode, Effects and Criticality Analysis) adds a criticality analysis and assigns a risk priority number to failure modes based on severity, occurrence, and detectability ratings. 3. The document defines key terms related to failure analysis and provides guidelines for conducting an FMEA/FMECA including identifying failure causes and mechanisms, performing a root cause analysis, defining corrective actions, and measuring the effectiveness of those actions.

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    © All Rights Reserved
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    Download as docx, pdf, or txt
    of 10

    FMEA/FMECA

    Failure Modes and Effects (Criticality) Analysis


    Glossary
    CA = Criticality Analysis
    CAR = Corrective Action Request
    CC = Contributing Cause
    DC = Direct Cause
    FBD = Functional Block Diagram
    FMEA = Failure Modes and Effects Analysis
    FMECA = Failure Modes and Effects Criticality Analysis
    FR = Failure Rate
    FS = Failure Scenario
    FTA = Fault Tree Analysis
    MTBF = mean time between failures
    NTF = No Fault Found
    OSD = Occurrence, Severity, Detectability
    PCA = Preventive Corrective Action
    PFM = Potential Failure Mode
    PIPs = Performance Improvement Projects
    QLA = Qualitative Assessment
    QTA = Quantitative Assessment
    RBA = Risk-Based Approach
    RC = Root Cause
    RCA = Root Cause Analysis
    RPN = Risk Priority Number
    RRA = Revised Risk Analysis
    SCA = Specific Corrective Actions
    SWIFT = Structured WHAT IF Technique
    SYCA = Systematic Corrective Actions
    RBD = Reliability Block Diagram

    FMEA is a methodology that helps to identify potential failure modes and


    their effects(consequences) and implement a strategy to prevent or lower the
    1

    failures and also the risks. It is used for a produc life-cycle and its based on
    experience from similar products/processes or based on failure logic.
    The FMEA can be done without a CA, but a CA requires the FMEA has
    already identified system level critical failures. Only after this, the result is
    FMECA.
    EFFECTS analysis refers to analysing the consequences of failure based on
    a system levels structure.
    RISK REDUCTION main goal is to reduce the severity of failure effects or
    to lower the probability of failure, or both. The probability should get to
    impossible to occur, fact that can happen by eliminating the root cause(s). It is
    ideally to early identify critical failure modes so they can be eliminated or at least
    minimized.
    FMECA is structured in 2 sub-analyses:
    1. FAILURE MODES (FM)

    EFFECTS ANALYSIS (EA)

    2. CRITICALITY ANALYSIS (CA)


    FAULT TREE ANALYSIS (FTA) is a top-down deductive failure analysis
    which may handle multiple failures, using a backward logic. It is used BOOLEAN
    LOGIC.

    The GATE symbols describe the relationship between input and output events.

    BENEFITS
    A well implemented FMEA should provide:

    High probability of successful operation and safety


    Knowledge of potential failure modes and their impact on system operation
    A list of failure modes ranked, according to the severity and probability of
    occurrence.
    Early planning of tests.

    The failure MODE is a specific manner by which a failure occurs.


    The MECHANISM (PROCESS) is a secquence of causes that leads to a failure
    mode, over a period of time. (Ex: fatigue,corrosion)

    DORMANCY/LATENCY PERIOD
    Is the average time that a failure mode may be undetected:

    Seconds auto detected by maintenance computer


    8 hours detected by turn-around inspection
    2 months detected by scheduled maintenance
    2 years detected by overhaul task (revizie generala)

    RISK PRIORITY NUMBER (RPN) = SEVERITY(S) x OCCURRENCE(O) x


    DETECTION(D)
    RPN is a product of the numerical Severity, Occurrence and Detection
    ratings.
    Risk is a measurement of consequence of a failure mode related to its probability
    of occurrence. High risk failure modes should receive risk reduction
    considerations.

    FAILURE CAUSES
    FAILURE CAUSES are defects in design, process and quality which are the
    cause of a failure or which initiate a process which leads to a failure.
    FAILURE MECHANISM : corrosion, welding, fatigue, dust accumulation
    ROOT CAUSE: human error design failure, operational errors,
    management failure,
    specification failure.
    FAILURE SCENARIO : secquence, combination of
    events/failures/conditions leading to an
    end failure state.
    - A failure scenario is for a system the same
    as the failure mechanism is for a component.
    - Scenario/Mechanism = complete
    description of the failure occurrence.
    Mechanical failure:

    Excessive DEFLECTION (deviatie, abatere)


    3

    BUCKLING (deformare)
    DUCTILE FRACTURE (fisura)
    BRITTLE FRACTURE (casare)
    IMPACT
    CREEP (alungire, dilatare)
    RELAXATION (slabire)
    THERMAL SHOCK
    CORROSION
    WEAR (frecare)
    FATIGUE

    ROOT CAUSE
    ROOT CAUSE is the initial/initiating cause that leads to a failure mode. It
    describes the depth in the causal chain.
    Root = deep, basic, fundamental, underlying, initial

    ROOT CAUSE ANALYSIS (RCA)


    RCA is a method of problem solving used to identify the root cause of a
    failure. A factor is considered a ROOT CAUSE if its removal prevents the final
    potential failure.
    The main goal is to :
    Prevent recurrence
    Be effective
    Have a secquence of events for understanding the relationship
    betweet factors.
    --General process for performing and documenting an RCA-based Corrective
    Action-RCA forms the most critical part of successful corrective action. So the steps we
    have to proceed are the following:
    1. Define the problem, describe the event including qualitative and
    quantitative attributes(properties)
    2. Gather data and evidence
    3. Identify corrective actions to prevent recurrence of harmful effects.
    4. Identify solutions
    5. Identify useful methodologies for problem solving and problem avoidance.

    Structured WHAT IF Technique (SWIFT)


    SWIFT is a hazard analysis method that uses a structured brainstorming
    with guide words (key words). The idea is to identify risks with the aim of
    being quicker than intensive methods like FMEA.

    Failure Rate () = is the frecquency with which a system/component


    fails, expressed in failures per unit of time.
    4

    MTBF = mean time between failures

    NTF = no fault found due to oxidation, defective connections of electrical


    components, temporary shorts or opens in circuit, software bugs, operator
    errors.

    THE CRITICAL FIVE


    1. Direct Cause

    = the cause that directly resulted in the event

    2. Contributing Cause = the cause that contributed to an event but


    itself would not have
    caused the event (the cause after
    the direct cause)
    3. ROOT Cause
    = the fundamental reason for an event, which if
    corrected would
    prevent recurrence.
    4. Specific Corrective Action = actions taken to correct/improve
    conditions noted in the
    event, by changing the direct
    cause or the direct cause and
    the effect.
    5. Preventive Corrective Action = actions takent that prevent
    recurrence of the condition
    noted in the event
    Example:
    Keep asking WHY?
    Problem : didnt get to work on time Why?
    Direct Cause: Car wouldnt start Why?
    Contributing Cause: Battery was dead Why?
    Contributing Cause: Dome light on all night Why?
    ROOT Cause: Kids played in car, left door ajar.(intredeschis)

    CORRECTIVE ACTION
    1. SPECIFIC Specific corrective actions are actions taken to correct the
    direct cause. Does
    not prevent recurrence
    2. PREVENTIVE Preventive corrective actions are actions taken that
    prevent recurrence of
    the condition noted in the event. It focuses
    on changing the root cause and
    any contributin cause(s).
    3. SYSTEMATIC Systematic corrective actions are actions taken that
    address the failure in
    the suppliers quality system that allowed
    the event to occur.

    EFFECTIVENESS MEASUREMENT
    Effectiveness measurement is a criteria used to evaluate if the
    corrective actions achieved the desire outcome, result. Periodic checks
    are necessary to be sure the corrective actions are still in place and
    continue to be effective.

    EVENT

    1.FORM

    2.

    TEAM

    DESCRIBE
    ISSUE

    GATHER

    DATA

    3.

    IMPLEMENT,
    VERIFY
    CORRECTIVE
    ACTIONS

    DIRECT

    4. DEFINE, VERIFY CORRECTIVE ACTIONS


    ROOT

    CONTRIBUTING

    DETERMINE CORRECTIVE ACTIONS

    SPECIFIC

    PREVENTIVE

    5. VERIFY CORRECTIVE ACTION


    N
    O

    6. IMPLEMENT PERMANENT CORRECTIVE ACTIONS


    7. PREVENT RECURRENCE
    SOLUTION ACCEPTABLE
    CONGRATULATIONS TEAM

    BASIC CAUSES OF A RISK EVENT


    1. Physical material item failed
    2. Human people did something wrong/did not do something they were
    supposed to.
    3. Organizational

    YE

    v
    O
    d
    R
    k
    T
    V
    Y
    IW
    H
    M
    F
    A
    E
    B
    r
    t
    e
    a
    n
    lP
    s
    iy
    D
    b
    h
    o
    g
    m
    C
    c
    u

    METHO
    DS

    -it can be used a combination of 2 RCA methods for better results (ex: 5
    WHYs + Fishbone Diagram)
    FISHBONE DIAGRAM includes people, methods, machines, materials,
    measurements, environment.

    QUALITATIVE ASSESSMENT
    -developed to rank the risk events based on severity
    -informations can be implemented into a heat map.
    -used in the first stages of a project

    QUANTITATIVE ASSESSMENT
    - how much capital is sufficient
    -Monte Carlo Simulation probability of certain outcomes by running
    multiple trial
    runs, called simulations, using
    random variables
    - efficient frontier shows the best possible expected level of return for
    its level of risk.
    -used in the later stages when more data is available

    BOTTOM UP / TOP DOWN


    There are 2 methods in which data can be analysed. Bottom up
    method not used anymore because it is too expensive.
    For redundant items of equipment carrying out the same duty, if one
    item has been analysed to component level it is reasonable to assume
    that the other item will behave the same as the first item.
    RELIABILITY BLOCK DIAGRAM (RBD) = shows the operational
    relationships between each
    subsystem or
    component
    OCCURRENCE RATING:

    106

    Remote failure is unlikely, fail rate

    Very Low isolated failure, fail rate

    Low isolated failure with similar systems, fail rate -

    Moderate occasional failure, fail rate

    High generally associated with systems which often fail, fail


    rate

    105
    104

    103

    102

    Very High failure is almost invitable, fail rate

    101

    SEVERITY RATING:

    Minor doesnt cause real effect on system. Failure might not be


    noticed
    Severity level is MINOR

    Low causes a slight deterioration of system capability


    Severity level is MINOR
    8

    Moderate causes some deterioration in system capability


    need for unscheduled work/repair; can cause minor injury to user
    Severity level is MARGINAL
    High causes loss of system capability; may cause serious health
    hazard or
    serious injury to user;
    Severity level is CRITICAL
    Veri High could cause system loss and/or death of user(s);
    Severity level is MAJOR

    DETECTION RATING

    Very High Controls will almost certainely detect the existence of


    a defect
    High Controls have good chance of detecting the existence of a
    defect
    Moderate Controls may detect the existence of a defect
    Low Controls have a poor chance of detecting the existence of
    a defect
    Very Low Controls probably will not detect the existence of a
    defect
    Absolute Certainty of Non-Detection Controls will not / cannot
    detect the existence of a defect
    CRITICALITY = Measure for gravity of failure mode effects and
    is determined from combination of severity and the likelihood of
    occurrence.

    Basic INFORMATIONS recquired for FMEA


    process
    What does the system do? MISSION
    What is its function? FUNCTION
    How could it fail to perform its function? FAILURE MODE
    What happens if it fails? EFFECT of failure
    What is the likelihood of failure? OCCURRENCE (O)
    What is the consequence of failure? SEVERITY (S)
    What is the predictability of failure ? DETECTABILITY (D)
    What is the Risk Priority Number (RPN)? RPN = O x S x D
    Risk Priority Number (RPN)
    If RPN>33 then consider the possibility to renew/replace the asset
    DAMAGE MODE and Effects Analysis = Is the analysis that
    determines the extent of
    damage on
    the system/equipment

    10

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