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Transcript of FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA) Module 4 UNIT II RCM PROCESS " Copyright...
FAILURE MODE, EFFECTS, FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS AND CRITICALITY ANALYSIS
(FMECA)(FMECA)
FAILURE MODE, EFFECTS, FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS AND CRITICALITY ANALYSIS
(FMECA)(FMECA)
Module 4Module 4
UNIT IIUNIT II
RCM PROCESSRCM PROCESSRCM PROCESSRCM PROCESS
"Copyright 2002, Information Spectrum, Inc. All Rights Reserved."
• IntroductionIntroduction• IntroductionIntroduction
Module Preview:Module Preview:Module Preview:Module Preview:
• FMECAFMECA• FMECAFMECA
IntroductionIntroductionIntroductionIntroduction
• ReferencesReferences• ReferencesReferences
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
• Review and SummaryReview and Summary• Review and SummaryReview and Summary
Module Objective:Module Objective:Module Objective:Module Objective: IntroductionIntroductionIntroductionIntroduction
1. Introduce the concept of Failure Mode, 1. Introduce the concept of Failure Mode, Effects, and Criticality Analysis (FMECA). Effects, and Criticality Analysis (FMECA).
2. Define the following FMECA terms:2. Define the following FMECA terms: FunctionFunction Functional FailureFunctional Failure Failure ModeFailure Mode Failure EffectFailure Effect Failure DetectionFailure Detection Severity ClassificationSeverity Classification Mean Time Between Failure (MTBF)Mean Time Between Failure (MTBF)
3. Identify FMECA reference materials3. Identify FMECA reference materials
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
1. Identify Team and responsibilities 4. Identify and document Review Process2. Identify analysis items 5. Orientation/Training3. Prioritize Items 6. Ground Rules and Assumptions
PLANNING AND PREPARATION
ANALYSIS
RCM ProcessRCM ProcessRCM ProcessRCM Process
AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan
AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan
MaintenanceMaintenanceRequirementsRequirements
MaintenanceMaintenanceRequirementsRequirements
Maintenance Maintenance ProgramProgram
Maintenance Maintenance ProgramProgram
DataDataDataData
1. Equipment Kick-off Meeting2. Initial Data Gathering3. Hardware Partition4. Function5. Functional Failure6. Failure Mode7. Failure Effects8. Failure Consequences9. Task Evaluation10. Task Selection
1. Package Maintenance Task2. Implement Other Actions
ResultsResults
IMPLEMENT RESULTS
1. Emergent Issues2. Age Exploration3. Hardware Changes4. Trend/degrader analysis5. Document Reviews
SUSTAIN
FMECAFMECAFMECAFMECA
FMECA
FMECA Definition:FMECA Definition:FMECA Definition:FMECA Definition:Process used to determine the functions, Process used to determine the functions, functional failures, and failure modes of functional failures, and failure modes of equipment; and the associated effects, severity, equipment; and the associated effects, severity, and frequency of each failure modes:and frequency of each failure modes:
Steps involve identifying... Steps involve identifying... • FunctionsFunctions• Functional FailuresFunctional Failures• Failure ModesFailure Modes• Failure Effects Failure Effects • Severity of Failure effectsSeverity of Failure effects• Frequency of occurrenceFrequency of occurrence
… … as they apply to the equipment under as they apply to the equipment under analysis in its operating contextanalysis in its operating context
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
Hydraulic PumpAssembly
FUNCTIONFUNCTIONWhat the user expects the asset or system to do What the user expects the asset or system to do within a required standard of performance.within a required standard of performance.
Provides hydraulic Provides hydraulic fluid at a pressure fluid at a pressure of 3000 psi +/- 200 of 3000 psi +/- 200 psipsi
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Consider all functions of an itemConsider all functions of an item
Describe functions in terms of specific Describe functions in terms of specific limits when possiblelimits when possible
State functions in terms of what the item State functions in terms of what the item is needed for, not its capability is needed for, not its capability
Do not combine functionsDo not combine functions
• Function descriptions should include a Function descriptions should include a verb, object, and applicable limitsverb, object, and applicable limits
Identifying FunctionsIdentifying Functions:Identifying FunctionsIdentifying Functions: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
All equipment has primary and secondary All equipment has primary and secondary functionsfunctions
FMECA for RCM analysis should identify ALL FMECA for RCM analysis should identify ALL primary AND secondary functions. Typical primary AND secondary functions. Typical Secondary Functions: Secondary Functions:
ControlControl Warning or status indicationWarning or status indication Environmental protectionEnvironmental protection Physical support or attachmentPhysical support or attachment Safety or protective functionsSafety or protective functions Fluid Containment Comfort and Aesthetics
Identifying Functions:Identifying Functions:Identifying Functions:Identifying Functions: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Identifying Functions:Identifying Functions:Identifying Functions:Identifying Functions: FMECAFMECAFMECAFMECA
Function sources:Function sources:
Maintenance Manual description/theory Maintenance Manual description/theory of of operation operation Operating ManualsOperating Manuals Other tech data providing system Other tech data providing system
descriptions descriptions
Common Errors: Common Errors: Missing secondary functions Missing secondary functions Listing functions of lower level hardwareListing functions of lower level hardware
itemsitems
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
NAVAIR 00-25-403 RCM adds a NAVAIR 00-25-403 RCM adds a categorization process to function categorization process to function identification called “identification called “significant function significant function identificationidentification””
• Intended to: Intended to:
1)1) eliminate analysis of inconsequential eliminate analysis of inconsequential functions functions
2)2) Ensure all significant functions are Ensure all significant functions are identifiedidentified
• Not technically part of the FMECA processNot technically part of the FMECA process
Identifying Functions:Identifying Functions:Identifying Functions:Identifying Functions: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
A SIGNIFICANT FUNCTION is one whose failure A SIGNIFICANT FUNCTION is one whose failure will have adverse effect on the end item with will have adverse effect on the end item with respect to:respect to:
• SafetySafety
• Environmental HealthEnvironmental Health
• OperationsOperations
• EconomicsEconomics
Identifying Functions:Identifying Functions:Identifying Functions:Identifying Functions: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
SIGNIFICANT FUNCTION (SF) IDENTFCATIONSIGNIFICANT FUNCTION (SF) IDENTFCATIONSIGNIFICANT FUNCTION (SF) IDENTFCATIONSIGNIFICANT FUNCTION (SF) IDENTFCATION
FUNCTION
SIGNIFICANTSIGNIFICANTFUNCTIONFUNCTION
NON-SIGNIFICANTNON-SIGNIFICANTFUNCTIONFUNCTION
YESYES
YESYES
YESYES
YESYES
NONO
NONO
NONO
NONO
DOES THE LOSS OF FUNCTION DOES THE LOSS OF FUNCTION HAVE AN ADVERSE EFFECT ON HAVE AN ADVERSE EFFECT ON
SAFETY OR ENVIRONMENT?SAFETY OR ENVIRONMENT?
DOES THE LOSS OF FUNCTION DOES THE LOSS OF FUNCTION HAVE AN ADVERSE EFFECT ON HAVE AN ADVERSE EFFECT ON
OPERATIONS?OPERATIONS?
DOES THE LOSS OF FUNCTION DOES THE LOSS OF FUNCTION HAVE AN ADVERSE ECONOMIC HAVE AN ADVERSE ECONOMIC
IMPACT?IMPACT?
IS THE FUNCTION PROTECTED BYIS THE FUNCTION PROTECTED BYAN EXISTING PM TASK?AN EXISTING PM TASK?
FUNCTIONFUNCTION
5 Fly-ins5 Fly-ins
Class ExerciseClass ExerciseFMECAFMECAFMECAFMECA
Objective:Objective:List the functions of List the functions of
a Coffee Makera Coffee Maker
Identifying Functions:Identifying Functions:Identifying Functions:Identifying Functions:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Function Function Exercise:Exercise:Function Function Exercise:Exercise:
3 Fly Ins
HOT PLATE HOT PLATE SUBSYSTEMSUBSYSTEM
1B41B4
PWR SWITCH PWR SWITCH SUBSYSTEMSUBSYSTEM
1B11B1
CLOCK CLOCK PROGRAMMEPROGRAMMER SUBSYSTEMR SUBSYSTEM
1B21B2
WATER WATER HEATING HEATING
SUBSYSTEMSUBSYSTEM
1B3
FILTRATION FILTRATION SUBSYSTEMSUBSYSTEM
1A21A2
CARAFE CARAFE SUBSYSTEMSUBSYSTEM
1A31A3
WATER WATER RESERVOIR RESERVOIR SUBSYSTEMSUBSYSTEM
1A11A1
COFFEE COFFEE MAKERMAKER
11
ELECTRICAL ELECTRICAL SYSTEMSYSTEM
1B1B
BREWING BREWING SYSTEMSYSTEM
1A1A
Analyze at Analyze at this levelthis level
Analyze at Analyze at this levelthis level
Remember Secondary Functions: Remember Secondary Functions: ControlControl Warning or status indicationWarning or status indication Environmental protectionEnvironmental protection Physical support or attachmentPhysical support or attachment Safety or protective functionsSafety or protective functions Fluid Containment Comfort and Aesthetics
Function Exercise:Function Exercise:Function Exercise:Function Exercise:
Coffee Maker Coffee Maker FunctionsFunctions
1.1. Brew 1 to 12 cups of coffee Brew 1 to 12 cups of coffee
2.2. Maintain coffee at 120°f Maintain coffee at 120°f 5°f 5°f
3. Automatically start brewing process within 15 3. Automatically start brewing process within 15 minutes of time specified by userminutes of time specified by user
4. Automatically shut down coffee maker 4 4. Automatically shut down coffee maker 4 hours after brew cycle is completedhours after brew cycle is completed
5. 5. Contain coffee in carafeContain coffee in carafe
6. Contain 1 carafe of water in reservoir6. Contain 1 carafe of water in reservoir
7. Provides safe handling of hot coffee7. Provides safe handling of hot coffee
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
Fails to provide Fails to provide hydraulic fluid at hydraulic fluid at a pressure of a pressure of 3000 psi +/- 200 3000 psi +/- 200 psipsi
Hydraulic PumpHydraulic PumpAssemblyAssembly
FUNCTIONAL FAILUREFUNCTIONAL FAILUREThe inability of an item to perform a The inability of an item to perform a specific function within specified limits.specific function within specified limits.
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Note that functional failure may not be a Note that functional failure may not be a complete loss of the functioncomplete loss of the function
Separate functional failures should be listed Separate functional failures should be listed where the effects of less than total loss of where the effects of less than total loss of the function are different from total lossthe function are different from total loss
Ensure functional failure addresses the Ensure functional failure addresses the function as definedfunction as defined
Common Errors:Common Errors:- - Confusion with failure modes of Confusion with failure modes of
hardwarehardware- Confusion with potential failures- Confusion with potential failures
Identifying Functional Failures:Identifying Functional Failures:Identifying Functional Failures:Identifying Functional Failures: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Identifying FMECA Terms:Identifying FMECA Terms:Identifying FMECA Terms:Identifying FMECA Terms: FMECAFMECAFMECAFMECA
Class ExerciseClass Exercise
Objective:Objective:
Identify and list the coffee Identify and list the coffee maker’s maker’s
Functional FailuresFunctional Failures
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 1 FUNCTION 1 – Brew 1 to 12 cups of coffee– Brew 1 to 12 cups of coffee
FUNCTIONAL FAILURE A - Fails to brew coffeeFUNCTIONAL FAILURE A - Fails to brew coffee
FUNCTION 2 FUNCTION 2 - Maintain coffee temperature at 120°f - Maintain coffee temperature at 120°f 5° f 5° f
FUNCTIONAL FAILURE A – Doesn't keep coffee warm(< 100°f)FUNCTIONAL FAILURE A – Doesn't keep coffee warm(< 100°f)
FUNCTIONAL FAILURE B – Heats Coffee too hot (>125° f)FUNCTIONAL FAILURE B – Heats Coffee too hot (>125° f)
FUNCTIONAL FAILURE C – Partial warm coffee (>100FUNCTIONAL FAILURE C – Partial warm coffee (>100°f°f but < than but < than 115°f)115°f)
Coffee Maker Coffee Maker Functional FailuresFunctional Failures
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 3 FUNCTION 3 - Automatically brew coffee within 15 minutes of - Automatically brew coffee within 15 minutes of time specified by usertime specified by user
FUNCTIONAL FAILURE A - Does not brew coffee at allFUNCTIONAL FAILURE A - Does not brew coffee at all
FUNCTIONAL FAILURE B - Brews coffee more than 15 minutes earlier FUNCTIONAL FAILURE B - Brews coffee more than 15 minutes earlier than specifiedthan specified
FUNCTIONAL FAILURE C - Brews coffee more than 15 minutes after FUNCTIONAL FAILURE C - Brews coffee more than 15 minutes after time specified by usertime specified by user
Coffee Maker Coffee Maker Functional FailuresFunctional Failures
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
FAILURE MODEFAILURE MODEA specific physical condition that causes a A specific physical condition that causes a particular functional failure.particular functional failure.
Scored Bearing
Worn Impeller
Bent Linkage
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
When possible list failure cause or When possible list failure cause or mechanism, ex. “cracked spar due to mechanism, ex. “cracked spar due to fatigue”fatigue”
List all failure modes that are “reasonable”. List all failure modes that are “reasonable”.
Be as descriptive as possibleBe as descriptive as possible
Do not combine failure modes where failure Do not combine failure modes where failure effects, rates, or possible failure effects, rates, or possible failure management solutions may be differentmanagement solutions may be different
Methods to identify “significant” failures Methods to identify “significant” failures vary by project. vary by project.
FMECAFMECAFMECAFMECAIdentifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Failure mode sources:Failure mode sources:
Existing PM Tasks Existing PM Tasks Operating/Maintenance ManualsOperating/Maintenance Manuals Operator/Maintainer InputOperator/Maintainer Input Prior FMECA, RCM or other analysesPrior FMECA, RCM or other analyses Failure Databases (Age Exploration)Failure Databases (Age Exploration) Engineer/SME inputEngineer/SME input 3M/CMMS data***3M/CMMS data***
FMECAFMECAFMECAFMECAIdentifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Common Errors:Common Errors:
Over dependence on CMMS or other “non-Over dependence on CMMS or other “non-specific” failure dataspecific” failure data
Lack of specificity in the failure mechanism, Lack of specificity in the failure mechanism, (“broken”) or of the failed part/location(“broken”) or of the failed part/location
Worrying about identifying all failures vice Worrying about identifying all failures vice the “important ones”the “important ones”
Confusing potential failures (e.g. “cracks”), Confusing potential failures (e.g. “cracks”), induced damage, or secondary damage from induced damage, or secondary damage from failure causesfailure causes
Failure to apply common sense or Failure to apply common sense or analyst/SME knowledge to data analyst/SME knowledge to data
FMECAFMECAFMECAFMECAIdentifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
SYSTEMSYSTEM1A1A
SYSTEMSYSTEM1C1C
GEAR BOXGEAR BOX1B3B1B3B
SUBSYSTEMSUBSYSTEM 1B21B2
SUBSYSTEMSUBSYSTEM1B41B4
SUBSYSTEMSUBSYSTEM1B11B1
MOTORMOTOR1B3A1B3A
PRESSUREPRESSUREREG 1B3EREG 1B3E SUB-ASSY
ITEMUNDER ANALYSIS
NEXT HIGHER
ENDITEM
HYDRAULICHYDRAULICSYSTEM 1BSYSTEM 1B
AIRCRAFTAIRCRAFT11
HYD PUMPHYD PUMP1B3D1B3D
CENT PUMPCENT PUMP1B3C1B3C
Impeller wornImpeller worn(FM)(FM)
FMECAFMECAFMECAFMECA
FAILURE EFFECTFAILURE EFFECTThe result of a failure mode and it’s functional The result of a failure mode and it’s functional failure on surrounding items, the functional failure on surrounding items, the functional capability of the end item, and hazards to personnel capability of the end item, and hazards to personnel and environment.and environment.
HYD PUMPHYD PUMPASSY 1B3ASSY 1B3
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
When listing effects:When listing effects: List most severe effectsList most severe effects Should be reasonableShould be reasonable
Qualify less likely effects with terms such Qualify less likely effects with terms such as “possible” or “potential”as “possible” or “potential”
Include restorative actions, as appropriateInclude restorative actions, as appropriate Consider compensating provisions Effects should be identified at point of
functional failure
FMECAFMECAFMECAFMECAIdentifying Failure Effects:Identifying Failure Effects:Identifying Failure Effects:Identifying Failure Effects:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECAFMECAFMECAFMECAIdentifying Failure Effects:Identifying Failure Effects:Identifying Failure Effects:Identifying Failure Effects:
When properly identified:When properly identified: Makes the rest of the analysis much Makes the rest of the analysis much
easier easier Effects must address functional failure Effects must address functional failure
but should also consider secondary but should also consider secondary damagedamage
Hidden failures must assume the Hidden failures must assume the condition that makes them evident condition that makes them evident has occurredhas occurred
Effects must be clearly related to operational scenarios
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Pay attention to level of effects: Pay attention to level of effects:
Local: effect on the failed part: “Loss Local: effect on the failed part: “Loss of Impeller effectiveness.” of Impeller effectiveness.”
Next higher: effect on the function of Next higher: effect on the function of the system/subsystem being analyzed, the system/subsystem being analyzed, often synonymous with functional often synonymous with functional failure: “Loss of Hydraulic Sys #1 failure: “Loss of Hydraulic Sys #1 pressure.”pressure.”
End: what the failure means to the End: what the failure means to the asset: “Loss of mission.”asset: “Loss of mission.”
FMECAFMECAFMECAFMECAIdentifying Failure Effects:Identifying Failure Effects:Identifying Failure Effects:Identifying Failure Effects:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Sources: Sources:
• Operating ManualsOperating Manuals• Maintenance Manuals Maintenance Manuals • Operator/maintainer/engineer inputOperator/maintainer/engineer input• Troubleshooting chartsTroubleshooting charts• SME/Analyst knowledgeSME/Analyst knowledge• Accident/Incident/Hazard reportsAccident/Incident/Hazard reports• Failure/Engineering InvestigationsFailure/Engineering Investigations• Test reportsTest reports
FMECAFMECAFMECAFMECAFailure Effects Sources:Failure Effects Sources:Failure Effects Sources:Failure Effects Sources:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECAFMECAFMECAFMECAFailure Effects ErrorsFailure Effects ErrorsFailure Effects ErrorsFailure Effects Errors
Common errors:Common errors:
• Assuming PM in placeAssuming PM in place• Incorrect levels Incorrect levels • Ignoring secondary damage Ignoring secondary damage • Improper treatment of hidden failuresImproper treatment of hidden failures
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Identifying FMECA Terms:Identifying FMECA Terms:Identifying FMECA Terms:Identifying FMECA Terms: FMECAFMECAFMECAFMECA
Class ExerciseClass ExerciseObjective:Objective:
Identify and list the Coffee Maker’s Identify and list the Coffee Maker’s
• Failure ModesFailure Modes
• Failure EffectsFailure Effects
Extra CreditExtra Credit
• Describe how operating context Describe how operating context impacts failure effects impacts failure effects (Residential vs Commercial Use)(Residential vs Commercial Use)
Failure Modes/Effects next ...
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 1FUNCTION 1- Brew 1 to 12 cups of coffee- Brew 1 to 12 cups of coffee
FUNCTIONAL FAILURE AFUNCTIONAL FAILURE A – Fails to brew coffee – Fails to brew coffee
FAILURE MODE 1FAILURE MODE 1 - Clogged heating chamber tubing - Clogged heating chamber tubing due to excessive calcium build-up.due to excessive calcium build-up.
FAILURE EFFECTFAILURE EFFECT - No coffee - No coffee
FAILURE MODE 2FAILURE MODE 2 - Shorted wiring due to frayed - Shorted wiring due to frayed insulation.insulation.
FAILURE EFFECTFAILURE EFFECT - Possible fire - Possible fire
FAILURE MODE 3FAILURE MODE 3 - Open On/Off switch due to - Open On/Off switch due to corrosion.corrosion.
FAILURE EFFECTFAILURE EFFECT - No coffee - No coffee
Coffee MakerCoffee MakerFailure Modes and Failure Modes and
EffectsEffects
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 2FUNCTION 2 - Maintain coffee temperature at 120°f - Maintain coffee temperature at 120°f 5°f. 5°f.
FUNCTIONAL FAILURE AFUNCTIONAL FAILURE A - Fails to heat coffee (< 100°f) - Fails to heat coffee (< 100°f)
FAILURE MODE 1FAILURE MODE 1 – Broken power supply wire to heating – Broken power supply wire to heating element connection.element connection.
FAILURE EFFECTFAILURE EFFECT - Cold coffee - Cold coffee
FAILURE MODE 2FAILURE MODE 2 – Heating plate thermostat internal – Heating plate thermostat internal failure.failure.
FAILURE EFFECTFAILURE EFFECT - Cold coffee- Cold coffee
FUNCTIONAL FAILURE BFUNCTIONAL FAILURE B - Heats coffee to hot (>125° f)- Heats coffee to hot (>125° f) FAILURE MODE 1FAILURE MODE 1 – Corroded heating plate thermostat. – Corroded heating plate thermostat.
FAILURE EFFECTFAILURE EFFECT - Possible damage to coffee maker. - Possible damage to coffee maker. Possible fire. Possible fire.
Coffee MakerCoffee MakerFailure Modes and Failure Modes and
EffectsEffects
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 2FUNCTION 2 - Maintain coffee at 120°f - Maintain coffee at 120°f 5°f. (continued) 5°f. (continued)
FUNCTIONAL FAILURE CFUNCTIONAL FAILURE C - Partially warm coffee (>100°f but < than - Partially warm coffee (>100°f but < than 115°f)115°f)
FAILURE MODE 1FAILURE MODE 1 - Corroded heating plate thermostat. - Corroded heating plate thermostat.
FAILURE EFFECTFAILURE EFFECT – Lukewarm coffee– Lukewarm coffee
Coffee MakerCoffee MakerFailure Modes and Failure Modes and
EffectsEffects
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 3 FUNCTION 3 - Automatically brew coffee within 15 minutes - Automatically brew coffee within 15 minutes of time specified by userof time specified by user
FUNCTIONAL FAILURE AFUNCTIONAL FAILURE A - Does not brew coffee at all - Does not brew coffee at all
FAILURE MODE 1FAILURE MODE 1 - Inoperative Clock due to internal - Inoperative Clock due to internal failurefailure
FAILURE EFFECTFAILURE EFFECT - No coffee- No coffee
FUNCTIONAL FAILURE BFUNCTIONAL FAILURE B - Brews coffee more than 15 - Brews coffee more than 15 minutes earlier than specifiedminutes earlier than specified
FAILURE MODE 1FAILURE MODE 1 - Clock operation too fast due to - Clock operation too fast due to internal failureinternal failure
FAILURE EFFECTFAILURE EFFECT - Old, bitter coffee- Old, bitter coffee
Coffee Maker Failure Coffee Maker Failure Modes and EffectsModes and Effects
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FUNCTION 3 FUNCTION 3 - Automatically brew coffee within 15 minutes - Automatically brew coffee within 15 minutes of time specified by userof time specified by user
FUNCTIONAL FAILURE CFUNCTIONAL FAILURE C - Brews coffee more than 15 - Brews coffee more than 15 minutes after time specified by userminutes after time specified by user
FAILURE MODE 1FAILURE MODE 1 - Slow clock operation due to - Slow clock operation due to internal failureinternal failure
FAILURE EFFECTFAILURE EFFECT - No coffee until more than 15 - No coffee until more than 15 minutes after time specifiedminutes after time specified
Coffee Maker Failure Coffee Maker Failure Modes and EffectsModes and Effects
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
A note on “human error” failure modes:A note on “human error” failure modes:RCM may be used to address human error… RCM may be used to address human error…
Example: “Operator forgot to add water to Example: “Operator forgot to add water to coffee pot” coffee pot”
Solution: “Post checklist by coffee pot”Solution: “Post checklist by coffee pot”
However… Care should be taken not to However… Care should be taken not to overcompensate for human error where overcompensate for human error where other processes (human factors other processes (human factors engineering) or common sense should engineering) or common sense should presidepreside
FMECAFMECAFMECAFMECAIdentifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:Identifying Failure Modes:
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
FAILURE DETECTIONFAILURE DETECTIONDescribes method(s) by which functional Describes method(s) by which functional failures are detected and failure modes are failures are detected and failure modes are identified.identified.
Failure DetectionFailure Detection• Visual alarmsVisual alarms• Audible alarmsAudible alarms• Gauges/IndicatorsGauges/Indicators• Operating Operating characteristicscharacteristics
Identifying Failure ModesIdentifying Failure Modes• Voltage checksVoltage checks• Continuity checksContinuity checks• Visual inspectionsVisual inspections• PHM systemsPHM systems
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECAFMECAFMECAFMECAFailure DetectionFailure DetectionFailure DetectionFailure Detection
Address both operator and maintainerAddress both operator and maintainer
• For operator: detection of FUNCTIONAL For operator: detection of FUNCTIONAL FAILURE (or effects)FAILURE (or effects)
• For maintainer: detection of FAILURE For maintainer: detection of FAILURE MODEMODE
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECAFMECAFMECAFMECAFailure DetectionFailure DetectionFailure DetectionFailure Detection
Sources: Sources: Operator/maintainer interviewsOperator/maintainer interviews Maintenance/Operator’s ManualsMaintenance/Operator’s Manuals Troubleshooting chartsTroubleshooting charts Accident/Incident/Hazard reportsAccident/Incident/Hazard reports Failure/Engineering Failure/Engineering
InvestigationsInvestigations Test reportsTest reportsCommon Errors: Common Errors: Not addressing both operator and Not addressing both operator and
maintainermaintainer Listing specific PMListing specific PM
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
SEVERITY CLASSIFICATIONSEVERITY CLASSIFICATIONA category assigned to a failure mode based on A category assigned to a failure mode based on the impacts if its potential effects.the impacts if its potential effects.
Categories are defined by the organization Categories are defined by the organization performing the analysisperforming the analysis
Categories for the same failure mode may be Categories for the same failure mode may be different in different operating phases or different in different operating phases or scenariosscenarios
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
SEVERITY CATEGORYSEVERITY CATEGORY
Category ICategory I CatastrophicCatastrophicCategory ICategory I CatastrophicCatastrophic
• Aircraft example: “Death, Permanent Disability, Aircraft example: “Death, Permanent Disability, destruction of equipment/system, damage in destruction of equipment/system, damage in excess of $1M, significant breach of environmental excess of $1M, significant breach of environmental regulation.regulation.
• Critical equipment example: “Death, Permanent Critical equipment example: “Death, Permanent Disability, destruction of equipment/system,Disability, destruction of equipment/system, damage in excess of $1M, significant breach of damage in excess of $1M, significant breach of environmental regulation, Down-time > 2 daysenvironmental regulation, Down-time > 2 days
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
SEVERITY CATEGORYSEVERITY CATEGORY
Category ICategory I CatastrophicCatastrophicCategory ICategory I CatastrophicCatastrophic
Category IICategory II CriticalCriticalCategory IICategory II CriticalCritical• Aircraft example: “Personal Injury, Damage Aircraft example: “Personal Injury, Damage more than $100K but less than $1M, Inability to more than $100K but less than $1M, Inability to perform a critical mission”perform a critical mission”
• Critical equipment example: “Personal Critical equipment example: “Personal Injury, Damage more than $100K but less than Injury, Damage more than $100K but less than $1M, Down-time more than 24 hours but less $1M, Down-time more than 24 hours but less than two days”than two days”
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
• Aircraft example: “Damage more than $1K Aircraft example: “Damage more than $1K but less than $100K, Degraded ability to but less than $100K, Degraded ability to perform a critical mission”perform a critical mission”
• Critical Equipment example: “Damage Critical Equipment example: “Damage more than $1K but less than $100K, Down-more than $1K but less than $100K, Down-time more than 8 hours but less than 24 time more than 8 hours but less than 24 hours”hours”
SEVERITY CATEGORYSEVERITY CATEGORY
Category ICategory I CatastrophicCatastrophicCategory ICategory I CatastrophicCatastrophic
Category IICategory II CriticalCriticalCategory IICategory II CriticalCritical
Category IIICategory III MarginalMarginalCategory IIICategory III MarginalMarginal
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
SEVERITY CATEGORYSEVERITY CATEGORY
• Aircraft example: “Damage less than $1K, Aircraft example: “Damage less than $1K, Unscheduled Maintenance or Repair”Unscheduled Maintenance or Repair”
• Equipment example: “Damage less than $1K, Equipment example: “Damage less than $1K, Down-time less than 8 hours”Down-time less than 8 hours”
Category ICategory I CatastrophicCatastrophicCategory ICategory I CatastrophicCatastrophic
Category IICategory II CriticalCriticalCategory IICategory II CriticalCritical
Category III Category III MarginalMarginalCategory III Category III MarginalMarginal
Category IV Category IV MinorMinorCategory IV Category IV MinorMinor
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FMECA Terms:FMECA Terms:FMECA Terms:FMECA Terms:
MEAN TIME BETWEEN FAILURE (MTBFMEAN TIME BETWEEN FAILURE (MTBF)Basic measure of reliability for an item.Basic measure of reliability for an item.
• Average time between failure occurrences Average time between failure occurrences during a specified period with no during a specified period with no preventive measures in placepreventive measures in place• Usually: Total operating time in given period Usually: Total operating time in given period
divided by number of failures that have divided by number of failures that have occurredoccurred
• Inverse of the failure rateInverse of the failure rate• Adjustment required if PM is already in-placeAdjustment required if PM is already in-place
Used in RCM for prioritizing failure modes, Used in RCM for prioritizing failure modes, performing cost analysis and Failure Finding performing cost analysis and Failure Finding Task Interval Calculations Task Interval Calculations
FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
CALCULATING MTBF (Method 1)CALCULATING MTBF (Method 1)
Total operating time/number of failures Total operating time/number of failures (mature populations in a specified time (mature populations in a specified time period)period)
When no failures have occurred use a When no failures have occurred use a conservative estimateconservative estimate
Evaluate like and similar equipmentEvaluate like and similar equipment Consider possibility of failure in short Consider possibility of failure in short period of timeperiod of time
Calculating MTBF:Calculating MTBF:Calculating MTBF:Calculating MTBF: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Calculating MTBF:Calculating MTBF:Calculating MTBF:Calculating MTBF: FMECAFMECAFMECAFMECA
Sources:Sources:
•CMMS dataCMMS data
•Third party repair recordsThird party repair records
•Supply usage data Supply usage data
•Artisan/Maintainer anecdotal Artisan/Maintainer anecdotal
estimatesestimates
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Method 1 Cautions:Method 1 Cautions: Need data specific to item Need data specific to item Understand difference between potential Understand difference between potential
failures and functional failuresfailures and functional failures
Note: MTBF based on potential failures may Note: MTBF based on potential failures may need adjustmentneed adjustment
Adjustments may be required to establish Adjustments may be required to establish MTBF where PM is already in placeMTBF where PM is already in place
Make sure time period chosen is Make sure time period chosen is representative (steady-state)representative (steady-state)
Assumes constant failure rate of the Assumes constant failure rate of the populationpopulation
May require periodic monitoring/updateMay require periodic monitoring/update
Calculating MTBF:Calculating MTBF:Calculating MTBF:Calculating MTBF: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
CALCULATING MTBF (Method 2)CALCULATING MTBF (Method 2)
Use Design or predicted valuesUse Design or predicted values
•Data sources:Data sources:•Design/vendor specs Design/vendor specs •““Like and similar” equipmentLike and similar” equipment•Analytical/handbook predictionsAnalytical/handbook predictions
•Caution: Often inaccurate Caution: Often inaccurate • Verify with real data if possibleVerify with real data if possible• Adjust with conservatism where Adjust with conservatism where
necessarynecessary• Monitor/Update when field data Monitor/Update when field data
becomes availablebecomes available
Calculating MTBF:Calculating MTBF:Calculating MTBF:Calculating MTBF: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
CALCULATING MTBF (Method 3)CALCULATING MTBF (Method 3)
Statistical Modeling methodsStatistical Modeling methods
•Beyond scope of this courseBeyond scope of this course• Requires specialized training and Requires specialized training and
knowledgeknowledge•May be most accurate if properly May be most accurate if properly
performedperformed
Calculating MTBF:Calculating MTBF:Calculating MTBF:Calculating MTBF: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
CriticalityCriticalityCriticalityCriticality FMECAFMECAFMECAFMECA• Combination of Severity and Frequency (MTBF)Combination of Severity and Frequency (MTBF)
• Hazard Risk Index (HRI)Hazard Risk Index (HRI)• Risk Priority Number (RPN)Risk Priority Number (RPN)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FREQUENCYFREQUENCY
SEVERITYSEVERITY
FREQUENTFREQUENT (A)(A)
>> 1 per 1,000 1 per 1,000 HoursHours
PROBABLEPROBABLE (B) (B)
>> 1 per 10,000 1 per 10,000HoursHours
OCCASIONALOCCASIONAL (C) (C)
>> 1 per 100,000 1 per 100,000HoursHours
REMOTE REMOTE (D)(D)
>> 1 per 1,000,000 1 per 1,000,000HoursHours
IMPROBABLEIMPROBABLE (E) (E)
<< 1 per 1,000,000 1 per 1,000,000HoursHours
CATASTROPHIC (I)CATASTROPHIC (I)
CRITICAL (II)CRITICAL (II)
MARGINAL (III)MARGINAL (III)
MINOR (IV)MINOR (IV)
• Death or Permanent disabilityDeath or Permanent disability• Significant Environmental breach Significant Environmental breach • Damage > $1M, Downtime>2 daysDamage > $1M, Downtime>2 days• Destruction of system/equipmentDestruction of system/equipment
• Personal InjuryPersonal Injury• Damage >$100K and < $1MDamage >$100K and < $1M• Loss of availability > 24 hrs and Loss of availability > 24 hrs and < 7 days< 7 days
• Damage >$10K and < $100KDamage >$10K and < $100K• Loss of availability > 4 hrs andLoss of availability > 4 hrs and < 24 hrs< 24 hrs
• Damage <$10K Damage <$10K • Loss of availability < 4 hrsLoss of availability < 4 hrs
11HIGHHIGH
33HIGHHIGH
44HIGHHIGH
22HIGHHIGH
55HIGHHIGH
88MEDMED
66MEDMED
77MEDMED
99MEDMED
1010LOWLOW
1212ACCEPTACCEPT
1313ACCEPTACCEPT
1515ACCEPTACCEPT
1616ACCEPTACCEPT
1717ACCEPTACCEPT
2020ACCEPT
1919ACCEPT
1414ACCEPT
1111LOWLOW
1818ACCEPTACCEPT
• Item – What it isItem – What it is• Functions – What you want item to doFunctions – What you want item to do• Functional Failures – How it fails to do it Functional Failures – How it fails to do it • Failure Modes – Why it fails to do itFailure Modes – Why it fails to do it• Failure Effects – What happensFailure Effects – What happens• Severity of Failure – How bad it isSeverity of Failure – How bad it is• Failure Frequency – How often it Failure Frequency – How often it
happenshappens• Criticality – Severity + Frequency Criticality – Severity + Frequency
• Item – What it isItem – What it is• Functions – What you want item to doFunctions – What you want item to do• Functional Failures – How it fails to do it Functional Failures – How it fails to do it • Failure Modes – Why it fails to do itFailure Modes – Why it fails to do it• Failure Effects – What happensFailure Effects – What happens• Severity of Failure – How bad it isSeverity of Failure – How bad it is• Failure Frequency – How often it Failure Frequency – How often it
happenshappens• Criticality – Severity + Frequency Criticality – Severity + Frequency
FMECA Summary:FMECA Summary:FMECA Summary:FMECA Summary: FMECAFMECAFMECAFMECA
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Guidance:Guidance:Guidance:Guidance: ReferencesReferencesReferencesReferences
• NAVAIR 00-25-403: Guidelines for the Naval Aviation RCM NAVAIR 00-25-403: Guidelines for the Naval Aviation RCM processprocess
• SAE JA1012: Society of Automotive Engineers Guide to RCM SAE JA1012: Society of Automotive Engineers Guide to RCM StandardStandard
• RAC-HDBK-1120: FMECA - Failure Mode, Effects and RAC-HDBK-1120: FMECA - Failure Mode, Effects and Criticality AnalysisCriticality Analysis
• MIL-STD-1629A: MIL-STD-1629A: Procedures for Performing a Failure Mode, Procedures for Performing a Failure Mode, Effects, and Criticality AnalysisEffects, and Criticality Analysis
• MIL-HDBK-217: Reliability Prediction of Electronic MIL-HDBK-217: Reliability Prediction of Electronic Equipment.Equipment.
• MIL-STD-882D: Standard Practice For System SafetyMIL-STD-882D: Standard Practice For System Safety
• NAVAIRINST 5100.11: Research and Engineering Review of NAVAIRINST 5100.11: Research and Engineering Review of Risk Process and Procedures for Processing Grounding Risk Process and Procedures for Processing Grounding BulletinsBulletins
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Sources:Sources:Sources:Sources: ReferencesReferencesReferencesReferences
Useful Data Sources For Identifying FMECA Useful Data Sources For Identifying FMECA Information are:Information are:• Maintenance/Operators ManualsMaintenance/Operators Manuals• Troubleshooting Guides/ChartsTroubleshooting Guides/Charts• DrawingsDrawings• Operators/Maintainers/Engineers/OEM Tech Operators/Maintainers/Engineers/OEM Tech RepsReps• Work Orders/CMMS or other failure data Work Orders/CMMS or other failure data • Block Diagrams/SchematicsBlock Diagrams/Schematics• Existing PM TasksExisting PM Tasks• Accident/Incident/Hazard reportsAccident/Incident/Hazard reports• Engineering/Failure Investigations/Test reportsEngineering/Failure Investigations/Test reports
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Review and Review and summarysummary
Review and Review and summarysummary
Provided an understanding of the Failure Provided an understanding of the Failure Modes, Effects, and Criticality Analysis Modes, Effects, and Criticality Analysis (FMECA).(FMECA).IntroductionIntroductionIntroductionIntroduction
Learning ObjectivesLearning Objectives
FMECAFMECAFMECAFMECA
• Definition of a FMEADefinition of a FMEA• Purpose of a FMECAPurpose of a FMECA• Definitions & Identification ProcessDefinitions & Identification Process
ReferencesReferencesReferencesReferences
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
FAILURE MODE, EFFECTS, AND FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS CRITICALITY ANALYSIS (FMECA)(FMECA)
Module ObjectiveModule ObjectiveModule ObjectiveModule Objective
End of Module up next……..
RCM Decision Logic
End of Module up next……..
RCM Decision Logic