Manper07 fmea
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This document discusses Failure Mode and Effects Analysis (FMEA). It begins by defining key terms like probability, risk, risk measurement, and risk management. It then explains that FMEA is a manual analysis method used to determine the consequences of failures in components, modules, or subsystems. The FMEA process involves identifying potential failure modes, their causes and effects, current controls, and developing recommendations to address high priority risks. Seven steps of the FMEA process are outlined, including determining failure modes and associated risks, effects, causes, controls, recommended actions, and comparing results. An example of applying FMEA to a truck stop coffee process is also provided.
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Manper07 fmea
- 1. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya 1 1 FAILURE MODE & EFFECT ANALYSIS Teknik Industri Universitas Brawijaya
- 2. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya MetodePengukuranResiko Fault Tree Analysis Failure Mode and Effect Analysis 2
- 3. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Definition Probabilitas: peluang atau kemungkinan kemunculan satu kejadian. Resiko: peluang kemunculan satu kejadian yang tidak diharapkan serta tingkat kritis dampak yang diakibatkan. Pengukuran Resiko: proses kategorisasi resiko secara kualitatif atau estimasi resiko kuantitatif. Manajemen Resiko : proses identifikasi resiko, pengukuran resiko, disposisi resiko serta monitor dan kontrol resiko. 3
- 4. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Definition Reliability: Probabilitas sistem berfungsi andal dan efektif dalam kondisi spesifik selama periode tertentu tanpa terjadi kegagalan atau kerusakan. Safety: Tingkat keamanan bebas dari kecelakaan, cedera, kerusakan atau kehilangan sumber daya. Hazard: Kondisi yang beresiko mungkin menyebabkan atau berkontribusi terjadinya mishap. Mishap: Kejadian yang tidak diharapkan karena dapat menyebabkan kecelakaan, cedera, kerusakan atau kehilangan sumber daya. 4
- 5. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya FailureMode&EffectAnalysis Failure Mode & Effect Analysis (FMEA) merupakan metode analisis manual untuk menentukan konsekuen dari kegagalan komponen, modul atau subsistem FMEA berwujud tabel spreadsheet yang mengidentifikasi macam kegagalan (failure), faktor kegagalan (failure mode), akibat kegagalan (failure effect), penyebab (possible causes), frekuensi kejadian (probability of occurrence), dampak kegagalan (severity) konsekuensi (consequences), dan rekomendasi (proposed safeguards). 5
- 6. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya FMEASteps 1. For each process input (start with high value inputs), determine the ways in which the input can go wrong (failure mode) 2. For each failure mode, determine effects. Select a severity level for each effect 3. Identify potential causes of each failure mode. Select an occurrence level for each cause 4. List current controls for each cause. Select a detection level for each cause 6
- 7. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya FMEASteps 5. Calculate the Risk Priority Number (RPN) 6. Develop recommended actions, assign responsible persons, and take actions. Give priority to high RPNs. 7. Assign the predicted severity, occurrence, and detection levels and compare RPNs 7
- 8. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya FailureModesandEffects The relationship between failure modes and effects is not always 1 to 1 8 Failure Mode 1 Failure Mode 2 Effect 1 Effect 2 Failure Mode 1 Failure Mode 2 Effect 1 Failure Mode 1 Effect 1 Effect 2
- 9. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Severity,Occurrence,andDetection Severity Importance of the effect on customer requirements • Often can’t do anything about this Occurrence Frequency with which a given cause occurs and creates failure modes Detection The ability of the current control scheme to detect or prevent a given cause 9
- 10. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Severity,Occurrence,andDetection Severity 1 = Not Severe, 10 = Very Severe Occurrence 1 = Not Likely, 10 = Very Likely Detection 1 = Likely to Detect, 10 = Not Likely to Detect 10
- 11. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Severity,Occurrence,andDetection Untuk menilai tingkat konsekuensi atau severity dari 11
- 12. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya RiskPriorityNumber(RPN) RPN is the product of the severity, occurrence, and detection scores. 12 Severity Occurrence Detection RPNRPNX X =
- 13. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Truck Stop Coffee Process Map 13 Inputs OutputsInputs Outputs Hot Water Soap Scrubber Clean Carafe Cold Water Measuring Mark Full Carafe Filter Maker w/Filter Fresh Coffee Dosing Scoop Maker w/Filter & Coffee Brewing Coffee Cleaned Carafe Dirty Water Wet Scrubber Full Carafe Filled Maker Empty Carafe Maker w/Filter Maker w/Filter & Coffee Operating Maker Heat Brewed Coffee Hot Coffee Customer Order Size Specification Complete Order Hot Coffee Cup Filled Cup Customer Cream Sugar Amount Desired Complete Order Money Coffee Delivery Complete Order Filled Cup Customer Reply Amount Specified Complete Order Make Change Temperature Taste Strength Smile Happy Customer Pour Coffee into Cup Pour Coffee into Cup Offer Cream & Sugar Offer Cream & Sugar Complete Transaction Complete Transaction Say Thank YouSay Thank You Receive Coffee Order Receive Coffee Order Clean CarafeClean Carafe Fill Carafe w/Water Fill Carafe w/Water Pour Water into Maker Pour Water into Maker Place Filter in MakerPlace Filter in Maker Put Coffee in Filter Put Coffee in Filter Select Temperature Setting Select Temperature Setting Turn Maker OnTurn Maker On
- 14. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Truck Stop Coffee C&E Matrix 14 Temp of Coffee Taste Strength Process Outputs 8 10 6 Importance Process Step ----- Process input ----- --------- Total --------- 0 Clean Carafe 0 3 1 36 Fill Carafe with Water 0 9 9 144 Pour Water into Maker 0 1 1 16 Place Filter in Maker 0 3 1 36 Put Coffee in Filter 0 9 9 144 Turn Maker On 3 1 0 34 Select Temperature Setting 9 3 3 120 Receive Coffee Order 0 0 1 6 Pour Coffee into Cup 3 1 3 52 Offer Cream & Sugar 3 9 3 132 Complete Transaction 1 1 1 24 Say Thank You 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 --------- Correlation of Input to Output ---------
- 15. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 1: For Each Input, Determine the Potential Failure Modes 15
- 16. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 2: For Each Failure Mode, Identify Effects and Assign Severity 16
- 17. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 3: Identify Potential Causes of Each Failure Mode and Assign Score 17
- 18. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 4: List Current Controls for Each Cause and Assign Score 18
- 19. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 5: Calculate RPNs 19
- 20. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 6: Develop Recommended Actions, Assign Responsible Persons, and Take Actions 20
- 21. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya Step 7: Assign the Predicted Severity, Occurrence, and Detection Levels and Compare RPNs 21
- 22. Manajemen Perawatan – 05 FMEA Arif Rahman – Universitas Brawijaya 22 Akhir Perkuliahan…Akhir Perkuliahan… …… Ada Yang DitanyakanAda Yang Ditanyakan