CBM+: Practitioner’s Guide to Implementing a Successful Program:

Failure Modes, Effects, and Criticality Analysis

Continuously Pushing the Limits of Innovation, Technology & Conventional Thinking

JC Leverette Jon.leverette@androsysinc.com 904.637.2016

Topics

FMECA Overview

Uses

Role in Supportability

sFMECA

FMECA Overview

FMECA Failure Modes, Effects, and Criticality Analysis

Identifies: Item – What it is (Tire)

Functions – What it does (Provides traction)

Functional Failures – How it fails to do it (Loss of traction)

Failure Modes – Why it fails to do it (worn tread)

Failure Effects – What happens when it fails (doesn’t channel water, hydroplane, car crashes)

Severity of Failure – How bad it is ($ damage, possible loss of life)

Failure Frequency – How often it happens (50K miles)

Criticality – Severity + Frequency (usually a Hazard Risk Index)

FMECA Uses The primary objective of an FMECA is to improve the design. For System FMEAs, the objective is to improve the design of the system. For Design FMEAs, the objective is to improve the design of the subsystem or component. For Process FMECAs, the objective is to improve the design of the processes such as manufacturing. 1

Other objectives for of FMEAs include:

Identify and prevent safety hazards Minimize loss of product performance or performance degradation Improve test and verification plans (in the case of System or Design FMEAs) Improve Process Control Plans (in the case of Process FMEAs) Consider changes to the product design or manufacturing process Identify significant product or process characteristics Develop Preventive Maintenance plans for in-service machinery and equipment Develop online diagnostic techniques

Develop Supportability Elements FM = Corrective Maintenance RCM = Preventive Maintenance

1 Effective FMEAs: Achieving Safe, Reliable, and Economical Products and Processes Using Failure Mode and Effects Analysis, Carl Carlson, May 2012

5

FMECA Role in Supportability

Design

Interface Maintenance

Planning

Maintenance

Scheduling

Maintenance

Execution

System Description & Operation Drawings Functional Block Diagram

LORA

Scheduled Maintenance Tasks

Off-Aircraft Maint.

On-Aircraft Maint.

O, I, D

Maint.

Data

Tools/SE

TTR

Skills/Rate

Facility Requirements

Manpower

Consumables

Repairables

PHS&T

Computer Resources

HAZMAT/Environmental

Operational Demand

Planning (i.e. CONOPs , Op. Architecture,

WSPD, TYCOM Plans)

FMECA

PSE LEMS

Training

Tech Data

Manpower

SE

Spares

PHS&T

Facilities

Tools, etc

Use study

BCS – CA

Functional RQMTS

Standardization/

interoperability

AoA Trade Studies

D/I

Failure Modes

Fly to Fail

Hard time

Failure Finding

Lube – Service

Condition monitoring • PHM/CBM+

• Inspect & Repair

• Conditional Task

Other (redesign, ECP)

Age Exploration

RCM

L&Sim Inputs

Existing Repair Cap

“Default” Data

MTA

O-level

I-level

D-level

O-level

I-level

D-level

Unscheduled Maintenance Tasks

Task level

feedback

sFMECA Use of Design FMECA for SA has been challenging

Typical product development organization: FMECA performed by Design engineers or R&M

“Kicked over the fence” to Supportability/Logistics for SA

Design vs sFMECA Focus

Design focus on elimination of critical failure modes

sFMECA focused on development of support elements necessary to maintain and repair

Level of Analysis Design: Piece part or lower

sFMECA: Only to level of support action (LOR)

Context sFMECA should also includes failures of the support system itself

Future SAE G-11 Project sFMECA Standard/Guide