EMT 480 Reliability & Failure Analysis

EMT 480 Reliability &
Failure
Analysis
Failure Modes Effect Analysis

(FMEA)
Learning Objectives
 To understand the use of Failure Modes Effect
Analysis
(FMEA)
 To learn the steps to developing FMEAs
 To summarize the different types of FMEAs
2
Benefits
 Allows us to identify areas of our process that most
impact
our customers
 Helps us identify how our process is most likely to fail
 Points to process failures that are most difficult to detect
3
Application Examples
 Manufacturing: A manager is responsible for moving a
manufacturing operation to a new facility. He/she wants
to be sure the move goes as smoothly as possible and that
there are no surprises.
 Design: A design engineer wants to think of all the a
possible ways product being designed could fail so that
robustness can be built into the product.
 Software: A software engineer wants to think of possible problems
a software product could fail when scaled up to large
databases. This is a core issue for the Internet.
4
What is Failure Mode and Effects
Analysis (FMEA)?
 For electronic systems, FMEA is the common method
for
assessing and improving reliability based on failure
analysis.
 Main objective of FMEA is to identify the potential
failure modes of the components contained in the
system under analysis
their consequences andfrequently
are, how their possible effects
they occur andon
how
the system
easily performance.
they can be detected.
 It also aims to prioritise the failures according to how serious
5
Examples
History of
FMEA
 First used in the 1960’s in the Aerospace industry during
the Apollo missions
 In 1974, the Navy developed MIL-STD-1629 regarding
the use of FMEA
 In the late 1970’s, the automotive industry was by
driven
liability costs to use FMEA
 Later, the automotive industry saw the
advantages of
using this tool to reduce risks related to poor quality
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What Can Go
Wrong?
What Is A Failure Mode?

 Failure Mode is:
A The way in which the component, subassembly,
 product, input, or process could fail to perform its
intended function
 Failure modes may be the result of upstream operations or
may cause downstream operations to fail
 Things that could go wrong
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FMEA
 Why
 Methodology that facilitates process improvement
 Identifies and eliminates concerns early in the of
development
a process or design
 Improve internal and external customer satisfaction
 Focuses on prevention
 FMEA may be a customer requirement (likely
contractual)
 FMEA may be required by an applicable
Quality Management System Standard (possibly
ISO)
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FME
A structured approach to:
A Identifying the ways in which a product or process
 can fail
 Estimating risk associated with specific causes
 Prioritizing the actions
Evaluating design that
validation should
plan (designbeFMEA)
taken or
to current
 reduce risk (process FMEA)
control plan
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When to Conduct an FMEA
 Early in the process improvement investigation
 When new systems, products, and being

processes are
designed
 When existing designs or processes are being changed
 When carry-over designs are used in new

applications
 After system, product, or process functions are
defined, but before specific hardware is selected
or released to manufacturing
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A Closer Look
The FME Form

A
Identify failure modes Determine and assess

Identify causes of the Prioritize
and their effects actions
failure modes
and controls
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Specialized
Uses
Types of FMEAs
 Design
 Analyzes product design before release to
production, with a focus on product function
 Analyzes systems and subsystems in early
concept and
design stages
 Process
 Used to analyze manufacturing and assembly processes
after they are implemented
12
SYTEM – focuses on global system
function
SERVICE – focus on service function.
SOFTWARE – focus on software functions

Types of FMEA
Team Input
Required
FMEA: A Team Tool

 A team approach is necessary.
 Team should be led by the Process Owner who is
the responsible manufacturing engineer or technical
person, or other similar individual familiar with
 FMEA.
The following should be considered for team members:
– Design Engineers – Operators
– Process – Reliabilit
– Engineers – y
– Materials Supplier
Suppliers s
Customers
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Process Steps
FMEA Procedure
1. For each process input (start with high value inputs), determine
the in which the input can go wrong (failure mode)
ways
2. failure mode, determine effects
For
 Select a severity level for each effect (ie scratch, crack, contaminate etc)
each
3. Identify potential causes of each failure mode
 Select an occurrence level for each cause (ie handling, machine
problem)
4.
List current controls for each cause
 Select a detection level for each cause (ie provide training,
maintenance of the machine)
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Process Steps
FMEA Procedure
(Cont.)
5. Calculate the Risk Priority Number (RPN)
6. Develop recommended actions, assign responsible

persons, and take actions (ie thorough inspection to the
problem machine)
 Give priority to high RPNs
 MUST look at severities rated a 10
7. Assign the predicted severity, occurrence, and detection levels
and compare RPNs
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Analyzing
Severity, Occurrence, Failure &

Effects
and Detection
 Severity
 Importance of the effect on requirements
customer
 Can be assigned from 1 (no danger) to 10 (critical)
 Occurrence
 The causes and frequencies of all possible failures from
(obtain past data if possible)
 Can be assigned from 1 (low) to10 (extremely high)
 Detection
 The ability of the current control scheme to detect
(then prevent) for a given cause (may be difficult to estimate
early in process operations).
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Calculating a
Composite
Score
Risk Priority Number

(RPN)
 RPN is the product of the severity, occurrence, and
detection
scores.
 The highest RPN is 10 x 10 x 10 = 1000, which
indicates that
the failure is very severe, that occurrence is almost
certain and itX Occurrence X Detection =
Severity RPN
is not detectable by inspection
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It is the name of the component which is analyzed
Identifies the name and ID of the systems or
subsystems
Contains names of the responsible individuals that
have the authority to perform task
Identifies the team responsible for this design
Used for document tracking purposes
Contains the original date and revised date
Contains the name and Id of item being analyzed as
well as one specific function of the item
Contains methods
1.May fail to meet design criteria
2.May cause potential failure in high level systems
and low level system
Severity(S)
Used to specify any additional controls
Reasons for failure
Occurrence(O)
Prevention measures
Risk priority number(RPN)=S*O*D
Corrective actions examined by the team
Target completion dates
After an action has been taken, the actual action
and the effective date should be entered in this
colums
Key Points
Summary
 An FMEA:
 Identifies the ways in which a product or fail
process can
 Estimatesthethe
 Prioritizes risk associated
actions with
that should be specific
taken to reduce risk
causes
 FMEA is a team tool
 There are two different types of FMEAs:
 Design

Process
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EMT 480 Reliability &

Failure Modes Effect Analysis

 To summarize the different types of FMEAs

 Points to process failures that are most difficult to detect

What Is A Failure Mode?

 When new systems, products, and being

 When carry-over designs are used in new

The FME Form

Identify failure modes Determine and assess

SERVICE – focus on service function.

SOFTWARE – focus on software functions

FMEA: A Team Tool

6. Develop recommended actions, assign responsible

Severity, Occurrence, Failure &

Risk Priority Number

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