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FMEA R2 Common New
FMEA R2 Common New
FMEA R2 Common New
FUNCTION
Severity
POTENTIAL
Class
S No.
S No.
PROCESS POTENTIAL FAILURE
EFFECT(S) OF
NAME MODE
FAILURE
2
1
1
REQU
IREM
ENTS 2
2
2
2
3
3
Abnormal Sound No Effect
2
4
4
2
5
5
Production Stop 8
6
6
Poor agitation
Reduced Production 8
7
1
8
1
9
1
10
10
11
12
8
13
13
14
1
15
15
Gearbox High
No Effect
Temerature 1
16
16
8
17
17
Production Stop
8
18
18
Tripping
8
19
19
Reduced Production
Tripping
Reduced Production
8
20
20
Product
Gearbox Oil Seal
Contamination, 3
21
21
leakage Unsafe Operation
1
2
2
2
3
Abnormal Sound No Effect
2
4
2
5
5
Production Stop 8
6
6
Poor agitation
Reduced Production 8
7
7
1
8
8
1
9
9
1
10
10
High Vibration No Effect
1
11
11
Agitator
Centrifugal
100/200/300/ 400/
Pumps
Utility area
1
12
12
8
13
13
14
1
15
15
Gearbox High
No Effect
Temerature 1
16
16
8
17
17
Production Stop
8
18
18
Tripping
8
19
19
Reduced Production
8
20
20
Product
Gearbox Oil Seal
Contamination, 3
21
21
Occurrence
Detection
S No.
S No.
S No.
POTENTIAL CAUSE(S)/ CURRENT PROCESS
RPN
MECHANISM(S) OF FAILURE CONTROLS PREVENTION
1
damaged
Bottom bush damaged PM 1 6
2
2
Gearbox bearings damaged Condition monitoring 1 4
3
3
Agitator Shaft Bearing
Bi-weekly Inspection 1 4
4
4
damaged
Oil in gearbox
Current AMP in DCS, 5 30
5
5
emptied/lowered
6
Gearbox drive failure LLF/ CM 2 32
7
7
Gearbox oil contamination Bi-weekly Inspection 1 2
8
8
Botttom support bush wear DCS indication
(Amperes drop, ) 1 3
9
9
out
Gearbox bearings damaged PM 1 2
10
10
10
2
Oil in gearbox
Shift LLF 5 15
11
11
11
3
emptied/lowered
12
12
1
Grease contamination 1 16
13
13
13
2
14
14
2
emptied/lowered
Gearbox oil contamination 5 10
15
15
15
2
16
16
3
emptied/lowered
Tank choked with rubber
Current AMP in DCS, 1 8
17
17
17
1
crumbs
Gearbox drive failure Shift LLF 1 16
18
18
18
2
2
Agitator blades broken/Bent Condition monitoring 16
19
19
19
1
Equipment operating in 2
PM, 16
20
20
20
1
reverse DOR
21
21
2
of continuous operation
1
damaged
Bottom bush damaged PM 1 6
2
2
Gearbox bearings damaged Condition monitoring 1 4
3
3
Agitator Shaft Bearing
Bi-weekly Inspection 1 4
4
4
damaged
Oil in gearbox
Current AMP in DCS, 5 30
5
5
emptied/lowered
6
Gearbox drive failure LLF/ CM 2 32
7
7
Gearbox oil contamination Bi-weekly Inspection 1 2
8
8
Botttom support bush wear DCS indication
(Amperes drop, ) 1 3
9
9
out
Gearbox bearings damaged PM 1 2
10
10
10
2
Oil in gearbox
Shift LLF 5 15
11
11
11
3
emptied/lowered
12
12
1
Grease contamination 1 16
13
13
13
2
14
14
2
emptied/lowered
Gearbox oil contamination 5 10
15
15
15
2
16
16
3
emptied/lowered
Tank choked with rubber
Current AMP in DCS, 1 8
17
17
17
1
crumbs
Gearbox drive failure Shift LLF 1 16
18
18
18
2
2
Agitator blades broken/Bent Condition monitoring 16
19
19
19
1
Equipment operating in 2
PM, 16
20
20
20
1
reverse DOR
21
21
2
of continuous operation
Rev. Number : 3
IS Rev. date : 07.02.2022
Occurrence
Detection
Severity
RESPONSIBILITY & TARGET ACTION TAKEN
RECOMMENDED ACTION(S)
COMPLETION DATE
22
ULTS
RPN
Severity
Effect Criteria: A failure could...
Occurance
Probability of Failure Time Period
Very High: More than once per day
Failure is almost inevitable Once every 3-4 days
High: Generally associated with
Once per week
processes similar to previous
processes that have often failed Once per month
Moderate: Generally associated with
Once every 3 months
processes similar to
previous processes which have Once every 6 months
experienced occasional failures, but
Once per year
not in major proportions
[Very high severity ranking when a potential failure mode Immediate equipment stoppage causing operation
affects safe operation and or involves noncompliance with disturbance to the extent leading to stoppage/ or requirement
government regulation without warning.] of stoppage of all Polymer or Finishing area
[Very high severity ranking when a potential failure mode Immediate equipment stoppage causing operation
affects safe operation andor involves noncompliance with disturbance to the extent leading to requirement of reduction
government regulation with warning.] in plant throughput of Polymer area
Occurance
Probability
> 30 %
< 30 %
<5%
<1%
< 0.03 %
Almost
10
Impossible
9 Very Remote
8 Remote
7 Very Low
6 Low
5 Moderate
4 Moderately High
3 High
2 Very High
1 Almost Certain
Ranking
10
9
5
4
Control
Required
Required
Safety Sign
Off
Detection
Criteria: Liklihood the existence of a defect will be detected by test
Ranking
content before product advances to next or subsequent process