FMEA

Reliability course
Goal

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FMEA – History

2000s & Today:

Widely used in a
1990s: Some variety of
Notable industries and
Instruction fully supported
1985: IEC 60812 Manuals were by the American
was published by introduced to Society for
the International target the Quality, ASQ
Electro-technical automotive
Commission and industry (AIAG
Late 1970s: Ford
it helped drive the FMEA 1993, 1995,
Motor Company
use of FMEA and 2001 and SAE
introduced FMEA
FMECA in J1739 1994, 2000,
Late 1940s: Department of to the automotive
industry European 2008)
Defense (DOD) developed MIL-
P-1629A for Failure Modes
Industries
Effects and Criticality Analysis
FMEA
Failure Mode and Effects Analysis

• FMEA is used to prioritize potential defects based on

their severity, expected frequency, and likelihood of
detection

• One of the first systematic techniques for failure analysis

• There are several different types of FMEA;

• Design
• Functional
• Process
• A successful FMEA helps to identify potential failure
modes based on past experiences

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 FMEA is a Living Document
• Initiated before or at design concept finalization stage
• Continually updated as changes occur or additional information is
obtained during product phase
• Fundamentally completed before the release of
• production drawing

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Potential
Benefits
Visualize
Risk
trade offs
Identify
Critical to
Identify Quality
Risk
Failure items
Early Modes and
Effects
Analysis Establish a
record for
future
Show designs
customers
how we
dealt with
risk
FMEA – Potential Impact
to the Bottom-Line

■ Improves designs for products and processes by providing:

- Higher reliability
- Better quality
- Increased safety
- Enhanced customer satisfaction
■ Costs savings:
- Decreases development time and re-design costs
- Decreases warranty costs
- Decreases waste, non-value added operations

“Rule of ten”: problem discovered in the field ($100),

discovered in final test ($10), discovered during incoming
inspection ($1), discovered during design or process
engineering phase ($0.10)
FMEA – Who performs it?

• Normally teams of 3-8 people with:

– Process/Product knowledge
– Skill in technical disciplines
– Authority and time Multiple Disciplines
– Team operation guidelines Required/Desirable
– FMEA guidelines
– Team/FMEA Facilitator

• That:
– Perform FMEA process on each part/subsystem/process
– Determine and Implement actions
– Conduct follow-up status meetings
 FMEA – Some Ground Rules

Team need to define and agree to some ground rules and assumptions:
■ Sources of failure rate and failure mode data
■ Whether the analysis will be functional or piece part
■ Criteria to be considered (mission, safety, maintenance etc)
■ Standardized mission profile with specific fixed duration mission phases
■ How faults will be known to exist
■ System for uniquely identifying parts or functions
■ Severity category definitions
 FMEA – Some Key Inputs

● Customer requirements
● Functional/technical specifications, Statement of Requirements (SOR)
● Development plans including product time and budget
● Design drawings, notes, calculations etc
● Bill of Materials (BOM)
● System Boundary diagram showing interaction of component/subassembly
with surrounding entities
● Functional block diagram
● Reliability block diagram
● Process flow chart
● Historical data (e.g. field and warranty)
● Maintenance manuals, service conditions tracking (MaPS)
● Field performance issues tracking (First Alert, Hyperion)
● Supplier (OEM) Information
 Failure Definition

• A degradation of a given material under stress until some

critical device parameter can no longer be met

• Stress
• In the context of this definition, stress is any external agent
capable of causing a degradation to occur in the material
properties such that a device can no longer function properly
in its intended environment

• Examples: Yielding, Buckling, Creep, Corrosion, Stress

Relaxation, Fatigue
 Process Failures

A Process is a sequence of tasks that is organized to

produce a product or provide a service

Process failure: deficiencies in instructions, training, and

associated transactions that lead to an inability to reach a
desired output

Examples: Inadequate training leads to over torqueing a joint,

unclear procedures leads to setting a slip in an incorrect sequence
Failure – Two Types

Physica • A degradation of a given material under

stress until some critical device
l parameter can no longer be met

Failure
Process • Deficiencies in instructions, training,
and associated transactions that lead to
Failure an inability to reach a desired output
Recipe for disaster

Failu
re
Theo
ry
System
Knowledge

F
a
i
l
u
Failure Mode and Effects Analysis
Why?

Why?
• Increasingly complex equipment and projects
• Revenue impact of large sites
• FMEA can be used at any time of the Lifecycle 15
 Steps to identifying failure

3. FAILURE MODE
1. SYSTEM DIAGRAM 2. FAULT TREE
AND EFFECT
ANALYSIS
ANALYSIS

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1. System Diagram

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Fault Tree Analysis

MODE: What can go wrong?

EVENT: What can occur to

create the MODE?

CAUSE: What CAUSES the

EVENT to happen?
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 FMEA ratings
Use the information from the Fault Tree Analysis;
• Mode
• Events
• Causes
We then assess and give a 1 to 10 rating for;
• Severity
• Occurrence Risk Priority Number (RPN) = SxOxD
• Detection

We can then prioritize; The higher

• Recommended actions the RPN the
• Responsibilities and Parts worst it is!

After Actions complete we can then reassess the RPN

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FMEA ratings

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System Diagram with RPN

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 Actions to reduce
RPN

Action: refers to recommended tasks to reduce risk.

Failure modes with RPN higher than 225 and/or Severity 9 or higher
should trigger a corrective action(s) to reduce and/or mitigate such
failure modes.

Actions should be focused on:

- Mitigating the cause of failure or eliminating the failure mode
- Actions that cannot be mitigated via design should be forwarded
to process FMEA for process mitigation (inspection, maintenance)

Typically involves changes in one or combination of: material (hardware,

software) process, procedure, Training
FMEA example – step 1

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FMEA example – step 2

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FMEA Example

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 Inspections
Mixture of daily/weekly/monthly/quarterly/annual checks in place

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 Equipment
Completed for;
• 45MVA, 25MVA, 10MVA Transformers
• 275kV Substation equipment
• 132kV substation
• 33kV substation
• Actom Switchgear
• ZS1 switchgear
• 6.3MVA Transformers
• HFO Generators (initial finding for Shanta)
• HPCMS gas area – Mozambique
• Started for SCADA - Mozambique

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 Possible links to TPM
The following aspects of TPM and FMEA can be linked;
• Tagging – tags to be created during inspections to help prioritize repairs and
maintenance
• One point learning – this can be used to demonstrate inspects and also for the
repairs required
• Equipment availability – to be expanded out to include non six pack equipment

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 Sites using FMEA
The following aspects of TPM and FMEA can be linked;
• Ressano Garcia, Mozambique
• Belualane, Mozambique
• Bisha, Eriteria
• 6.3MVA, Large MVA transformers and ZS1 inspections were requested to be
rolled out in East Africa. Unsure degree of sustainment in these areas
• Ghorashal
• Medan
• B.Baria

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 Example 1
Site Technician, Mozambique
‘Today 03/10/2014 at around 08:00 a.m. during daily checks on Ressano
Garcia HV equipment it was picked up that the auxiliary 110V dc circuit
breaker supply to 275 kV Buszone protection has tripped’.

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 Example 2
EHV Specialist, Mozambique
‘Attached are the pictures of the Safe plus switch gear(AAB) that has a
leakage on SF₆ gas pot’.

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 Example 3
EHV Technician, Mozambique
‘Attached also is the LV Bushing that is leaking oil for the
transformer(3.15MVA_415V/11kV) _ here we require one set of the LV
bushing with O-rings and gaskets’.

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 Example 4 : Ashuganj

Initial inspection showed abnormal

temperature at 48.5 oC

Deeper inspection showed overheated cables at

57.3 oC- risk
Action is required.

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Example 5: Macapa

Extreme high
temperature 114.7 oC
was inspected at the
insulator connection of
the main line.

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