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    Failure Mode and Effects Analysis (FMEA) : SIT IN PROJECT GROUPS (But Not Necessarily Teams)

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    James Calos
    The document discusses conducting a Failure Mode and Effects Analysis (FMEA) on a project. It provides guidance on performing each step of an FMEA, including defining the scope, creating a functional block diagram, identifying potential failure modes and causes, analyzing the effects, assigning severity, probability and detection ratings, calculating the risk priority number, and recommending improvements. Examples of past engineering failures are provided such as the Quebec bridge collapse and hindenburg disaster. The document concludes by providing an example FMEA worksheet and explaining each of the 10 steps to fill it out.

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    Failure Mode and Effects Analysis (FMEA) : SIT IN PROJECT GROUPS (But Not Necessarily Teams)

    Uploaded by

    James Calos
    150 views23 pages
    The document discusses conducting a Failure Mode and Effects Analysis (FMEA) on a project. It provides guidance on performing each step of an FMEA, including defining the scope, creating a functional block diagram, identifying potential failure modes and causes, analyzing the effects, assigning severity, probability and detection ratings, calculating the risk priority number, and recommending improvements. Examples of past engineering failures are provided such as the Quebec bridge collapse and hindenburg disaster. The document concludes by providing an example FMEA worksheet and explaining each of the 10 steps to fill it out.

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    W8 FMEA

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    The document discusses conducting a Failure Mode and Effects Analysis (FMEA) on a project. It provides guidance on performing each step of an FMEA, including defining the scope, creating a functional block diagram, identifying potential failure modes and causes, analyzing the effects, assigning severity, probability and detection ratings, calculating the risk priority number, and recommending improvements. Examples of past engineering failures are provided such as the Quebec bridge collapse and hindenburg disaster. The document concludes by providing an example FMEA worksheet and explaining each of the 10 steps to fill it out.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    150 views23 pages

    Failure Mode and Effects Analysis (FMEA) : SIT IN PROJECT GROUPS (But Not Necessarily Teams)

    Uploaded by

    James Calos
    The document discusses conducting a Failure Mode and Effects Analysis (FMEA) on a project. It provides guidance on performing each step of an FMEA, including defining the scope, creating a functional block diagram, identifying potential failure modes and causes, analyzing the effects, assigning severity, probability and detection ratings, calculating the risk priority number, and recommending improvements. Examples of past engineering failures are provided such as the Quebec bridge collapse and hindenburg disaster. The document concludes by providing an example FMEA worksheet and explaining each of the 10 steps to fill it out.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 23

    SIT IN PROJECT GROUPS (but not necessarily teams)

    Failure Mode and Effects Analysis (FMEA)

    Quebec Bridge collapse, August 29 1907

    TEMPLATE C: Get a form, fill it out, stick it in your logbook.

    What were doing today


    Template F (FMEA) must do! Scope of Analysis System Diagram Risk Analysis

    Engineering Failure
    Andrew Purchase gave lecture: Engineering is serious business. Requires meticulous and ethical behaviour. How do we avoid failure and how do we learn from it through reflection? Engineering is about structured approaches, rational processes, and systematic methods. Predicting failure means thinking about how it might occur (provisional thinking).

    Prediction implies considering probabilities

    http://en.wikipedia.org/wiki/Category:Engineering_failures

    Probability
    Difficult to assign values to likelihood:
    Common Causes Phenomena constantly active within system and therefore predictable (quantifiable) but against cost and time. Derived from previous instances. Special Causes New, unanticipated or previously neglected phenomena within system and therefore unpredictable but possible to allow for within design through redundancies or other mitigations.
    http://en.wikipedia.org/wiki/Common-cause_and_special-cause

    Standard Risk Model


    Identify Risk Event Estimate Impact of Risk Event

    Risk Event Driver = rationale for believing risk event will occur Impact = consequence that might result if risk event occurs

    Failure
    Negative outcome caused by:
    Defects in the design
    Materials Components Configuration of components

    Errors in Design Process


    Decision making Validity of Data

    Inadequate Operation
    Usage (Human Error)

    A common mistake that people make when trying to design something completely fool proof is to underestimate the ingenuity of complete fools. - Douglas Adams

    Failure Mode and Effects Analysis


    A process which helps define, identify, prioritise, and eliminate known and/or potential failures of the system before they reach the customer.

    What you dont want to happen!

    Scope and Analysis


    Resolution

    Base your FMEA on your prototype and Demo Day.

    The 4 major subsystems: electrical system, safety valve, thermostat, and pressure gauge

    Focus
    Safety (but could be reliability)

    Lets begin
    1) Define scope of analysis for demo day. Resolution
    Decide on system level for FMEA: subsystem, assembly, subassembly, component, part, materials, etc.

    Focus
    General or focused on an individual areas such as safety, reliability, or usability.

    Template: Define your resolution and scope (3 mins)

    Time to sketch
    2) Prepare functional block diagram of system graphically showing the operation and interrelationships between functional entities in the system.

    Block diagram - Pressure Cooker


    Pressure Cooker Cooks food under pressure

    Lid 1. Allows lid rotation 2. Connects lid to vessel

    1. Access to vessel 2. Contains pressure

    Vessel

    1. Holds food 2. Contains pressure

    Hinge

    Clamp

    Relief Valve

    Gauge

    Hinge

    Element

    Clamp

    Pin

    Thermostat

    Fastener

    Electrical System
    Spring Body Ball Cord/Plug

    Template: Draw your functional block diagram (10 mins)

    Some Failure Cause Terms


    Mechanical: Friction: binding Stress: bending, stretching/yielding, buckling, warping, shearing Misalignment Fasteners loosening Leaking Electrical: Battery drain Short circuit/Open Circuit Overheating/melting Operational: Mishandle Forget
    (Motiva acid tank 2001)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    2) Items from Functional Block Diagram

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    3) Identify possible failure modes for each subsystem/component (item).


    What is the failure mode?
    A concise description of how a part, system, or manufacturing process may potentially fail to perform its functions (e.g. Drive motor Loss of power)

    (Tacoma Narrows Bridge 1940)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    4) Identify possible causes for each failure mode.

    What is the root cause?


    e.g. short circuit caused by sealant failure allowing ingress of water? Or dead batteries? Or my team mate wired it up wrong?

    (Freeway collapse, Always happening)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    5) Analyse the effects of the failure modes. What are the effects of the failure?
    Local effects (e.g. Loss of motor rotation) System effects (e.g. Loss of mobility i.e. dead in the
    water)

    (Chernobyl Reactor 1986)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    6) Classify the severity of the effects of each failure:


    4 - Catastrophic (0%, total system failure, open warfare among team members) 3 - Critical (barely passed, extreme embarrassment) 2 - Marginal (loss of 20%, lots of anxiety) 1 - Negligible (loss of 10%, some nervousness)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    7) Classify the failure mode probabilities of each failure:


    4 - Expected (Likely to occur immediately or within a short period of time) 3 Occasional (Probably will occur in time) 2 Remote (Possible but not likely) 1 - Improbable (Very unlikely but could happen)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    8) Classify the detection probabilities of each failure:


    4 Impossible (impossible to detect/no inspection) 3 - Possible (some chance/ 50% inspection) 2 - Likely (quite likely/ 75% inspection) 1 - Certain (will be detected/ 100% inspection)

    (Wind turbine, Undetected thermostat malfunction)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    9) Calculate Risk Priority Number (RPN):


    The product of Severity, Occurrence, & Detection. RPN = Sev x Prob x Det RPNs often sorted from high to low for consideration in action planning step. BUT RPNs can be misleading- you must look for patterns.

    (Hindenburg disaster 1937)

    FMEA Worksheet
    Item Failure mode Causes (failure Mechanism) Effects Risk Priority Rating Recommended Risk Priority Rating Sev Prob Det RPN Improvement Sev Freq Det RPN

    10) Recommended improvement: Based on the FMEA analysis, strategies to reduce risk are focused on:
    Reducing the Severity Rating. Reducing the Probability Rating. Reducing the Detection Rating.

    A thoroughly thought out and well developed FMEA with High Risk patterns that is not followed with corrective actions has little or no value, other than having a chart for an audit

    FMEA
    Item Failure mode Causes (failure Mechanism) Defective cord No current Defective plug Defective heating coil Effects Risk Priority Rating Sev Prob Det RPN Recommended Improvement Periodically inspect cord and plug Use high-quality components Use a grounded (3-prong) plug Use outlets with groundfault circuit interrupters Design spring to handle the fatigue and corrosion that it will be subjected to Cooking interruption (mission failure) Cooking interruption

    2 1 3

    1 2 3

    6 6 27 3

    Electrical System

    3 1 1

    Current flows to Faulty insulation ground by an alternate route

    Shock Steam could burn operator Increased cooking time

    4 3

    4 3 2

    Open

    Safety Valve
    Closed

    Broken valve spring

    FMEA Worksheet Steps


    1. 2. 3. 4. 5. 6. 7. 8. 9. Item(s) from Block diagram How might this item fail Possible causes of the failure Effects of the failure Severity (negligible/catastrophic) Probability (improbable/expected) Detection (certain/impossible) RPN (multiplication) Mitigation (how to prevent)
    Mechanical: Friction: binding Stress: bending, stretching/yielding, buckling, warping, shearing/breaking Misalignment Fasteners loosening Leaking Electrical: Battery drain Short circuit/Open Circuit Overheating/melting Operational: Mishandle Forget

    Template: Fill in your FMEA (~10 mins)

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