This document outlines steps for conducting a Failure Mode and Effects Analysis (FMEA) for a piece of equipment called the Crustbreaker. It provides instructions for identifying potential failure modes of components, determining the frequency and duration of failures, and suggesting actions to address failures. Participants are guided through brainstorming failure modes, discussing potential causes and impacts, and rating solutions according to their effectiveness. The goal is to develop an optimal preventative maintenance approach for the Crustbreaker to minimize downtime from component failures.

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Crustbreaker SFMEA
SFMEA
Simplified Failure Mode
Effects Analysis

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An Optimal Approach
Condition
Old
Definition
of Failure
There is a Science to defining
> The Right Work
> At the Right Time
Time
Detectable
Change in
Condition Intervention
Window
P
Potential
Failure
Large Business
Consequences!
Too Much, Too Early
F
Functionally Failed
or Equipment not
performing intended
function
New definition
of failure
Too Little,
Too Late
COSTS

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HelixPLAN
Idea Generation – General Rules
For all ideas that come to mind, print them on cards.
• 1 idea per card, but no limit on the number of ideas (cards).
• Don’t judge you ideas. Be freewheeling in your thinking.
• Go for lots of ideas.
• Make sure your statement has a verb. This improves clarity.
• Try to express each idea in 7 words or less.
– More than 7 words usually means you are trying to express
multiple ideas on one card.
– Watch out for ANDs & ORs (2 ideas).
– Use the black flip-chart marker pen to print your ideas.
PLEASE PRINT
LARGE BLOCK
LETTERS LIKE
THIS.

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Note the Asset (green card) column headings.
Please print up any component failures you have that fit under any of the
assets. (Note the components listed for each asset on the hierarchy
handout)
One Failure per card. Failures Based On Past History or Potential
Once you have printed your first three ideas, go and post them under the
appropriate column(s).
• Read what others have posted. This may stimulate additional
ideas, and it may save you from duplicating ideas already posted.
• Print up three more ideas.
• Post them.
• Read what others have posted.
• Continue until you have no more ideas.
WHAT ARE THE FUNCTIONAL FAILURES OF CRUSTBREAKER
COMPONENTS?

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What are the frequency and duration of each of these
functional failures?
Print the frequency and duration of each failure on the Green cards posted
under the peach failure card.
• Read what others have written
• If someone has written a frequency &/or duration that you do not
agree with, print your opinion under theirs
• Continue under there is a frequency and duration listed under every
failure in each column

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What actions would eliminate or lesson the downtime
due to these functional failures?
Note the potential actions listed on violet cards and on the next slide.
• Print the alphabetical heading of the appropriate action or actions
on the Green cards posted to the right of the corresponding failure
mode.
• Review each failure mode for the actions posted and add any you
believe may have been missed.
• Continue under there is an action listed for every failure mode

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Possible Actions to Eliminate or
Lesson Downtime:
A. Add to Operator Checklist
B. Add to PM
C. Add to Critical Parts List
D. Adjust Stores Quantity
E. Replace on Timed Basis
F. Do Oil Analysis
G. Do Vibration Analysis
H. Do Infrared Inspection
I. Possible Modification
J. Training Needed

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To what extent ...
You have one rating dot (vote) for each item.
Rate each item using the following scale:
5 = Definitely
4 = To a large extent
3 = To some extent
2 = Only slightly
1 = Not at all
Each item should receive exactly 1 vote.
5 4 3 2 1
Item 1
Item 2
Item 3
Item 4

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