The ultimate guide on constructing a FMEA process for Manufacturing, Maintenance, Services and Design.
The presentation include step by step on how to determine the failure modes, failure effects, assign severity, assign occurrence, assign detection, calculate risk priority numbers and prioritize the RPNs for action. With some examples and illustrations.
Presentation contents:
1. Determing failure modes, effects and causes.
2. FMEA team & team leader.
3. Brainstorming.
4. The basic steps of FMEA.
5. Examples.
ABOUT THE TRAINING PROGRAM :-
Failure Mode and Effects Analysis or FMEA is a structured technique to analyze a process to determine shortcomings and opportunities for improvement. By assessing the severity of a potential failure, the likelihood that the failure will occur, and the chance of detecting the failure, dozens or even hundreds of potential issues can be prioritized for improvement.
DESIGNED FOR :-
Sr. Engineer, Engineer, Supervisor and Foreman engaged in maintenance, operation, Store, Supply chain, Quality, Safety and Engineering activities.
OBJECTIVE :-
Employees completing this training will be able to effectively participate on an FMEA team and can make immediate contributions to quality and productivity improvement efforts.
Failure mode and effects analysis (FMEA)—also "failure modes", plural, in many publications—was one of the first highly structured, systematic techniques for failure analysis. It was developed by reliability engineers in the late 1950s to study problems that might arise from malfunctions of military systems. An FMEA is often the first step of a system reliability study. It involves reviewing as many components, assemblies, and subsystems as possible to identify failure modes, and their causes and effects. For each component, the failure modes and their resulting effects on the rest of the system are recorded in a specific FMEA worksheet. There are numerous variations of such worksheets. An FMEA can be a qualitative analysis.
ABOUT THE TRAINING PROGRAM :-
Failure Mode and Effects Analysis or FMEA is a structured technique to analyze a process to determine shortcomings and opportunities for improvement. By assessing the severity of a potential failure, the likelihood that the failure will occur, and the chance of detecting the failure, dozens or even hundreds of potential issues can be prioritized for improvement.
DESIGNED FOR :-
Sr. Engineer, Engineer, Supervisor and Foreman engaged in maintenance, operation, Store, Supply chain, Quality, Safety and Engineering activities.
OBJECTIVE :-
Employees completing this training will be able to effectively participate on an FMEA team and can make immediate contributions to quality and productivity improvement efforts.
Failure mode and effects analysis (FMEA)—also "failure modes", plural, in many publications—was one of the first highly structured, systematic techniques for failure analysis. It was developed by reliability engineers in the late 1950s to study problems that might arise from malfunctions of military systems. An FMEA is often the first step of a system reliability study. It involves reviewing as many components, assemblies, and subsystems as possible to identify failure modes, and their causes and effects. For each component, the failure modes and their resulting effects on the rest of the system are recorded in a specific FMEA worksheet. There are numerous variations of such worksheets. An FMEA can be a qualitative analysis.
We all want to support the accomplishment of safe and trouble-free products and processes. Failure Mode and Effects Analysis has the potential to be a powerful reliability tool to reduce product design and manufacturing risk in a cost effective manner. With shorter product development times, tighter budgets and intense global competition, Design for Reliability tools such as FMEA must be applied correctly. Yet in practice, FMEA does not always achieve the expected results. Why is it that some companies have outstanding success in their FMEA application and others do not? What is the difference between well done and poorly done FMEAs? What are the essential elements of an effective FMEA process? These questions and more are answered in these three new short courses on FMEA.
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Failure Mode & Effects Analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. The purpose of the FMEA is to take actions to eliminate or reduce failures, starting with the highest-priority ones. FMEA also documents current knowledge and actions about the risks of failures, for use in continuous improvement.
In this training presentation, you can teach your employees on the proper steps to construct an FMEA for a design or process, and then implement action plans to eliminate or reduce the risks of potential failures.
LEARNING OBJECTIVES
1. Understand what an FMEA is, why it is used, and when can it be deployed
2. Understand the definitions, scoring system and calculations used in an FMEA
3. Learn the steps to developing an FMEA and the pitfalls to avoid
CONTENTS
1. Introduction to FMEA
2. FMEA: Definitions, Scoring System & Calculations
3. FMEA Procedure
4. FMEA Example
ABOUT THE TRAINING PROGRAM :-
Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events. The practice of RCA is predicated on the belief that problems are best solved by attempting to address, correct or eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. By directing corrective measures at root causes, it is more probable that problem recurrence will be prevented.
DESIGNED FOR :-
Managers, Engineers, Supervisor and officers engaged in maintenance operation and engineering activities.
OBJECTIVE :-
At the end of the training program, participants will be able
- To gain a basic understanding of the problem solving and decision-making process and the applicable quality tools that support this process.
- To develop specific competencies to use the structured approach to problem solving and decision making and the supporting quality tools.
TRAINING PROGRAM COVERAGE :-
- Basic knowledge about RCA program.
- What are the RCA tools ?
- More about Why- Why analysis ?
- Videos and case studies on RCA
The FMEA relates to a very broad spectrum on how effective this tool can be utilized as solver aid in dealing with the histories/pattern of failure in the product.
And how well can it be hierarchically deal with analysis the root cause of the problem.
This methodology is widely adopted in almost all manufacturing branch industries, due to its efficiency is tracking down all the possibilities occurrence in failure with the severity, occurrence, etc and other parameters to define the intensity of the failure being occurred.
To understand the tools usage a bit further, I have enumerated a case study via a example in this slides.
We all want to support the accomplishment of safe and trouble-free products and processes. Failure Mode and Effects Analysis has the potential to be a powerful reliability tool to reduce product design and manufacturing risk in a cost effective manner. With shorter product development times, tighter budgets and intense global competition, Design for Reliability tools such as FMEA must be applied correctly. Yet in practice, FMEA does not always achieve the expected results. Why is it that some companies have outstanding success in their FMEA application and others do not? What is the difference between well done and poorly done FMEAs? What are the essential elements of an effective FMEA process? These questions and more are answered in these three new short courses on FMEA.
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Failure Mode & Effects Analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. The purpose of the FMEA is to take actions to eliminate or reduce failures, starting with the highest-priority ones. FMEA also documents current knowledge and actions about the risks of failures, for use in continuous improvement.
In this training presentation, you can teach your employees on the proper steps to construct an FMEA for a design or process, and then implement action plans to eliminate or reduce the risks of potential failures.
LEARNING OBJECTIVES
1. Understand what an FMEA is, why it is used, and when can it be deployed
2. Understand the definitions, scoring system and calculations used in an FMEA
3. Learn the steps to developing an FMEA and the pitfalls to avoid
CONTENTS
1. Introduction to FMEA
2. FMEA: Definitions, Scoring System & Calculations
3. FMEA Procedure
4. FMEA Example
ABOUT THE TRAINING PROGRAM :-
Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events. The practice of RCA is predicated on the belief that problems are best solved by attempting to address, correct or eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. By directing corrective measures at root causes, it is more probable that problem recurrence will be prevented.
DESIGNED FOR :-
Managers, Engineers, Supervisor and officers engaged in maintenance operation and engineering activities.
OBJECTIVE :-
At the end of the training program, participants will be able
- To gain a basic understanding of the problem solving and decision-making process and the applicable quality tools that support this process.
- To develop specific competencies to use the structured approach to problem solving and decision making and the supporting quality tools.
TRAINING PROGRAM COVERAGE :-
- Basic knowledge about RCA program.
- What are the RCA tools ?
- More about Why- Why analysis ?
- Videos and case studies on RCA
The FMEA relates to a very broad spectrum on how effective this tool can be utilized as solver aid in dealing with the histories/pattern of failure in the product.
And how well can it be hierarchically deal with analysis the root cause of the problem.
This methodology is widely adopted in almost all manufacturing branch industries, due to its efficiency is tracking down all the possibilities occurrence in failure with the severity, occurrence, etc and other parameters to define the intensity of the failure being occurred.
To understand the tools usage a bit further, I have enumerated a case study via a example in this slides.
This presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
When working for Petrobras at PRSI (Pasadena Refining System Inc.) I had this opportunity to share my experience as a Maintenance Manager in Brazil with PRSI operators and maintenance crew.
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
This presentation provides a nice introduction to Failure Mode, Effects and Criticality Analysis (FMECA). Includes history and background, definitions, timelines for implementing and describes the FMEA methodology.
TPM is for improving productivity by making processes more reliable and less wasteful. To achieve this objective, preventive and predictive maintenance is adopted. The objective of TPM is to maintain the plant or equipment in good condition.
FMEA failure-mode-and-effect-analysis_Occupational safety and healthJing Jing Cheng
Failure mode and effect analysis (FMEA) is one of the methods of hazard analysis. Through FMEA, failures in a system that may lead to undesirable situation can be identified
To identify which failures in a system can lead to undesirable situation.
On the nature of FMECA... An introductionMartGerrand
Here's a presentation on Failure Modes, Effects and Criticality Analysis (FMECA) I did a few years ago, so the references may be truly historical. It's for educational use only - not for resale - so just enjoy!
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
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Failure Mode Effect Analysis and Total Productive Maintenance: A ReviewAM Publications
The goal of quality and reliability systems is the same-to achieve customer satisfaction. Quality and reliability are
synonymous. A system cannot be reliable if it does not have high quality. Likewise, a system cannot be of high quality if it is not
reliable. The quality performance of a firm is often assessed by the reliability of the firm's equipment or machinery. If a system is
unreliable, it is unpredictable and if it is unpredictable, it is not of high quality. FMEA is a one of the most important quality
management Techniques. Total Productive Maintenance is useful technique to increase the productivity of plant and equipment
with a modest investment in maintenance. The paper reviews various approaches of Failure Mode Effect Analysis and Total
Productive Maintenance has been developed so far and discussion about use of FMEA-TPM in integrated approach.
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
The FMEA is introduced as a tool here to analyze engineering failures and case studies have been provided to explain their methodologies and corrections to improve the quality and reliability of Designs and components.
This paper was published in Jan/Feb issue of Industrial Management. All rights reserved.
To cite this publication please use: Soliman, M.H.A (2018). Healthcare is Ripe for Lean. Industrial Management 60(1), 25-30. DOI: 10.6084/m9.figshare.9037805
Process Mapping is one of the most important lean tools in identifying wastes, spot on areas that need improvement, improve lead times, and develop a new standard.
A corrective maintenance work order form to be used in executing maintenance in cases of breakdowns, emergencies and when an immediate action is required.
The seven quality tools for problems solving. A practical guide on implementation and usage within the industrial process.
The presentation content:
1. Brainstorming
2. Case Study: Brainstorming the Causes of a Defective Capacitor
3. Fault-Tree Analysis + Example
4. Cause and Effect Diagram (5Whys)
5. Pareto Analysis & Pareto Diagram
6. Case Study.1: Tackling Defects in the Polyurethane Foam Cushions
7. Case Study.2: Tackling the Reasons of Low Productivity and Eliminate the Root Causes
8. Process Flow Chart & Process Mapping
9. Case Study.1: Improving the Process of Manufacturing a Die-Cut Envelopes
10. Case Study.2: Improving the Planned Maintenance Process
11. Implementation of 5S and Other Improvement Methodologies
12. Continuous Improvement Cycle
13. Cost of Quality
14. Toyota Recalls
A complete guide on preparation, planning and execution of a computerized maintenance management system with examples and illustration of the program modules interaction and the way these programs operate.
A complete guide on machinery oil analysis and oil condition monitoring.
Topics covered:
1. Oil sampling procedures
2. Oil analysis process
3. Oil analysis parameters
4. Oil specs and oil selection methodology
5. Case study: Car Engine
6. Case study: Power Turbine
7. Case study: Electric Transformer
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
1. A proactive tool to minimize the risk of failures and improve reliability
Reliability Centered Maintenance 1
2. Reliability Centered Maintenance 2
FMEA can provide the answer to many problems:
•How can we prevent this problem from occurring again in the future?
•How can we minimize the risk of this potential failure?
•How can we produce an error-free product?
•How can we reduce the warranty costs?
•How can we improve the safety condition in the workplace?
3. What is Failure Mode Effect Analysis FMEA?
An FMEA is a systematic method for identifying and preventing product and process
problems before they occur. FMEAs are focused on preventing defects, enhancing safety
and increasing customer satisfaction.
FMEAs are conducted in the product design or process development stages, although
conducting an FMEA on existing products and processes can also yield substantial
benefits.
What is the purpose of a FMEA?
Preventing the process and product problems before they occur is the purpose of
Failure Mode Effect Analysis. Used in both the design and manufacturing process, they
substantially reduce costs by identifying product and process improvement early in the
develop process when changes are relativity easy and inexpensive to make.
Reliability Centered Maintenance 3
4. FMEA as a part of a Comprehensive Quality System
Can FMEA be used a lone? While FMEAs can be effectively used a lone, a company
won’t get maximum benefit without systems to support conducting FMEAs.
Two things are necessary needed:
1. A reliable product or process data. Without this data, FMEA becomes a guessing
game based on opinions rather than actual facts. Without data the team may
focus on the wrong failure modes or missing significant opportunities to improve
the failure modes that are the biggest problems.
2. Documentation of procedures. In the absence of documents and procedures,
people working in the process could be introducing significant variation in to it by
operating it slightly different each time the process is run.
Reliability Centered Maintenance 4
5. Reliability Centered Maintenance 5
FMEA is one of the ISO 9001:2000 requirements as you must
have a system capable of controlling process that determine the
acceptability of your product or services.
6. Benefits of Failure Modes Effect Analysis “FMEA”
The object of an FMEA is to look for all of the ways a process or product can fail. A
product failure occurs when the product does not function as it should or when it
malfunction in some way.
•Contribute to improve design for product & process.
-Higher reliability
-Better Quality
-Increase Safety
•Contribute to cost saving.
-Decrease development time & redesign cost
-Decrease warranty costs.
-Decrease wastes
•Contribute to continuous improvement.
Reliability Centered Maintenance 6
7. Reliability Centered Maintenance 7
• System FMEA focuses on global system functions.
• Design FMEA focuses on components and subsystems.
• Process FMEA focuses on manufacturing and assembly processes.
• Service FMEA focuses on service functions.
Apply to: System, Process, Design, Service
Service engineers use FMEA to improve the lifecycle of the product and
lower its service costs by developing a proper maintenance program.
FMEA helps manufacturing engineers control the process and eliminate
errors during production, thus decreasing warranty costs and wastes.
8. Potential Applications:
•Equipment components & parts.
•Component proving process.
•Outsourcing/resourcing of product.
•Develop suppliers to achieve quality.
•Major process/ Equipment / Technology.
•Changes.
•Cost Reductions.
•New Product/ Design Analysis
•Assist in analysis in a flat Pareto chart.
Reliability Centered Maintenance 8
9. Failure Modes:
•Any event which causes a functional failure.
Example failure modes:
•Bearing Seized
•Motor burned out
•Coupling broken
•Impeller jammed
Compressors Failure Modes :
•Discharge pressure low
-Air leakage
-leaking valves
-Defect gauge
Engines Failures Mode:
•Knocking
-Pistons hitting the head
-Crankshaft plays
-Oil pump not function
Reliability Centered Maintenance 9
•Ways in which product or process can fail are called failure modes. The FMEA is a
way to identify the failures, effects, and risks within a process or product, and then
eliminate or reduce them.
10. Even the simple products have many opportunities for failure. For example, a drip coffee
maker. A relativity simple household appliance-could have several things fail that would
render the coffeemaker inoperable. Here are some ways the coffee make can fail:
• The heating element doesn’t heat water to sufficient temperature to brew coffee.
• The pump doesn’t pump water into the filter basket.
• The coffee maker doesn’t turn on automatically by the clock
• The clock stops working or running too fast or too slow.
• There is a short in the electrical cord.
• There is either not enough or too much coffee used.
Reliability Centered Maintenance 10
12. Reliability Centered Maintenance 12
Failures are not limited to problems with the product. Because
failures also can occur when the user makes a mistake. Those
types of failures should be included in the FMEA. Anything can
be done to ensure the product works correctly, regardless of how
the user operates it, will move the product closer to 100 percent
total customer satisfaction. The use of mistake-proofing
techniques, also known by its Japanese term poka-yoke, can be a
good tool for preventing failures related to user mistakes.
The goal is
13. The failure effect as it applies to the item under
analysis.
Ex. Water pump stop
The failure effect as it applies at the next higher
indenture level.
Ex. Water system pressure drop down.
The failure effect at the highest indenture level or total system.
Ex. System stop.
Local Effect
Next Higher Effect
End-Effect
Failure Effects Description
Reliability Centered Maintenance 13
14. The team size should be between 4 to 6 persons. But the number
of people is dedicated by the number of areas affected by the FMEA
for example (manufacturing, maintenance, design, engineering,
material, technical service…etc). The customer add another unique
perspective and should be considered for team membership.
Team Leader:
The team leader is responsible for coordinating the FMEA process as
follow:
1. Setting up and facilitate meeting.
2. Ensuring the team has the necessary resources available.
Reliability Centered Maintenance 14
15. Reliability Centered Maintenance 15
3. Making sure the team is progressing toward the completion of
the FMEA process.
4. The team leader role is more like of a facilitator rather than
decision maker.
17. Reliability Centered Maintenance 17
Select a high-risk process, then follow these steps.
1. Review the process: this step usually involves a carefully selected team that includes
people with various job responsibilities and levels of experiences. The purpose of an
FMEA team is to bring a variety of perspectives and experiences to the project.
2. Breakdown the system into components and sub-components.
3. Brainstorm potential failure modes.
4. List potential effects of each failure mode.
5. Assign a severity ranking for each effect.
6. Assign an occurrence ranking for each failure mode.
7. Assign a detection ranking for each failure mode.
8. Calculate the risk priority number (RPN) for each effect.
9. Prioritize the failure modes for action using RPN.
10. Take action to eliminate or reduce the high-risk failure modes.
11. Calculate the Resulting RPN as the failure modes are reduced or eliminated.
Steps of FMEA Process :
18. Reliability Centered Maintenance 18
FMEA Working Sheet
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
Component/Item Name:
Function :
19. Step.1 Review the Process or Product
Reliability Centered Maintenance 19
If the team is considering a product, they should review the
engineering drawing of the product.
If the team considering a process, they should review the operation
flowchart.
This is to ensue that everyone has the same understanding about the
process or product.
For a product, they should physically see the product and operate it.
For a process, they should physically walk through the process
exactly as the process flows.
20. Reliability Centered Maintenance 20
Step.2 Breakdown the system into components and sub-components
If the system is a large system, like a water system that supplies an industrial process,
the pump can be a critical component inside the system. A motor pump is a critical
subcomponent because its failure can break down the entire process. The motor pump
should be broken down into more subcomponents that are likely to fail and will affect
the system, such as the motor’s bearings and the rotor shaft. The FMEA will be used to
prevent the probability of failure for each component or subcomponent.
21. Step.3 Brain Storm Potential Failure Modes
Reliability Centered Maintenance 21
Once everyone in the team has an understanding about the
product or the process, team members should begin thinking
about the potential failure modes that could affect the
manufacturing process or the product quality.
Focusing should be on the different elements
(people, material, equipment, method,…etc).
Once the brainstorming is completed, the ideas
should be organized by grouping them into like categories. There
are many ways to group failure modes, they can be grouped by
type of failure (electrical, mechanical, user created). Where on the
product or process the failure occurs.
22. Reliability Centered Maintenance 22
Main Rules of Brainstorm:
1. Do not comment on, judge or
critique ideas at the time they are
offered.
2. Encourage creative and offbeat
ideas.
3. The goal is to end up with a large
number of ideas; and evaluate ideas
later.
4. Each idea should be listed and
numbered exactly as offered, on a
flip chart.
5. Expect to generate at least 50 to 60
concepts in a 30-minute
brainstorming session.
23. Failure Mode & Effect Analysis FMEA
-How can this sub system fail to perform its function?
-The Way the failure occurred
-What will the operator see?
Reliability Centered Maintenance 23
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
24. Step.4 List Potential Effects for Each Failure Mode
Reliability Centered Maintenance 24
For some of the failure modes, there may be one effect, while for
other modes, there may be several effects.
This information must be through because it will feed into the
assignment of the risk ranking for each of the failure.
Tips:
1. One failure mode could have several effects. For example, an electrical cutoff in the home
could stop the refrigerator and damage food or prevent you from doing work on the
computer.
2. Several failure modes could have one effect. A dead car battery or tire failure has the same
effect on your vehicle – it will be difficult to make it to work on time with such a failure early
in the morning.
3. The team must determine the end-effect each failure mode has on the system or the process.
This means examining how each failure affects the entire system, the facility or the other
connected processes.
25. Failure Mode & Effect Analysis FMEA
-What happen when failure mode occurs?
-Immediate consequences of a failure on operation, function or
functionality, or status of some item.
Reliability Centered Maintenance 25
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
26. Steps 5-7 Assign Severity, Occurrence, and Detection Rankings
Reliability Centered Maintenance 26
Each of these three rankings is based on 10-point scale, with 1 being
the lowest ranking, and 10 the highest.
27. Failure Mode & Effect Analysis FMEA
Effect of failure is determined by the worst case outcome with
respect to safety and environment impact, production
availability and direct economic cost and all that in numerical
measure which are identified from ranking criteria
Reliability Centered Maintenance 27
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
28. Failure Mode & Effect Analysis FMEA
Safety and Environment severity degree
Impact degree on availability of Production
Impact degree on Cost
Reliability Centered Maintenance 28
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
29. Description of Failure Effect Effect Ranking
No reason to expect failure to have any effect on Safety, Health, Environment or Mission. None 1
Minor disruption of production. Repair of failure can be accomplished during trouble call. Very Low 2
Minor disruption of production. Repair of failure may be longer than trouble call but does
not delay Mission.
Low 3
Moderate disruption of production. Some portion too of the production process may be
delayed.
Low to
Moderate
4
Moderate disruption of production. The production process will be delayed. Moderate 5
Moderate disruption of production. Some portion of production function is lost.
Moderate delay in to High restoring function.
Moderate to
High
6
High disruption of production. Some portion of production function is lost. Significant
delay in restoring function.
High 7
High disruption of production. All of production function is lost. Significant delay in
restoring High function.
Very High 8
Potential Safety, Health or Environmental issue. Failure will occur with warning. Hazard 9
Potential Safety, Health or Environmental issue. Failure will occur without warning. Hazard 10
Severity Ranking Criteria
Reliability Centered Maintenance 29
30. Reliability Centered Maintenance 30
Step.6 Assign an occurrence ranking for each failure mode
The best method for determining the occurrence ranking is to use
actual data from the process. This may be in the form of failure logs.
When actual failure data are not available, the team must estimate
how often a failure mode may occur, The team can make better
estimate on how likely a failure mode is to occur and at what
frequency by knowing the potential cause of failure. Once the
potential causes have been identified for all of the failure modes, an
occurrence ranking can be assigned even if the failure data are not
exist.
31. Failure Mode & Effect Analysis FMEA
For each failure mode there may be several failure causes. Assign a Cause for each
failure mode.
Select only potential failure to get failure causes.
Use Why Why Technique to get the root causes.
Identifying the failure cause can be the second option to determine the occurrence if
no data is available in the form of failure logs.
Reliability Centered Maintenance 31
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
32. Failure Mode & Effect Analysis FMEA
The probability of failure Occurrence during the expected life of the
system “potential occurrence”
Reliability Centered Maintenance 32
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
33. Rank Freq Description
1 1/10,000 Remote probability of occurrence; unreasonable to expect failure to occur
2 1/5,000 Low failure rate; similar to past design that has, in the past, had low failure rates for given volume or load
3 1/2,000 Low failure rate; similar to past design that has, in the past, had low failure rates for given volume or load
4 1/1000 Occasional failure rate; similar to past design that has, in the past, had similar failure rates for given volume or
load
5 1/500 Moderate failure rate; similar to past design that has, in the past, had moderate failure rates for given volume or
load
6 1/200 Moderate failure rate; similar to past design that has, in the past, had moderate failure rates for given volume or
load
7 1/100 High failure rate; similar to past design that has, in the past, had high failure rates that have caused problems
8 1/50 High failure rate; similar to past design that has, in the past, had high failure rates that have caused problems
9 1/20 Very High failure rate; almost certain to cause Problems
10 1/10 Very High failure rate; almost certain to cause Problems
Occurrence Ranking Criteria
Operating hours based on the automotive industry benchmark.
Ranking can be determined based on historical data or similar system
benchmarking
Reliability Centered Maintenance 33
34. Reliability Centered Maintenance 34
Step.7 Assign a detection ranking for each failure mode and/or
effect
First, the current control should be listed for all of the failure
modes, or effects , and then the detection rankings assigned.
*If one failure mode or effect has several causes, detection
and occurrence rankings should be assigned based on these
causes. When potential causes are eliminated, the risk of
failure is lowered.
35. Current control/fault detection methods applied to detect this failure. This will help
assign the detection ranking. Each detection method should be assigned for each failure
mode or effect.
Reliability Centered Maintenance 35
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
36. Failure Mode & Effect Analysis FMEA
Probability that a failure of mode will be Detected using the control
methods that are in place.
Reliability Centered Maintenance 36
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
37. Rank Description
1-2 Very high probability of detection
3-4 High probability of detection
5-7 Moderate probability of detection
8-9 Low probability of detection
10 Very low probability of detection
Detection Ranking Criteria
Reliability Centered Maintenance 37
38. Step.8 Calculate the Risk Priority Number RPN
Reliability Centered Maintenance 38
Risk Priority number= Severity x Occurrence x Detection
This number alone is meaningless because each FMEA has a
different number of failure modes and effects. However, it can
serve as a gauge to compare the revised RPN once the
recommended actions has been instituted.
39. Failure Mode & Effect Analysis FMEA
Risk Priority Number Calculation
Occurrence
X
Severity
X
Detection
RPN= O x S x D
Reliability Centered Maintenance 39
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
40. RPN Calculation Benefits:
•Contribute in Risk Assessment.
•Compare components to determine priority for corrective action.
What is RPN?
The Risk Priority Number (RPN) methodology is a technique for
analyzing the risk associated with potential problems identified
during a Failure Mode and Effects Analysis (FMEA)
Reliability Centered Maintenance 40
41. Assessing the risk priority number.
Each potential failure mode or effect is rated in each of these three
factors on a scale ranging from 1 to 10. By multiplying the ranking a
risk priority number RPN can be determined for each potential
failure mode and effect.
The RPN will range from 1 to 1000 for each failure mode. It is used to
rank the need for corrective action. Those failure modes with the
highest RPN number should be attended first. Although the special
attention should be given when the severity ranking is high from (9
to 10) regardless of the RPN.
Once a corrective action is takes, a new RPN is determined . This
new RPN is called the resulting RPN.
Reliability Centered Maintenance 41
42. Step.9 Prioritize the Failure Modes for Action
Reliability Centered Maintenance 42
Failure modes should be prioritized by ranking them in order, from
the highest risk priority number to the lowest. Chances are that you
will find that the rule 80/20 rule applied with the RPNs.
The team must now decided which item to work for. Usually it helps
to set a cutoff RPN (cutoff point), where any failure modes with an
RPN above that point are attended to. Those below the cutoff are left
alone for the time being.
Tip:
High-risk numbers should be given attention first; then you can pay attention to the
severity rankings. Thus, if several failure modes have the same risk priority number, that
failure mode with the highest severity should be given more priority.
43. Failure Mode & Effect Analysis FMEA
Appropriate maintenance action, appropriate maintenance task
Corrective actions may include: reduce the severity of occurrence ,or increase
the detection probability
Reliability Centered Maintenance 43
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
44. Step.10 Take Actions to eliminate or Reduce the High-Risk
Failure Modes
Reliability Centered Maintenance 44
This is organized using the problems-solving approaches and
implement actions to reduce or eliminate the high risk failure
modes.
Often the easiest way to make an improvement to the product or
process is to increase the detectability of the failure, thus lowering
the detection rate.
Increase the detection rate can be done though assigning a schedule
PM action, use a proper condition monitoring program or consider a
mistake proofing method in the design. For example, ac computer
software will automatically warn incase of low disk space.
45. Reliability Centered Maintenance 45
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
Appropriate actions taken to reduce the risk of failure
46. Reliability Centered Maintenance 46
Step.11 Calculate the Risk Priority Number RPN as the High
Risk is Removed
Once actions have been taken to reduce the risk priority number, a
new ranking for the severity, occurrence, and detection should be
calculated. And a resulting RPN is calculated.
Expectation is at least 50 percentage reduction in RPN with the
FMEA approach.
There will always be a potential for failure modes to occur. The
question the company must ask is how much relative risk the team
is willing to take. That answer might depend o the industry and the
seriousness of the failure. For example, in the nuclear industry, there
is a little margin for errors,; they can’t risk a disaster occurring. In
other industries, it may be acceptable to take the high risk.
47. Reliability Centered Maintenance 47
Item Function
Failure
Mode
Failure
effect
Severity
Failure
Cause
occurrence
Current
Controls
Detection
RPN
Recommendation
Take
action
Resulted
S O D
RPN
NEW RPN based on the new Severity, Occurrence, and Detection rankings
48. Reliability Centered Maintenance 48
Failure mode Failure Effect Failure Effect
(System)
Failure Effect (End) Failure cause
Level 1
Root cause
Fan operate
with high
vibration
level
Equipment
damage/breakdown
Unexpected plant
shutdown
Major production
losses
Bearing fails Poor Maint
Equipment
damage/breakdown
Unexpected plant
shutdown
Major production
losses
Housing wear Poor Maint
Equipment
damage/breakdown
Unexpected plant
shutdown
Major production
losses
Unbalance fan
blade
Poor Maint
Equipment
damage/breakdown
Unexpected plant
shutdown
Major production
losses
Looseness in
foundation
Poor Maint
Equipment
damage/breakdown
Unexpected plant
shutdown
Major production
losses
Shaft wear Poor Maint
49. Item name Failure mode Failure
Effect (local)
Failure
Effect
(System)
Failure
cause
Failure
Cause
Root cause
Oil
1.Short circuit
in transformer
Functional
stop
Production
losses
Particles in
the oil
Overheated
Bad
Maintenance
Functional
stop
Production
losses
Water in the
oil
Overheated
Bad
Maintenance
Aging
Tap
Changes
2-Can’t change
voltage level
Functional
stop
Production
losses
Mechanical
damage Wear
Life time/
maintenance
Ex.2 Transformer
Reliability Centered Maintenance 49
50. Ex.3 Water System
Function Functional failure/failure modes Causes
Provide water to the industrial
process
Total loss of pressure, volume &
flow
Pump failed
Motor failed
Valve out of position
Electric Motor
Function Functional failure/failure modes Causes
Drive the water pump Burn out
Circuit Breaker tripped
Bearing seized
Insulation Rotor
Insulation Stator
Failure mode Failure Cause Sources of failure/causes Causes
Bearing seized,
this include
bearing, seals,
lubrication
Lubrication
Contamination
Supply dirty
Sealing failed
Wrong type
Procedure wrong
Supply information wrong
Tool little
Human error
Procedure error
Too much
Human error
Procedure error
Motor Bearing
Reliability Centered Maintenance 50
51. Failure effect Severity Causes Root
Cause
Occurrence
Current
fault
detection
methods
Detection
RPN Actions
Local sys end S A C
Seal failed
Seal
failed
Motor
shutdown
System
shutdown
TPL
Procedure
wrong
Lack of
trainingHuman error
Human error
Final Table
Reliability Centered Maintenance 51
52. Consequence or Severity
Probability
or frequency (1)
Low
(2)
Medium
(3)
High
(1)
Low
(2)
Medium
(3)
High
1
L
2
L
3
M
6
H
4
M
2
L
9
H
6
H
3
M
It’s important to design your own matrix
Risk=Probability x Severity
Reliability Centered Maintenance 52
53. Reliability Centered Maintenance 53
References:
Raymond J. Mikulak, Robin McDermott. (2008). The Basics of FMEA. Productivity
Press; 2 edition.
Robert T. Amsden and Davida M. Amsdenand. (1998). SPC Simpliefied: Practical
steps to quality. Productivity Press; 2 edition.
Ahmed Soliman, Mohammed. Hamed. “Analyzing Failure to Prevent Problems” Institute of
Industrial Engineers IM Magazine Sept2014, Vol.56, Issue 4, USA.
Risk Based Inspection (RBI) Lectures by Professor Dr Attia Gomaa, Banha University & The
American University in Cairo.
Eng. Mohammed Hamed Ahmed Soliman
The American University in Cairo
Email: mhamed206@yahoo.com
m.h.ahmed@ess.aucegypt.edu
https://eg.linkedin.com/in/mohammedhamed
Tel: +201001309903