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Engineering
g g Drawing
g and Design
g
ME 1105

Lecture 21

FMEA -Failure Mode and Effects Analysis

D Ah
Dr Ahmed
dKKovacevic
i
School
S h l off Engineering
E i i andd Mathematical
M h i l Sciences
S i
Room CG08, Phone: 8780, E-Mail: Design@city.ac.uk
www city-design tk
www.city-design.tk www staff city ac uk/~ra600/intro
www.staff.city.ac.uk/ ra600/intro.htm
htm

Ahmed Kovacevic, City University London

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A
Announcements
t

z Written TEST – Monday 29th March 15,00

z T ti off the
Testing th paper structure:
t t
» Groups
p A&B Friday
y 26/03 10,00-12,00
, ,
» Groups C&D Thursday 25/03 14,00-16,00

Ahmed Kovacevic, City University London

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The business
process

Ahmed Kovacevic, City University London

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Phases of Engineering Design

Ahmed Kovacevic, City University London

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E i
Engineering
i D Design
i Process
P

Phase 1 (Concorde Window)

Phase 2 (Satellite hinge)

Phase 3 (Car axle/Helicopter)

Phase 4 (Paper structure)

Product
Phase 5

Ahmed Kovacevic, City University London

 Design web

F il
Failure Mode
M d and
d Effects
Eff Analysis
A l i

A failure mode is any event, which causes a

f ti l failure
functional f il off a machine
hi or a system!
t !

Failure
F il effects
ff t describe
d ib what
h thhappens
when a failure mode occurs

The best way to address all failure modes and to estimate

th i effects
their ff t isi to
t list
li t all
ll functions
f ti andd to
t analyse
l how
h eachh
of these can fail and what causes will it make.

Ahmed Kovacevic, City University London

 Design web

"A problem well-defined is half solved."

Ahmed Kovacevic, City University London

 Design web

Ahmed Kovacevic, City University London

 Design web

FMEA in
i DDesign
i and
d M
Maintenance
i
Any Design and/or Maintenance process shall ensure that all of
the following seven questions are answered satisfactorily in
the sequence shown below:
1. FUNCTIONS - What are the functions and associated desired
standards of performance of the asset in its present operating
context?
2. FUNCTIONAL FAILURES - In what ways can it fail to fulfil its
functions?
3. FAILURE MODES - What causes each functional failure?
4. FAILURE EFFECTS - What happens when each failure occurs?
5. FAILURE CONSEQUENCES - In what way does each failure
matters?
6. PROACTIVE TASKS and TASK INTERVALS - What should be
done to predict or prevent each failure?
7. DEFAULT ACTIONS - What should be done if a suitable proactive
task cannot be found? Ahmed Kovacevic, City University London
 Design web

C t
Categories
i off ffailure
il modes
d

Failure modes can be classified in to three groups:

1
1. When capability falls below desired performance
» Deterioration
» Lubrication failure
» Dirt
» Disassembly
» ‘Capability reducing ‘ human errors.
2
2. When desired performance rises above initial capability
» Sustained, deliberate overloading
» Sustained, unintentional overloading
» Sudden unintentional overloading
Sudden,
» Incorrect process material.
3. When the asset is not capable of doing what is wanted
from the outset.
outset
Ahmed Kovacevic, City University London
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H
How d
detailed?
t il d?

Failure modes should be defined in enough

d t il for
detail f it tot be
b possible
ibl to
t select
l ta
suitable failure management policy.
z Too little detail and/or too few failure modes
lead to superficial and sometimes dangerous
analyses.
z Too many y failure modes and/or too much
detail causes the entire process to take much
longer
g than it needs to.

Ahmed Kovacevic, City University London

 Design web

Th effects
The ff t off failure
f il
While describing the effects of a failure, the followings should
be recorded:
z What evidence that the failure has happened/occurred?
» Warning signals, smell, noise, leak, fire, smoke …
z In what way it poses a threat to safety or the
environment?
» Cause explosion, fire, leak if hazardous chemicals, colapse of
structure …
z In what way it affects production or operation?
» How does it affects p
production or p
process
z What physical damage is caused by the failure?
» Effects on other parts and processes, cost …
z What must be done to prevent or to repair the failure?
» Replace components or subsystems, lubricate on time …
Ahmed Kovacevic, City University London
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M d and
Modes d effects
ff t

One needs to be proactive, while drawing up

the FMEA
FMEA, as such,
such much emphasis should
be placed on what could happen than what
has happened
happened.
The common sources of information with a brief
review of their main advantages and
disadvantages are:
» The manufacturer or vendor of the equipment
q p
» Other users of the same equipment
» Technical historyy records
» The people who operate and maintain the
equipment Ahmed Kovacevic, City University London
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Severity Occurrence
or
Probability

Risk
Detection
Priority
Number

Ahmed Kovacevic, City University London

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A
Agenda
d

Ahmed Kovacevic, City University London

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P 1
Part
Engineering Drawing and Design

2nd TEST
z ROOM: Poynton
y
z Day and Date: Monday 29th March 2010
z Time:
Ti 15 00
15,00
z Duration: 1 hour
Ahmed Kovacevic, City University London