Manufacturing Systems: Concurrent Engineering Failure Mode & Effect Analysis (FMEA)
Manufacturing Systems: Concurrent Engineering Failure Mode & Effect Analysis (FMEA)
11/5/2004
MANUFACTURING SYSTEMS
CONCURRENT ENGINEERING
Failure Mode & Effect Analysis
(FMEA)
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Concurrent Engineering:
Module Plan
I.
II.
III.
IV.
V.
VI.
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Introduction
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FMEA: Definition
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[Aven, 1992]
N.B. Only one component is considered at a time, the other components
are then assumed to function perfectly. FMEA is therefore not suitable
for revealing critical combinations of component failures.
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Level 1
Failure
mode
Level 2
First-level
cause
System
Design
Process
Service
Failed to
work
Cannot
generate
pulse
Open circuit
Poor
material
feed.
Operator
variability.
Poor service.
On/off
switch
Lack of
training.
Material
too thin
(may be a
spec issue).
Level 3
Material
Secondbroken
level cause: (may be
root
a stress
cause
issue)
No
availability
of said
service.
Not enough
personnel.
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Severity
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Occurrence
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Detection
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Ref: MIL-STD-1629A
A Criticality Matrix
A
B
lity
ica
t
i
r
c
ing
eas
r
c
In
Iso-criticality
curve
C
Minor
Marginal
Critical
Catastrophic
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10
10
10
10
10
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Reducing RPN
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4 Types of FMEA
I. System FMEA - Used to analyse systems and
subsystems in the early concept and design stage.
II. Design FMEA - Used to analyse products before
they are released to manufacturing.
III. Process FMEA - Used to analyse manufacturing
and assembly processes.
IV. Service FMEA - Used to analyse services before
they reach the customer.
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A
Normal input
E2
E1
And gate A
Secondary input
E2
E1
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Fault tree
Top
Series structure
1
Top
2
3
Parallel structure
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Example
Engine will not
start
Fuel flow
failure
Fuel pump
failure
Carburettor
failure
Ignition
failure
Blocked
jet
Faulty
jet
L.T.
failure
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Ignition
system
Ignition
system
Blocked
fuel
H.T.
failure
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The figure shows a partial FTA for a food manufacturer who has a problem with potato chip
breakage. In this analysis, potato chips break because they are too thin or because they are too
brittle. The options for fixing the problem of too-thin chips--increasing thickness or reducing
size--are undesirable, as indicated by the Xs. The problem of too-brittle chips can be alleviated by
adding more moisture or having fewer ridges or adjusting the frying procedure. We choose to
adjust the frying procedure, which leads to the question of how hot the oil should be and how
long to fry the chip. Once these values are determined, the issue of too-brittle chips (and thus chip
breakage) is solved, as indicated.
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The figure shows an open container for preliminary storage of fluid for
use in the production process.The consumption of fluid is not constant.
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When the the liquid level reaches a certain height - normal level, then
the Level Switch High (LSH) will be activated and send a closure signal
to the valve v1.The fluid supply to the tank then stops.
If this mechanism does not function and the liquid level continues to
increase to abnormal level, then the Level Switch High High (LSHH)
will be activated and send a closure signal to valve V2. The fluid supply to
the tank then stops. At the same time the LSHH send an opening signal to
valve V3 so that the fluid is drained.
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LSH
V2
LSHH
V1
Tank
To
consumer
V3
Drain
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Fault Tree
V1 does not
close
V1 does not
function
No signal
from LSH
LSH doe not
send signal
Associated
reliability
diagram
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V3 does not
open
V2 does not
close
V2 does not
function
No signal
from LSHH
LSHH doe not
send signal
V3 does not
function
No signal
from LSHH
LSHH doe not
send signal
Can you do it ?
Dr. A.W. Labib (UMIST)
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Other Methods
(Coarse Risk Analysis)
Hazard
Cause
Main effects
Poisonous H 2S causes
release
cylinder
leakage
H 2S not
consumed in
the process
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Preventing/imp
roving action
Large releases
- Alert system.
may cause
- Minimise
severe accidents storage at the
site.
- Develop
procedures for
cylinder
inspection.
As above
- Construct
collection
system foe
excess of H2S,
and stop the
process.
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Uses of FMEA
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SUMMARY
FMEA definitions.
Severity.
Occurrence.
Detection.
Performing FMEA.
FMEA in a TQM
Context.
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Levels of Failure
Modes.
Risk Priority umber
(RPN).
4 Types of FMEA.
Other Tools Related to
FMEA.
Example.
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Further Reading(s)
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