Module 5 Design for Reliability and Quality

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Lecture 1
Failure Mode and Effect Analysis

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Instructional objectives
By the end of this lecture, the students are expected to learn (a) the principle, basic structure, procedure followed and the importance of Failure Mode and Effect Analysis (FMEA), and (b) how to effectively apply and sustain FMEA to any process, product or system.

What is FMEA?
A failure modes and effects analysis (FMEA) is a process by which the identification and the evaluation of potential failure modes for a system, product, component or a process is done for classification by the severity and likelihood of the failures. A successful FMEA activity helps to identify potential failure mode, its causes, identifying the impact of these potential failures and then prioritizing actions to reduce or eliminate these failures out of the system with the minimum of effort and resource expenditure, thereby reducing development time and costs. Failure modes are faults or defects in a design, component, or system, especially those that affect the intended function of the product and or process, and can be potential or actual. Effects analysis refers to studying the consequences of those failures. The underlying principle of FMEA is to resolve potential problems before they occur, enhancing safety, and increasing customer satisfaction

FMEA History
FMEA was first described in US Armed Forces Military Procedures in 1949. Later, various groups and departments of NASA used FMEA principles under variety of names in mid 1950s and 1960s. Ford Motor Company published instruction manuals for FMEA in the 1980s and the automotive industry collectively developed standards in the 1990s. Engineers in a variety of industries have adopted and adapted the tool over the years.

VARIOUS FAILURE MODES

Failure is usually perceived to be fracture or complete separation of a member or an assembly. Failures can also occur due to excessive elastic or plastic deformation, or a variety of other
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reasons. Various failure modes of the mechanical components can be classified in the following four groups. [1] Excessive elastic deformation that is temporary and reversible resulting in stretching of metallic bonds. [2] Excessive plastic deformation which is permanent and irreversible, and can lead to thinning of cross-sectional area with increased stress concentration. [3] Fracture which refers to breaking or rupture of a component into two or more pieces as a result of stress. [4] Loss of required part geometry through corrosion or wear that may lead to loss or material directly affecting the geometry of the component. In general, the failure of mechanical parts can occur due to a variety of reasons. Some of the most common failure modes for a mechanical component are mentioned below. [a] [b] [c] Force and/or Temperature-Induced elastic as well as plastic Deformation Ductile and Brittle failure Fatigue that includes high-cycle and low-cycle fatigue, thermal fatigue, surface fatigue, impact fatigue, corrosion fatigue and fretting fatigue. [d] Corrosion due to direct chemical attack, galvanic corrosion, crevice and pitting corrosion, intergranular corrosion, selective leaching, biological corrosion, stress corrosion, corrosion due to erosion, hydrogen induced corrosion, etc. [e] Wear [adhesive wear, abrasive wear, corrosive wear, wear due to deformation, impact, fretting and surface fatigue] [f] [g] [h] [i] [j] [k] [l] Impact [deformation, wear and fracture due to impact, impact fretting and fatigue] Fretting [fatigue, wear and corrosion due to fatigue] Galling and seizure Creep related failure, combined creep and fatigue. Thermal shock and thermal relaxation. Buckling due to static or dynamic load or due to creep. Localized oxidation

[m] Radiation damage [n] [o] Bonding failure and / or delamination Erosion
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FAILURE ANALYSIS TECHNIQUES

Various techniques are used to identify the mode of failure of a part or component. Following are some of the major techniques

Field inspection
The most useful and primary approach is to inspect the failure on site as soon as the failure has occurred. This visit should be documented in detail with photographs and should also contain insights from the various personnel involved in operation and maintenance of the component. If possible the failed component should be brought back to laboratory for more detailed study,

Macroscopic examination
This type of examination is done at a magnified scale of 1x to 100x range. The main purpose of this is to observe the gross features of the fracture and presence or absence of cracks, defects, corrosion or oxidation. Working at such magnification it should be possible to make an initial assessment of the origin of fracture and other defects and thus narrow down the region of the fracture for further study at higher magnification.

Microscopic Examination
This type of examination is made at a magnification greater than 100x for microstructure analysis. To achieve such magnification we need instruments like Scanning Electron Microscope (SEM), Transmission Electron Microscope (TEM), X-ray microprobe analyzer and so on. Microstructure analysis is essential because it helps to identify important features like grain size, inclusion size, crack growth, arrangement of phases and so on and give a better understanding of the microstructure and the cause of failure.

Timing of an FMEA program

One of the most important elements for the successful implementation of an FMEA technique is its timeliness. It is meant to be a before-the-event action and not an after-the-fact exercise. Actions resulting from an FMEA can reduce or eliminate the chance of implementing a change that would create an even larger concern. Ideally, FMEAs are conducted in the product design or process development stages, although conducting an FMEA on existing products or processes may also yield benefits.

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Why do FMEAs?
FMEA has been an indispensable tool for industries such as aerospace, automobile industries and Government agencies (Army, Navy, Air Force, etc) because of the following reason Improves design by discovering unanticipated failures Highlights the impact of the failures Provides a method to characterize product safety It records and documents the logic of the engineers and related design and process considerations It is an indispensable resource for new engineers and future design and process decisions.

TEN Steps to conduct a FMEA

[1] Review the design or process
The reviewing of the design or process is to identify all of the components of the system at given level of the design or process hierarchy and determine the function or functions of each of those components. Many components have more than one function.

[2]

Brainstorm potential failure modes

Identify failure modes for each component/system. Typically there will be several ways in which a component can fail. Potential Failure Mode comes from things that have gone wrong in the past, concerns of designers, and brainstorming. A potential failure mode represents any manner in which the component or process step could fail to perform its intended function or functions. Brainstorm the potential failure modes for each function for each of the components identified.

[3]

List potential failure effects

Determine the effects (both locally and globally) associated with each failure mode on the system. The effect is related directly to the ability of that specific component to perform its intended function. An effect is the impact a failure could make if it occurred.

[4]

Assign Severity ratings

Assign a severity ranking to each effect that has been identified. The severity ranking is an estimate of how serious an effect would be should it occur. To determine the severity,
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consider the impact the effect would have on the customer, on downstream operations, or on the employees operating the process. The severity ranking is based on a relative scale ranging from 1 to 10. Table 5.1.1 depicts relative severity and corresponding rankings.

Table 5.1.1 Rank 1 2 3 4 5

Severity and corresponding ranks of failures Effect None Rank 6 7 8 9 10 Effect Severe High Severity Very High Severity Extreme Severity Maximum Severity

Very Slight Slight Minor Moderate

[5]

Assign Occurrence ratings

Determine the failures probability of occurrence. Assign an occurrence ranking to each of those causes or failure mechanisms. The occurrence ranking is based on the likelihood or frequency, that the cause (or mechanism of failure) will occur. The occurrence ranking scale, like the severity ranking, is on a relative scale from 1 to 10 as shown in Table 5.1.2.

Table 5.1.2 Rank 1 2 3 4 5

Likely occurrences of failures and corresponding ranking Occurrence Rank 6 7 8 9 10 Occurrence Medium Likelihood Moderately High Likelihood Very High Likelihood Extreme Likelihood Maximum Likelihood

Extremely Unlikely Remote Likelihood Very Low Likelihood Low Likelihood Moderately Low Likelihood

[6]

Assign detection rating

To assign detection rankings, identify the process or products related controls in place for each failure mode and then assign a detection ranking to each control. Detection rankings
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evaluate the current process controls in place. The Detection ranking scale, like the Severity and Occurrence scales, is on a relative scale from 1 to 10 as shown in Table 5.1.3. Table 5.1.3 Rank 1 2 3 4 5 Likely detection of failures and corresponding ranking Occurrence Extremely Likely Very High Likelihood High Likelihood Moderately High Likelihood Medium Likelihood Rank 6 7 8 9 10 Occurrence Moderately Low Likelihood Low Likelihood Very Low Likelihood Remote Likelihood Extremely Unlikely

[7]

Calculate RPN
The RPN is the Risk Priority Number. The RPN gives us a relative risk ranking. The RPN is calculated by multiplying the three rankings together. Multiply the Severity ranking times the Occurrence ranking times the Detection ranking. For example, Risk Priority Number (RPN) = (Severity) X (Occurrence) X (Detection) Calculate the RPN for each failure mode and the corresponding effect. RPN will always be between 1 and 1000. The higher the RPN, the higher will be the relative risk. The RPN gives us an excellent way to prioritize focused improvement efforts.

[8]

Develop an action plan to address high RPNs

Develop an action plan by which reduction in the RPN. The RPN can be reduced by lowering any of the three rankings (severity, occurrence, or detection) individually or in combination with one another.

[9]

Take action
The action plan outlines what steps are needed to implement the solution, who will do them, and when they will be completed. Responsibilities and target completion dates for specific actions to be taken are identified. All recommended actions must have a person assigned responsibility for completion of the action. There must be a completion date accompanying each recommended action. Unless the failure mode has been eliminated, severity should not change. Occurrence may or may not be lowered based upon the
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results of actions. Detection may or may not be lowered based upon the results of actions. If severity, occurrence or detection ratings are not improved, additional recommended actions must to be defined

[10] Reevaluate the RPN after the actions are completed

This step is to confirm the action plan had the desired results by calculating the resulting RPN. To recalculate the RPN, reassess the severity, occurrence, and detection rankings for the failure modes after the action plan has been completed.

Tables 5.1.4 and 5.1.5 respectively show a typical worksheet and an example of failure mode and effect analysis for typical failures of engineering components.

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Gas Cooler Conducts heat to the external environment Blockage in refrigerant flow Function Potential Failure mode Potential Effect of Failure Severity Rating Cause of Failure Rating Current Control Rating Low cooling capacity, increase in pressure 6 Bends, blockages 2 Deformation guard; design of components 10 Function

Component Component

Potential Failure mode Potential Effect of failure Rating Cause of failure Occurrence Detection Rating Current Control Rating RPN Table 5.1.5 Severity Occurrence Detection Table 5.1.4

Parallel procedures, pressure sensor switched in front of the gas cooler, plausibility control via regulation control Mr. Rahul 17th May 2012 Yes 6 2 6 72

Recommended Action

An example of Failure mode and effect analysis (FMEA)

Responsibility and Target completion date Action taken Sev Occ Det RPN
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Schematic worksheet for Failure mode and effect analysis (FMEA)

RPN

120

Recommended Action Responsibility and Target completion date Action taken Sev Occ Det RPN Action Result Action Result

Applications and Benefits for FMEA

The Failure Modes and Effects Analysis (FMEA) procedure is a tool that has been adapted in many different ways for many different purposes. It can contribute to improved designs for products and processes, resulting in higher reliability, better quality, increased safety, enhanced customer satisfaction and reduced costs. The tool can also be used to establish and optimize maintenance plans for repairable systems and/or contribute to control plans and other quality assurance procedures. It provides a knowledge base of failure mode and corrective action information that can be used as a resource in future troubleshooting efforts and as a training tool for new engineers. Cost effective tool for maximizing and documenting the collective knowledge, experience, and insights of the engineering and manufacturing community for the particular product or system

Further advancements
1. SFMEA When FMEA is applied to interaction of parts it is called System Failure Mode and Effects Analysis (SFMEA) 2. DFMEA When applied to a product it is called a Design Failure Mode and Effects Analysis (DFMEA) 3. PFMEA When applied to a process it is called a Process Failure Mode and Effects Analysis (PFMEA).

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Exercises
1. Prepare and evaluate a FMEA table for a bicycle pedal.

References
1. G Dieter, Engineering Design - a materials and processing approach, McGraw Hill, NY, 2000. 2. http://www.qualitytrainingportal.com/resources/fmea/fmea_10step_pfmea.htm

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