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Effective Analysis
(FMEA)
Failures
•severity ,
•probability of occurrence ,
•and probability of detection
FMEA
Failure
Mode and Effect Analysis (FMEA) is a
systematic method of identifying and
preventing product and process problems
before they occur.
FMEAs are focused on preventing defects,
enhancing safety, and increasing customer
satisfaction.
FMEA
FailureMode Effect Analysis (FMEA) is an
analytical technique that goes in for
combining Technology and Experience of
people to identify foreseen failures in a
product or process and planning to eliminate
the Failure
FMEA
FMEA includes
Recognize and evaluate the potential failure of a
product / Process and its effects
Identify
actions that could eliminate / reduce the
chance of potential failures
Document the process
Types of FMEA
Process FMEA
Equipment FMEA
Environmental FMEA
Service FMEA
Design FMEA
MaintenanceFMEA
Concept FMEA
System FMEA – Combination of Process and
Design
Design FMEA
Used in the design process by identifying
known and foreseeable failure modes and
ranking failures according to their impact on
the product.
It
reduces development time and cost of
manufacturing process
Process FMEA
Itis used to identify potential process failure
modes by ranking failures and establishing
priorities, and its impact on the Internal or
external customers.
RELIABILITY
Reliability
is defined as the probability that the
product will perform as per the expectation for
a certain period of time, under the given
operating conditions, and the given set of
product performance characteristics.
FAILURE RATE
Majority of products flow a very familiar
pattern of failure.
When no information is known, except the
failure rate with constant period, reliability can
be expressed as
𝑡
−
Rt = 𝑒 −𝑡𝜆 = 𝑒 𝜃
or
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹𝑎𝑖𝑙𝑢𝑟𝑒𝑠
𝜆 =
𝑈𝑛𝑖𝑡 𝑇𝑒𝑠𝑡𝑒𝑑 𝑋 𝑁𝑜 𝑜𝑓 𝐻𝑜𝑢𝑟𝑠 𝑡𝑒𝑠𝑡𝑒𝑑
FAILURE RATE
Mean Time To Failure (MTTF) (for non repairable
systems)
MTTF = 1/ 𝜆
Mean Time Between Failure (MTBF) for
repairable systems
MTBF = T/R
Where
T – Total Time
R – Number of Failures
Failure Rate Calculation
Product has constant failure rate of 𝜆 = 0.002,
per hour . What is the reliability or survive during
the first 10 hours?
Answer
Given 𝜆 = 0.002 / hour
t = 10 hours
Reliability is Rt = 𝑒 −𝑡𝜆 = 𝑒 −10 𝑋 0.002 = 0.9802 = 98%
Failure Rate Calculation
The components in the system below are
exponentially distributed with the indicated
failure rates. Develop an expression for the
reliability of the system. What is the system
reliability at time = 100 hours ?
Failure Rate Calculation
For the exponential distribution, the reliability
Rt = 𝑒 −𝑡𝜆
Rt = 𝑒 −𝑡0.002 X𝑒 −𝑡0.002 X𝑒 −𝑡0.001 X𝑒 −𝑡0.003
Rt = 𝑒 −𝑡0.008
Rt = 𝑒 −100 𝑋 0.008 = 0.4493 = 45%
Failure Rate Calculation
A system has three components in series with
reliabilities 0.9, 0.7, and 0.5. What is the
reliability of the system ?
Ans
RS = R1 x R2 x R3 x……x Rn\
RS = 0.8 x 0.7 x 0.5 = 0.28 = 28%
Documentation of FMEA
Allow all involved engineers to have access to
others thoughts and to design and manufacture
products / services
Which includes
Block Diagram
Shows different flows involved within the components
Boundary diagram and Interface matrix
Illustration
of the relationships among the subsystems,
assemblies, subassemblies with neighboring systems
Parameter diagram
Representation of input and output response
Stages of FMEA
Specifying Possibilities
Functions
Possible failure modes
Root Causes
Effects
Detection / Prevention
Stages of FMEA
Quantifying Risks
Probability of Cause
Severity of Effect
Effectiveness of Control to Prevent cause
Risk Priority Number
Stages of FMEA
Correcting High Risk Causes
Prioritizing Work
Detailing Action
Assigning Action Responsibility
Check Points on Completion
Stages of FMEA
Re-evaluation of risk
Recalculation of Risk Priority number
DFMEA Documentation
0.6. 0.6.
FMEA Procedure
Describe the product or process functions
Create a block diagram of product or process
Complete the header on the FMEA form
Enumerate the items that make up the
product / service
Identify all potential failure modes
List down each failure mode using technical
team
Describe the effects of each failure modes
FMEA Procedure
Identify all possible cause(s) of each failure mode
Quantify the probability of occurrence
Identify all possible existing controls to prevent
failure mode causes
Detecting the failure modes
Calculate RPN
Determine the recommended actions
Implement the defined actions
Review the results
Keep update the FMEA table