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FMEA FMECA The Workhorse
FMEA FMECA The Workhorse
Don Ogwude
Principal Consultant
Lloyd’s Register Energy Consulting
October 10, 2013
Safety Driven Performance Conference 2013
Overview
Benefits:
• Insures reliable systems/ components that
result in production uptime optimization;
• Reduces/ prevents failures that could have
severe impact on personnel safety, the environment, and/or
assets
Safety Driven Performance Conference 2013
Overview
• FMEA (Failure Modes Effect Analysis) is the baseline for effective
reliability analysis and the preferred systematic technique for
failure analysis
• Many industries are integrating the use of this technique to
eliminate or reduce downtime and refine the design of their assets
• The history, evolution and application of this technique will be
discussed including its application in reduction of costly product
design issues and in the development of new processes and
procedures that improve a facility's asset integrity throughout its
life cycle
Safety Driven Performance Conference 2013
Definition
History
• FMEA was developed by the U.S. Military. The first guideline was Military
Procedure MIL-P-1629 “Procedures for performing a failure mode, effects and
criticality analysis” dated November 9, 1949
• First systematic techniques for failure analysis and most widely used reliability
analysis technique in the initial stages of product/system development and system
reliability studies
• Usually performed during the conceptual and initial design phases of the system in
order to assure that all potential failure modes have been considered and the proper
provisions have been made to eliminate these failures
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FMEA Derivatives
FMECA
FMECA
FMECA
FMECA
Data Triangle
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FMEA Requirements
Resources:
(1) Documentation of mission requirements
(2) Schematics or drawings of the system.
(3) An understanding of component, subsystem, & systems operations
(4) Block diagram which graphically shows the operation and interrelationships between
components of the system defined in the schematics
(5) Bill of materials list (for hardware only)
(6) Component failure rate data
• Meeting facility with enough space to display schematics, block diagrams or other documents for
all members to view
• Convenient to have two computer display projectors; one for drawings, the other displays the
FMECA form
• Ground rules and the goals of the mission should be established at the beginning of the meeting
Safety Driven Performance Conference 2013
Methodology
•Used in early design phase before the whole system structure is decided - the analysis
is usually function oriented
•Analysis starts with the main system functions - and how these may fail
•Functional failures with significant effects are prioritized in the analysis
•The analysis may not capture all components for analysis
•The top-down approach may also be used on an existing system to focus on problem
areas
Safety Driven Performance Conference 2013
Methodology
Component Level/ Bottom-up Approach (Commonly used)
• The bottom-up approach is used when a system concept has been decided
• Each component on the lowest level of indenture is studied one-by-one, starting at the component level and
expanding upward
• The bottom-up approach is also called hardware approach
• The analysis is complete since all components are considered
• A general rule: the analysis should be conducted at a level where failure rate estimates are available or can be
obtained
Safety Driven Performance Conference 2013
Methodology
• Identify all functions in scope of study and decompose each function into
components
• For each component, determine the ways in which it can fail
• For each failure mode, determine effects
• Select a SEVERITY level for each effect
• Identify potential causes of each failure mode
• Select an OCCURENCE level for each cause
• List current controls for each cause
• Select a DETECTION level for each cause
Safety Driven Performance Conference 2013
Methodology
Methodology
Failure Effects
Methodology
• Failure effect levels are:
a. Local effects are those effects that result specifically from the failure mode of the item in the
indenture level under consideration
b. Next higher level effects are those effects which concentrate on the effect of a particular failure
mode has on the operation and function of items in the next higher indenture level
c. End effects are the effects of the assumed failure on the operation, function and/or status of the
system
FMECA
Risk Ranking - Probability
FMECA
Risk Ranking - Consequence
FMECA
Risk Ranking - Matrix
PROBABILITY
P=1 P = 2 P = 3 P = 4 P = 5
Could occur, Has occurred Incident has Incident has Incident has
but never in the world, occurred in occurred occurred
heard of in but very some several times in several times
the world. unlikely. operators some in most
operators. operators.
Description Less than Less than Once every Once every Once every
once in once in 10000 100 - 1000 100 - 10 years 1 - 10 years
10 000 years years years
C= 5 30+ fatalities
C= 4 10 - 30 fatalities
CONSEQUECE
C= 3 1 - 10 fatalities
C = 2 Serious Injury
C = 1 First aid /
medical
treatment case
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Methodology - General
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Lessons Learned
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Success criteria
• Preparation to ensure good understanding of system
• System should be accurately broken down to subsystems and components
• Preparation of worksheet with components and failure modes prior to start
of FMECA
• Good communication with client to ensure agreement on system limits,
criticality matrix and worksheet format
• Updated and detailed drawings and procedures are available prior to start of
study
• FMECA team composed of participants possessing relevant and sufficient
knowledge in system being analysed
Safety Driven Performance Conference 2013
Success criteria
• FMECA leader with good facilitation skills
• Clear and consistent description of failure modes, causes, effects,
detection methods and safeguards
• Clear and concise recommendations
• The follow-up and close-out responsibility must be defined
• A follow-up / close-out report should include all the action items from the
FMECA
• The effects of redundancy should be taken into consideration when
calculating criticality numbers or assigning occurrence rankings because
redundancy reduces the failure rate, thus increasing the availability
Safety Driven Performance Conference 2013
Pitfalls
FMEA Standards
• MIL-STD 1629 “Procedures for performing a failure mode and effect analysis”
• IEC 60812 “Procedures for failure mode and effect analysis (FMEA)”
• BS 5760-5 “Guide to failure modes, effects and criticality analysis (FMEA and
FMECA)”
• SAE ARP 5580 “Recommended failure modes and effects analysis (FMEA)
practices for non-automobile applications”
• SAE J1739 “Potential Failure Mode and Effects Analysis in Design (Design
FMEA) and Potential Failure Mode and Effects Analysis in Manufacturing and
Assembly Processes (Process FMEA) and Effects Analysis for Machinery
(Machinery FMEA)”
• SEMATECH (1992) “Failure Modes and Effects Analysis (FMEA): A Guide for
Continuous Improvement for the Semiconductor Equipment Industry”
• ISO 14224 – Examples for breakdown etc…
• ISO 20815. RAM and production assurance
For more information, please contact:
Don Ogwude
Principal Consultant
Lloyd’s Register Consulting
T 832-638-8646
E [email protected]
W www.lr.org/consulting
W www.riskspectrum.com