Professional Documents
Culture Documents
(FMEA)
INTRODUCTION
While defining the functions and desired standards of performance of an asset, the
objectives of maintenance with respect to that asset are defined. Defining functional
failures enables us to spell out exactly what we mean by failed. These two issues
were addressed by the first two questions of the RCM process. The next two questions
seek to identify the failure modes which are reasonably likely to cause each functional
failure, and to ascertain the failure effects associated with each failure mode. This is
done by performing a Failure modes and effect analysis (FMEA) for each functional
failure.
Functional Failure
(Loss of function)
Failure Mode
(Cause of failure)
1.To transfer water from A.Unable to transfer any water 1. Bearing seizes
tank X to tank Y at not
less than 800 ltrs/min
at all
The worksheet above indicates, a description of a failure mode, which should consist
of a noun and a verb. The description should contain enough detail, so that it will be
possible to select an appropriate failure management strategy, but not so much detail
that excessive amounts of time are wasted on the analysis process itself.
Impeller jammed:
Impeller adrift:
This example also suggests that one of the failure mode could be eliminated by a
design change and another by improving training or procedures. So, not every failure
mode is dealt with by scheduled maintenance.
Identification of failure mode is one of the most important steps in the development of
any program intended to ensure that any asset continues to fulfil its intended
functions. In practice, depending on the complexities of the item, its operating context
and the level at which it is being analysed, between one and thirty failure modes are
usually listed per functional failure.
Example one: the user of the pump were to increase the off take from the tank to 1050
litres per minute (as against delivery capacity of 1000 litres per minute). In this case,
the users have simply opened a valve bit wider somewhere else in the system.
Example two: if the owner of a motor car whose engine is redlined at 6000 rpm
persists in reviving the motor to 7000 rpm. This causes the engine to deteriorate more
quickly than if the user keeps the revolutions within the prescribed limits, so it fails
more often.
Desired performance
Performance
Initial capability
INITIAL CAPABILITY
FAILURE EFFECTS
The fourth step in RCM review is: listing out of what happens when each failure
modes occurs. These are known as failure effects.
Failure effects describe what happens when a failure mode occurs
(Note: failure effects are not same as failure consequences. Failure effect = what
happens, and, Failure consequences = how does it matters? )
While describing the effects of a failure, the followings should be recorded:
What evidence that the failure has happened/occurred?
In what way it poses a threat to safety or the environment?
In what way it affects production or operation?
What physical damage is caused by the failure?
What must be done to repair the failure?
Evidence of Failure:
Failure effects should be described in a way, which enables the team doing the RCM
analyses to decide whether the failure will become evident to the operating crew
under normal conditions.
For example: the description should state whether the failure causes warning lights to
come on or alarms to sound (or both), and whether the warning is given on a local
panel or in a central control room (or both).
Also, the description should state whether the failure is accompanied or preceded by
obvious physical effects such as loud noises, fire, smoke, escaping steam, unusual
smells or pools of liquid on the floor, and whether the machine shots down as a result
of the failure.
Find the
person who
Can repair
system, cooling system, fuel system so on before starting the analysis? What about
subdividing the fuel system into tank, pump. Pipes and filters?
Starting at a low level
RCM
INFORMATION WORKSHEET
FUNCTION
SYSTEM: ENGINE
SUB-SYSTEM
FUEL SYSTEM
40 ton truck
Sub-system:
FUNCTION
1. To transfer up to 40 tons
of material from Startsville
to Endburg speeds of up to
75 kph (average 60 kph)
on one tank of fuel
Intermediate levels
After seeing top and the low level of analysis, it may be sensible to carryout an
analysis at intermediate level. At top level, too many failure modes per function exists
to permit any sensible analysis.
With a bit of practice, the most suitable level at which to carry out any analysis
eventually becomes intuitively obvious. It should also be noted that, it is not
necessary to analyse every system at the same level throughout the asset hierarchy.
HOW FAILURE MODES AND EFFECTS SHOULD BE RECORDED
Once the level of the entire RCM analysis has been established, we then have to
decide what degree of details is necessary to define each failure mode within the
framework of that analysis. There is no technical reason why all the failure modes
cannot be listed (together with their effects) at a level which enables a suitable failure
management policy to be selected. Depending on the context and consequences, these
sub-assemblies can be handled in four different ways.
The failure of services (power, water, steam, air, gases, vacuum, etc) are treated as a
single failure mode from the point of view of the asset which is supplied by that
service, because detailed analysis of these failures is usually beyond the scope of the
asset in question.
A completed Information Worksheet
Failure effects are listed in the last column of the Information Worksheet alongside
the relevant failure mode.
RCM II
SYSTEM:5 MW Gas Turbine System no Facilitator Date sheet no
INFORMATION
216-05
N Smith 7/2/01 1
WORKSHEET
Sub-System Exhaust system. S-Sys. No Auditor Date of
216-05-11 P Jones 7/3/01 5
FUNCTION
FUNCTIONAL
FAILURE
FAILURE EFFECTS
FAILURE
MODE
REFERENCE:
1.Moubray, J.(1999), Reliability Centered Maintenance (2nd Edition) , Butterworth
Heinmann
2.Coetzee, J.L,(1998),Maintenance, Maintenance Publishers (pty), South Africa
3.Wilson,A,(1999), Asset Maintenance Management, Conference
Communication,UK