Workshop Failure Mode Effect Analysis

Content
◦ Asset Hieararchy
◦ System Equipment Reliability Prioritization
◦ Failure Mode Effect Analysis
Failure Defense Plan
ENJINIRING
1. SERP 2. FMEA 3. RCFA
RENDAL
Task EKSEKUTOR
Identification CR/PD/PM/OH
Continuous Improvement
4. Baseline 5. FDT

6.1 PdM

6.1 PM

Design Out Plan Schedule Implement Task

Run To Measurement
Failure

Overhaul Task Execution

ASSET HIERARCHY
 Penentuan Hierarki Aset mulai dari level Plant-Unit-System-Equipment-Component
 Semua informasi manajement aset ditempelkan pada level function

PLANT
PLANT

UNIT
UNIT
SYSTEM
SYSTEM
EQUIPMENT
EQUIPMENT

COMPONENT
COMPONENT
SERP

 Meranking kekritisan equipment menggunakan Metode SERP (System

Equipment Reliability Prioritization)
 Metode / cara me-ranking risiko (dampak x kemungkinan) suatu sistem

peralatan, untuk menentukan prioritas “analisa” kebutuhan

pemeliharaan”.
 SERP (System Equipment Reliability Prioritization) ditentukan beberapa

parameter kriteria antara lain :

• SCR (System Criticality Ranking)
• OCR (Operational Criticality Ranking)
• AFPF (Asset Failure Probability Factor)
SERP

Mengapa perlu SERP ?

- Jumlah sistem peralatan banyak
- Dampak kerusakan thd operasi & kerusakan lanjut berbeda
- Harga penggantian part berbeda
- Waktu pemulihan berbeda
- Keandalan masing-masing sistem peralatan berbeda
- Sumber daya terbatas

Hasil Proses SERP : Maintenance Priority Index ( M P I )

Mendahulukan yang mempunyai risiko tertinggi  Pemeliharaan Efektif & Efisien
 SERP
Step 1

PT (1-10)
Divide
Divide Into
Into OC (1-10) Step 3
SCR SCR * OCR
PQ (1-10) Applies to
Average Determine
Sub-Systems
Sub-Systems SC (1-10)
RC (1-10) (1-10)
Equipment
(1-10) (1-10)
Operational Impact

PT – Process Throughput Step 2

OC – Operational Cost Calculate for Each Sub-system.

Equals
PQ – Product Quality
SC – Safety Considerations
RC – Regulatory Compliance

MPI AFPF ACR

* ACR
Equals Applies to
Equipment
(1-100)
(1-1000) (1-10) (1-100)

Step 4
Determine
Sort

Probability of Occurrence

SCR – System Criticality Ranking

OCR – Operational Criticality Ranking
Critical ACR – Asset Criticality Ranking
AFPF – Asset Failure Probability Factor
Equipment MPI – Maintenance Priority Index
* = Multiply Values
SYSTEM EQUIPMENT RELIABILITY PRIORITIZATION
 SRCM

Failure Failure
Effect Mode
Failure
RTF Cause REDESIGN
SPARES REPLACE

MS
(PM,PDM,OH,CM)
Redesign or Maintenance first?
The RCM process considers maintenance first for two reasons:
1. Most modification take long time from six months to three
years from conception to commissioning
2. Most organizations are faced with many more apparently
desirable design improvement opportunities than are
physically or economically feasible
FMEA

* Metode untuk menentukan pemeliharaan yang tepat

pada suatu peralatan dengan mempertimbangkan :
 Failure Mode
 Failure Cause
 Failure Effect
dengan memprioritaskan berdasarkan RPN dan mengidentifikasi task pemeliharaan
yang sesuai
FMECA & Maintenance Strategy

 Maintenance is Equipment based activity

 Equipment is the lowest describable function in the plant
 Function means asset that must to do what their user want

them to do
 1 Equipment – 1 Maintenance Strategy Sheet
 Consist of :

◦ Component Part

◦ Failure Mode
◦ Failure Cause
◦ Failure Defense Task
 Failure Mode

The term “failure mode” combines two words that both have unique
meanings.
The Concise Oxford English Dictionary defines the word “failure”
as the act of ceasing to function or the state of not functioning.
“Mode” is defined as a way in which something
occurs
 Failure Mode

A “failure mode” is the manner in which the item or operation

potentially fails to meet or deliver the intended function and
associated requirements.
may include failure to perform a function within defined limits
inadequate or poor performance of the function
intermittent performance of a function
and/or performing an unintended or undesired function
Example: Insufficient friction delivered by hand brake subsystem between
brake pads and wheels during heavy rain conditions.
 Failure Effect

An “effect” is the consequence of the failure on the system or end

user.
This can be a single description of the effect on the top- level system and/or
end user, or three levels of effects (local, next-higher level, and end effect)
For Process FMEAs, consider the effect at the manuf. or assembly level, as well
as at the system or end user.
There can be more than one effect for each failure mode. However, typically the
FMEA team will use the most serious of the end effects for the analysis.
Example: Bicycle wheel does not slow down when the brake lever is pulled
potentially resulting in accident.
 Failure Cause

A “cause” is the specific reason for the failure, preferably found by

asking “why” until the root cause is determined.
For Design FMEAs, the cause is the design deficiency that results in the failure mode.
For Process FMEAs, the cause is the manufacturing or assembly deficiency that results
in the failure mode.
at the component level, cause should be taken to the level of failure mechanism.
if a cause occurs, the corresponding failure mode occurs.
There can be many causes for each failure mode.

Example: Cable breaks

This illustration is from the book Effective
FMEAs, by Carl S. Carlson, published by John
Wiley & Sons, © 2012
 Failure Effect

Severity

“Severity” is a ranking number associated with the most serious

effect for a given failure mode
based on the criteria from a severity scale.
a relative ranking within the scope of the specific FMEA
determined without regard to the likelihood of occurrence or
detection.
 Failure Cause

Detection

“Detection” is a ranking number associated with the best control from the list of
detection-type controls, based on the criteria from the detection scale.
considers the likelihood of detection of the failure mode/cause, according to
defined criteria.
a relative ranking within the scope of the specific
FMEA
determined without regard to the severity or
likelihood of occurrence.
 Failure Cause

Detection

“Detection” is a ranking number associated with the best control from the list of
detection-type controls, based on the criteria from the detection scale.
considers the likelihood of detection of the failure mode/cause, according to
defined criteria.
a relative ranking within the scope of the specific
FMEA
determined without regard to the severity or
likelihood of occurrence.
CRITERIA FMEA

 RPN (Risk Priority Number)

◦ Severity
 10 = Catastrophic failure, safety hazard, fire hazard
 8 = Shutdown/tripped, loss of production, failed to start
 6 = Partial loss of production
 4 = Abnormal operation, performance degradation
 2 = No effect, additional house keeping
CRITERIA FMEA

 RPN (Reliability Priority Number)

◦ Detectability
 10 = No known technique, RTF/spare strategy
 8 = Failures can only be managed by time based PM
 6 = Advance PdM technology
 4 = Common practice PdM technology
 2 = Operator visual check (See, listen, feel)
CRITERIA FMEA

 RPN (Reliability Priority Number)

◦ Occurance
 10 = >1 failure in 1 year or major inspection scope
 8 = 1 failure in 1 year
 6 = 1 failure in 5 years or simple inspection scope
 4 = 1 failure in 10 years
 2 = 1 failure in more than 10 years or no regular inspection
FMECA & Maintenance Strategy

 Maintenance Strategy Optimization 40%

◦ Top 40% MPI melalui FMECA dan RCFA
◦ Next 30% MPI menggunakan vendor
30%
manual/good practice dan RCFA
◦ Sisanya menggunakan vendor manual/good
practice 30%
FMEA (BOLEN)
REPORT FMEA (BOLEN)
FAILURE MODE & EFFECT ANALYSIS

Unit : Urea 5 Date : 24-10-2017

System : Baggi ng Uni t Revision :
Equipment ID : JD602-K5 Page :1
Equipment Description : Product Bucket El evator
Template : Bucket El evator
Function : Menai kkan urea granul dari output granul ation untuk pros es crus hi ng dan s creeni ng

Component ID Component Description FF Mode Occ FF Effect Sev FF Cause Det RPN FDT Frequency Responsibility
JD602-K5 Product Bucket Elevat or Belt misalignment 6 Belt put us 8 Deposit urea 2 96 Pembersihan 4 W eek(s) Operat or
pada pulley
Belt put us 6 Bucket elevat or t idak 8 Deformasi 2 96 Inspeksi visual 12 W eek(s) Pemeliharaan
berfungsi Mekanikal &
Operat or
6 Bucket elevat or t idak 8 Beban 2 96 Inspeksi kondisi 12 W eek(s) Pemeliharaan
berfungsi berlebih belt Mekanikal &
Operat or
Pulley macet 6 Bucket elevat or t idak 8 Kont aminasi 2 96 Pembersihan 1 Day(s) Operat or
berfungsi kot oran
JDM-602-1-K5 Mot or for JD602-K5 Bearing aus 4 Mot or failure 8 Unballance 6 192 Analisa Vibrasi 4 W eek(s) Inspeksi 2

Fan mot or rusak 6 Mot or overheat 6 Erosi 2 72 Pembersihan 12 W eek(s) Pemeliharaan

List rik
Isolat ion w inding 6 Mot or t erbakar 8 Aging 4 192 Megger T est 12 W eek(s) Pemeliharaan
damage List rik
Rot or bar rusak 4 Mot or failure 8 Vibrasi t inggi 6 192 Analisa Vibrasi 4 W eek(s) Inspeksi 2

St at or w inding 4 Mot or t erbakar 8 Overload 4 128 Analisa 12 W eek(s) Pemeliharaan

overheat T hermography List rik
JDM-602-K5 Mot or for JD602-K5 Bearing aus 4 Mot or failure 8 Unballance 6 192 Analisa Vibrasi 4 W eek(s) Inspeksi 2

Fan mot or rusak 6 Mot or overheat 6 Erosi 2 72 Pembersihan 12 W eek(s) Pemeliharaan

List rik
Isolat ion w inding 6 Mot or t erbakar 8 Aging 4 192 Megger T est 12 W eek(s) Pemeliharaan
damage List rik
Rot or bar rusak 4 Mot or failure 8 Vibrasi t inggi 6 192 Analisa Vibrasi 4 W eek(s) Inspeksi 2

St at or w inding 4 Mot or t erbakar 8 Overload 4 128 Analisa 12 W eek(s) Pemeliharaan

overheat T hermography List rik
Life Cycle Strategy (BOLEN)
Life Cycle Strategy (BOLEN)
Penentuan Task Pemeliharaan
Thank You