Fault Tree Analysis

How to use FTA in Problem Solving Process

April/May, 2001 Revised by Tak Yamada
Original Submitted by Ken Mihara December, 2000
V2.2

Agenda
What is FTA ? When it is used? How does it compare with other techniques? How to develop FTA How is it placed on problem solving roadmap?

What is FTA ?

Method to analyze the failure

causes from top event to basic

events in order to detect the root

causes and find the failure

mechanism

History

First used in the early 1960s during development of ICBM launching control system at Bell Telephone Laboratories In 1965 a couple of papers were presented regarding the use of FTA In the late 1960s, FTA applied for nuclear power generation systems for its effectiveness on reliability analysis and safety analysis Komatsu introduced FTA in middle of 1970s. It has been adapted to include schedule for efficient failure analysis.

FTA-Prerequisites

Failed parts investigation

Field survey

Record review
FTA
3-Reality Principle

Why FTA & not other techniques

Just Another Term for Fishbone. Hishakawa. PFMEA.

Fault Tree Analysis

2. Determine possible causes and rank their importance.

E F F E C T

STEP 1: Identify the Problem

people machine materials

STEP 2: Record the problem statement

E F F E C T
methods environment

Step 3: Draw & label the main categories

Step 4: Brainstorm for possible causes

Step 5: Check for logical validity of each causal chain

Step 6: Check for completeness

Fault Tree Analysis

2. Determine possible causes and rank their importance.

Example: Potential Failure Modes and Effects Analysis (PFMEA)

Action Results

Classificatio

Occurances

Potential Process Potential Effect(s) Function Failure of Requirements Mode Failure

Potential Causes/ Mechanism(s) of Failure

Current Process Controls

Responsibility & Target Recommended Completion Actions Action(s) Date Taken

Occurances

Detection

Detection

Severity

Severity

R.P.N.

RPN

Why FTA?---

Helps organizing failure analysis

Helps finding root causes which is the key to problem solving

Decisions based on data not just opinions or experience. FTA is a tool for finding root causes, effectively and efficiently that prevents us from jumping to the conclusion.

Introduction to FTA
FTA Team formation Team approach is necessary Representatives recommended - Design - Metallurgist - Service - Quality - Manufacturing - Materials - Suppliers Team leader must be assigned

Concept of FTA
Engine won't start Top Event = Problem Wrong Injection Timing
Intermediate events

Low Compression Lack of Fuel

Analyzed down to Basic Events

Basic events are investigated to find root causes and then failure mechanism is presumed.

Fault Tree Analysis Phases

Fault Tree Analysis (FTA) Phases

FTA Background Information Summary of Failure and Top Event Fault Tree Development, 5 Whys Investigation Schedule

What - Basic product/process characteristics Who - Person responsible When - Target completion date

Analysis - Investigation Results Develop Presumed Failure Mechanism Statement Conclusion and Corrective Actions

Procedure of FTA <phase 1>

Common shared understanding All the team members should have the good understanding on the system to be analyzed. - Functions, Configuration, Environment, etc. Remarks - Confirm the requirements of reliability and durability for the system. - Provide drawings. (Assembly drawings, Component drawings ) - Provide parts (failed, new, survived) - Provide the result of 3-R investigation

Fault Tree Analysis Background Information

Fault Background Information

Abstract
Title
Date Model

Unit
Part

Name

Authorization

Failed parts investigation

Look at the failed parts in details

Compare with brand-new parts,

survived parts Compare with other applications, models, etc. Remark Additional data is preferable: Cut parts, Metallurgical analysis result, SEM picture,etc.

Record review

Failure / Problem Record classified by: - Mileage / SMR (Service Meter Reading) - Production / Build Date - Application / OEM / Customer - Location / Country - Failed Date - Others, e.g. Number of Cylinder ---->This data must be expressed in ratio compared with production volume

Check Design/Process Change Record - Correlation with the failure record

Remark: Use templates for the analysis

Procedure of FTA <phase 2>

Summary of Failure and Top Event

Summarize the failure and Identify the Problem (Top Event ) based on the summary. The summary must include the result of 3-Rs
1) failed parts investigation 2) field survey 3) failure record review, design/process change record review

Summary of Failure

Must include 3-Rs Itemize the problem statements Express with quantity Be aware: Clear Concise Specific

Top Event

Too general top event will cause too much work. Too specific top event will leave missing possible causes.

Common understanding of the problem in the team is essential

Note: Look at failed Parts !

Discuss based on Data! every time

Procedure of FTA <phase 3>

Fault Tree Development Develop possible causes for higher events down to the Basic Events. Basic events are possible causes. Then they are expressed in basic characteristics. Remarks - Use 5 Whys for developing possible causes

Basic Characteristics

The basic characteristics accompanies the basic events. They are expressed in the product/process characteristics. All the basic characteristics must be quantifiable and measurable

Basic Events & Characteristics -example

Basic Events
Low Torque Design Low Hardness Excessive engine Speed

Basic Characteristics
Torque Spec. Hardness Engine Speed

5 Whys

Procedure of FTA <phase 4>

Investigation schedule
Determine investigation items and set schedule

Investigation items are determined for each characteristics. Sequential number is assigned to each investigation item*

*This makes the identification easier and helps to know the volume of the investigation.

Investigation Items - example

Basic Characteristics Investigation Items Torque Spec. Specification comparison - vs. standard/other models Hardness comparison - vs. spec/brand new parts Tachometer read Slope of the ground Operators information

Hardness
Engine Speed

Investigation Schedule
Investigation = Data collection - Prioritize the investigation items - Make Action Plan for investigation and set schedule for each item - Follow the action to keep the schedule

Remarks - Make clear by who, by when Who is responsible for each item When investigation is to be completed

What?

Who?

When?

Procedure of FTA <phase 5>

Make judgement on investigation Results Summarize the result for each corresponding basic characteristics. Judgement - Comparison of basic characteristics using the Data gathered in the investigation (FTA process promotes a Data-Based Decision)

Note: No changes dont mean no problems.

Problems may occur within specifications.

Comparison
- Finding Differences
Drawing/Specification

vs. Failed

parts Survived parts vs. Failed parts Development vs. Field Problem Cross check with other applications in the same engine series Cross check with other engines

Procedure of FTA <phase 6>

Failure Mechanism Presumption
Compose failure mechanism based on the judgement

Remark Check whether the presumed failure mechanism is consistent with the Summary of Failure and 3-Rs

Procedure of FTA <phase 7>

Failure Replication
Conduct the test to replicate the failure for confirmation

Remark This phase is often skipped, but it is essential for proving the failure.

Fault Tree Analysis

Corrective Action/Communication
Corrective action
Product

changes Process changes

Record & Route

Technical

report FTA charter

Fault Tree Analysis Summary

Go slow to go fast The 3 Rs

Complete the Summary of failure first Include the items in the FTA that the data supports Add your FTA to the database when done

Look at the Real Parts Go to the Real Place Understand the Real Situation