Systems Engineering

Risk Analysis with FMEA

Special Topics Fishbone Chart FMEA

Risk/Failure Models
At the project level.
At the system or device level.
Common methods include Fishbone analysis or FMEA FMEA Failure Modes and Effects Analysis

Fishbone Chart
Cause and Effect Analysis Create an Ishikawa or Fishbone Chart Head is Problem Skeleton are the Causes Typical categories, 5Ms + E
Man Machine Material Method Measurement Environment

Industrial Monitoring Sensor

Create a Fishbone Chart for Sensor Not Working

Analysis Tool FMEA

Failure Mode and Effects Analysis
FMEA is an enhanced Cause and Effect Analysis. (the 5Ms plus E)
Do Fishbone Chart for Industrial Sensor.

Apply FMEA to a Design or Processes at many levels.

Systems often have many SPFs single points of failure.

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Design Tool FMEA

The Concept of FMEA:

People Make Mistakes Products and Processes Fail

Anticipate these errors and eliminate them with design or process changes !!

FMEA Example
How many ways can a floppy disk be inserted ??

What design features make this possible??

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FMEA Steps
1. 2. 3. 4. 5. 6.

-The traditional approach

Team activity Select component, system, process step, etc. Identify possible failure modes. Identify causes of failure modes. Identify effects of failures. Estimate (1-10 ranking):
1. Occurrence how often (1=not, 10=often) 2. Severity how bad (1=not, 10=severe) 3. Detection how easy (1=easy, 10=difficult)

7. Calculate RPN risk priority number

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FMEA RPN example

Occ 1 1 1 1 10 10 10 10 Sev 1 10 1 10 1 10 1 10 1 1 10 10 1 1 10 10 Det RPN 1 10 10 100 10 100 100 1000 Comments No Problem No action, easy to detect. No action, not often or severe. Action Chronic problem, fix ? Chronic and severe, fix Chronic and customer issues, fix Bad, Bad, Bad top priority

Rules for OSD Values Threshold for Action Varies Thresholds 55-100 (?)

From National Instruments

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From National Instruments

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Detection in Design or Manufacturing

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POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

Design FMEA System
Part Number

Process FMEA
Page Prepared by Original FMEA Date FMEA Number Telephone # FMEA Revision Date

Internal Use Only

Subsystem

Component
Design or Process Responsibility

Core Team

Design Item or Process Function Requirements

Potential Failure Mode

Potential Effect(s) of Failure

S e v

C l a s s

Potential Cause(s) / Mechanism(s) of Failure

O c c

Current Design or ProcessControls

D e t

R P N

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S e v

O c c

D e t

R P N

Many versions of this chart

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Occurrence and Severity

O and S are often the two critical factors and some analysis just looks at these two.

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From Dieter

Industrial Monitoring Sensor

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FMEA Summary
Combines ideas of Cause and Effect chart, mistake proofing, and risk.
Useful to identify and prioritize possible failure modes and fixes. Possible Fixes :
High reliability components, De-rate components, Redundancy, Change the design.

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FMEA

- A Requirements Approach

FMEA often starts with:

Identify possible failure modes. How? guess, experience, brainstorm, etc.

Consider
Requirements are what the system is supposed to do. Counter-requirements (not being met) are failure modes. Use counter-requirements to populate the FMEA table.

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Design FMEA Example

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Design

FMEA

Coyote Hoist

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Class Discussion Process FMEA

You are responsible for developing a process to stuff several hundred envelopes for a charity group. Each envelope is to contain three separate flyers and a cover sheet with the recipients name on it. After folding, the name must show in the cutout in the envelope. The final step is to seal and place stamps on the envelope for mailing.

Develop a PFMEA* for this process.

*Process FMEA

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