An Introduction to Failure Mode and Effects Analysis (FMEA)

116 Pages·2011·3.29 MB·English

Ais INTRODUCTION TO FAN URE MODE

AND EFFECTS ANALYSIS (FMEA

by

Anthony Gojanovic

B.A., Univer

ity of Colorade, 1987

A thesis submitted to the

University of Colorado at Denver

in partial fulfillment

of the requirernents for the degree of

oe

F of Basie Seienom

1396
‘This thesis for te Master of Basic Science
dogroa by
Anthony Gojunavie
has been approved

by

tf /
Kaleh Ketacor
: af ye
2 eae Made

Poe eedies
Gojanevic, Anthony (M.B.S}

[An Introduction to Fallura Modo and Effects Analysis ‘FMEA:

‘Thesis dizectod by Protessor Karen Kafadsr

ABSTRACT

Falke Mode and Effecia Analysis (FMEA) is » developmental toal used
t0 Identity failures and effects on systems, products or services. In
addizion 70 identifying faiaro modes and [allure mode effects, FMEA
Brovides to¢ quantification ard categorization of failure information in
iter to aliacate and prioritize resources for risk abatament. The areates:
impact of FMEA is in pre-production prases af naw product or systern
development ir order to provide tor filure free systems and products
during imptementesinn. FMEA is @ versatile tool that Ras mary
expressions tind can be integrated with statistical arid saftware tools 10
provide for a comarchensive view of “isk.

This ubsirect accurately represents the content of the candidate's thesis.
Ireeommena its pubiicarian.

snes tts febn

7 oro Re
CONTENTS

Figures

CHAPTER

1. INTRODUCTION

Failure Study Motivations

Corre

Solution, Wrong Problem?

1 Need It Now and | Need It Perfect!

ORIGINS OF FAILURE MODE
AND EFFECTS ANALYSIS (FMEA)

3. FAILURE MODE AND EFFECTS ANALYSIS (FMEA)

Tabular FMEA

Failure Made Effects and Critieatity Analysis,

4, FAILURE MODE AND EFFECTS ANALYSIS
FOR MANUFACTURING

1“

on

“4

23
Process and Design FMEA .

FAILURE MODE AND EFFECTS ANALYSIS.
AND SOFTWARE DEVELOPMENT

STATISTICAL BASIS OF THE
FMEA WORKSHEET

FAILURE MODE EFFECTS ANALYSIS
INTEGRATION

Surveys

Reliability Analysis

Lingar Moeels

Exploratory Teowayues .

stistieal Process Control

FAILURE MODE AND EFFECTS ANALYSIS.
TERMINOLOGY

FMEA Formas

PERFORMING A SUCCESSFUL FAILURE
MODE EFFECTS ANALYSIS

27

29

31

33

33

37

28

a9
10. LIMITATIONS OF FAILURE MODE
AND EFFECTS ANALYSIS... 43

14, OTHER TECHNIQUES ......-.. 45

12. THE FUTURE OF FAILURE MODE
AND EFFECTS ANALYSIS 2.0... . a7

APPENDIX

A. CASE STUDY A: & FMEA OF A PHOENIX MODEL
ROCKET RECOVERY SYSTEM... 43.

8. CASESTUDY B; STRATEGIC "zST
DESIGN MATRIX : 87

©. CASE STUDY C: FMEA COMPUTER

IMPLEMENTATION... 22.0... 60
FMEAPAS oo ee scons 68
FMEADATA.PAS........ 78
FMEAMAT.PAS . aa
FMEASORT.PAS .. 109
BIBLIOGRAPHY . 108
Figure 1.4

Figure 1.2

Figure 3.1

Figura 3.2

Hguee 3.3

Figure 3.4

Figure 3.5

Figure 4.4

Figure 4.2

Figure 7.1

Figure A.

FIGURES.

Quality Lever

Change Comparison

Tabular FMEA .

Failure Mode and Eftects Worksheet
for Task 101 in MIL-STD-1629A ..

Critigatity Analysis for Task 102 in.
MIL-S10-1629A (Gvautitative Metho

Griticatty Analysis for Task 102 in
Ma, -STO-1629A (Qualitative Method

Critieatity Matrix

FMEAC tor New Product Development

FMEAC for New Product Development with:
Correctes RN.

Life Cycle Hazard Funcior

Phoenix Recovery System Block Diagcarn

20

2

2a
Figure A.2

Figure AS

Figue Aa

Figure A.

Figure 8.1

Flguer 1

Figure C.2

Figuen €.3

Figure €.4

Figure C5

Figure ¢.6

Figure C.7

Figure C8

Phownix Recovery System FMEA

Sorted FMEA by RPS

Sorted FMEA by Sev

Phoenix Recovery Sysiar: DFMEA
and PEMEA Exampse

Strategic Tes! Design Matrix

FMEA Data Manipulation Options

FMEA Data Graphing Options

FMEA Sorting Options

FMEA Data Entry Scraen

Craieality Matrix of 9 FMEA Data Set .

Stam and Leaf Pot of FMEA Probabilities

Stem and Leaf Pot of FMEA Sevuritins

Stem and Leaf P.o; of FMEA Risk

82

53

Ba

58

61

61

4

82

83

84

86
4

CHAPTER 1
INTRODUCTION

Current criteria for the suucese of vonsumer goads rely upa:
product introductions thot are as fallute free as possibie. The costs
associated with defective products from 2 liabtity or lost consumer
standpoint can have dramatic impacts an a comoaey, In a business
environmen: that is becoming extremely competitive and global, the
presence of failures in a system, product or service, can only serve 70
destabilize a company financially. Indeed, many companies have fallec
due ta the inability of providing @ product tat is able to mee: basic
‘customer expectations and requirements.

‘The definition of faiture is the inability of a system ar product to
mest 4 required function, Failures ean be dramatic and sudden ar subtle
ang gradual resulting in system or product dearadation. Defeczive
consumer products teen carmagn househo'd appliances t much
publicized automotive recalls have imuuvied tram @ tw 2 mil!ons of
individua's. Not ooiy product failure but ever: breakdowns in a service ere
potantiatly damaging. & misdiagnosed patien- 7 a hospital ae & result of
a communication falure can be hareful to the patien: and to the
Fopuratian af the haspilal itsel.

With increasing technological sophistication, the problem af finding
and carrecting fallures is becorning more compiox and at the same time
ircreasingly imperative. The need for “first pass marutacturing". ir
which a product or sorviee has baen made failure [ree prior 1a widespread
iniplementaton, is critical. No longer are product recalls oF fied! fixes
‘ieasible, desirable or cost effective. Figure 1.1 shows the cost associated
with fixing problems as tims progresses through a new product
development eycle (2, p. 170) and Fig.ire 1.2 curipares U.S. vs lepanese
‘company changes through a development cycie (7, p. 172i. Cranges
made later in the design cycle are not only expensive but glve away any
competitive edge.

With ineseasing technological sophistication, requirements tor
failure tree products are becoming more siringen, and for yood reasons.
For examsie, ita 0.1% failure level ware allowed ir the United States, the
Lig

Figura 1.1. Quality Lover

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Figure 1.2. Change Compsriser

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y