www.avtechnology.co.

uk

Successful Failure Mode and

Effect Analysis (FMEA)
Simon Mills
Director of Training Services
AV Technology Ltd

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 1

Introduction
FMEAs and other maintenance optimisation

processes can generate huge amounts of data

Its important to keep these processes
manageable, for example:
Ask questions which can easily be answered
Use engineering approximations where possible
Limit the depth of investigations

This module outlines how to carry out FMEAs

and achieve successful results and real benefits
AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 2

CM41 Successful FMEA V1.1m

Page 1

www.avtechnology.co.uk

Objectives

Contents

What youre responsible for, & what your deliverables are

Pre-Requirements

What information you need up front

Simplified Methodology

Keep it Simple (KISS)

How to make approximations
Easy and hard ways

Practical Processes

Best Practice & Key References

Outputs & Deliverables E.g. Optimised Maintenance Plan
Examples
AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 3

Objectives
Review design and operation of chosen

equipment
Review failure history & failure modes
Review current maintenance
Agree failure mode criticalities
Assign optimised maintenance tasks /
frequencies & owners
Produce a revised maintenance plan for the
selected asset(s)

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 4

CM41 Successful FMEA V1.1m

Page 2

www.avtechnology.co.uk

Pre-Requirements
To assist in the FMEA, examples of the following
information are useful to support the review on the
selected Pilot Area/Equipment:

General layout and schematics

O&M Manuals for the selected equipment
Any operator checks for the selected equipment
List of current maintenance inspections (with history)
Latest listing of plant breakdown history
O&M logbooks referring to plant operation
Listings of spares usage

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 5

Simplified FMEA Best Practice

ISO 17359:2011 Condition monitoring and

diagnostics of machines General

guidelines.
New 2nd Edition
Incorporates ISO 13380 Condition Monitoring
and Diagnostics of Machines using performance
parameters
Adds 9 tables of different machine type FMEAs

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 6

CM41 Successful FMEA V1.1m

Page 3

www.avtechnology.co.uk

ISO 17359:2011 CM Procedure

The latest issue now has 8 key steps for bestpractice implementation of CM:

Cost benefit analysis

Equipment audit
Reliability and criticality audit
Select appropriate maintenance strategy
Select monitoring method
Data acquisition and analysis
Determine maintenance action
Review

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 7

Additional Machine Type Examples

ISO 17359:2011 now includes nine different machine types
with typical examples of fault and failure modes
with associated symptoms and measurement parameters.

Examples of fault and symptom diagrams are now

included for the following machine types:

Electric motor
Steam turbine
Aero gas turbine
Industrial gas turbine
Pump
Compressor
Electric generator
Rotary internal combustion engine
Fan

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 8

CM41 Successful FMEA V1.1m

Page 4

www.avtechnology.co.uk

For each of the machine

types, the revised ISO
17359 gives a matrix of 27
applicable CM &
Performance measurement
parameters
AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 9

For each machine type there

is a table with:
A selection of faults and
A range of measureable
symptoms / parameters
AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 10

CM41 Successful FMEA V1.1m

Page 5

www.avtechnology.co.uk

Practical FMEA
A full reliability-centred maintenance process

can generate huge amounts of data

Its important to keep the process
manageable
Ask questions which can easily be answered
Use engineering approximations
Use simple understandable models

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 11

KISS Tips
FMEAs should be kept as simple as possible.
Over complication is rarely a good idea so FMEAs
should be kept as simple as possible to both evaluate
and understand.

FMEAs should be easily carried out.

The easier it is to do, the more likelihood of the

FMEA data being available at timely intervals and on
an on-going basis

FMEAs should be quantifiable.

Both Objective and Subjective data must always be

quantified.

FMEAs should be done in a short time.

FMEAs should always be completed in a relatively

short time so as to limit the load on personnel.

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 12

CM41 Successful FMEA V1.1m

Page 6

www.avtechnology.co.uk

KISS Tips
FMEAs should be understandable by the whole
maintenance team

This ensures engagement of all team members, and

encourages participation

FMEAs should be reviewed or subject to

continuous improvement

As business needs and techniques change then so

should the FMEAs which support them

FMEAs should be communicated in an

appropriate manner to all sections of the

workforce
A key to driving improvement is the effective
communication of progress to the very people who are
making it happen

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 13

Typical FMECA Tools

Identify process
Itemise components and connections
Produce system level block diagrams
Process Flow Diagram
Reliability Block Diagram
Asset Criticality Pareto
Asset MTTR / Events / MTBF
Availability
AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 14

CM41 Successful FMEA V1.1m

Page 7

www.avtechnology.co.uk

Limiting the depth of an FMEA

Keep choices simple at every level
Asset Type
Asset Configuration
Asset Local Performance Requirements
Top 10 faults and failure modes
Preferred maintenance/CM technique
Match frequency to LTTF
Technique fault detectability & confidence
Output is maintenance plan
AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 15

Making FMEAs Manageable

We should concentrate on:

known facts about the asset
expected failure modes
Examples of Easy Facts

Examples of Difficult Facts

Motor Driven Pump

No. of rotor bars

Open Drive with Coupling

Coupling No. of teeth or bolts

Rolling element bearings

Bearing make, size and number of balls

Motor label Speed / Power

Pump impeller number of vanes

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 16

CM41 Successful FMEA V1.1m

Page 8

www.avtechnology.co.uk

Example
Estimate of How Many Maintainable Assets?
E.g. Total 2500

Number of Key Asset Types (Variants)

Rotating, Static, Electrical
Typically Max 30 per site

First Estimate Criticality [A, B, C]

A: Important
B: Routine
C: Ad Hoc (As and when)
AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 17

Simple Criticality Review

Use consequence cards or
spreadsheet
Include relevant factors

Operational
Availability
Maintainability
Quality
Health and Safety
Environment

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 18

CM41 Successful FMEA V1.1m

Page 9

www.avtechnology.co.uk

Example Asset Types (Typically Max 30)

Motor Driven Fan

Motor Driven Pump
Compressors
Conveyor
Mixer/Blender
Chillers
Tanks
etc
AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 19

Example Asset Components

Ref

Component

Ref

Component

Bearing

11

Pump Impeller

Cable

12

Seal

Coupling

13

Valve

Drive Belt

14

etc

Electric Motor

15

Fan Rotor

16

Filter

17

Gearbox

18

Mount

19

10

Pulley

20

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 20

CM41 Successful FMEA V1.1m

Page 10

www.avtechnology.co.uk

Example
Asset Type
Pump
1430 rpm 18kW

Configuration

Open drive coupled

Local Performance
Requirements

Cooling Water 5 Deg C

Downtime < 5%
AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 21

Example of Top 10 Faults

Top faults and failure modes

Unbalance
Misalignment
Looseness
Lack of Lubrication
Bearing Damage
Leaks
Motor overload
Impeller erosion/damage
Seal Leaks
Corrosion

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 22

CM41 Successful FMEA V1.1m

Page 11

www.avtechnology.co.uk

Workshop Examples of FMEAs

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 23

Importance of Local History

Sources
Operator Log Books
Fault Reporting
Work Orders
CMMS
Local Staff

Actual failure rates, MTBF, MTTR

Actual Lead Time to Failure (LTTF)
AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 24

CM41 Successful FMEA V1.1m

Page 12

www.avtechnology.co.uk

Assemble FMEA Data

Assemble the following for the selected asset
type
Asset
Components
Failure Modes
Warning Effects
Root Causes
Task, Periodicity, Skill

For example:AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 25

Maintenance Planning & Management

Most tasks can have estimated time & skill

FMEA sets requirements for techniques
CBM / PdM, PPM, Lube, Casual Inspections etc

Needs to be managed and scheduled

Schedule inspections
CBM / PdM Measurements

Feedback needs to be short but useful

Dont just say Completed
Better to add Completed no faults found
Or Completed following faults found
AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 26

CM41 Successful FMEA V1.1m

Page 13

www.avtechnology.co.uk

Create the Maintenance Plan

Assemble Tasks
Allocate Resources
Carry out Maintenance
Feedback History

AV Technology Ltd

02.2012

CM41 Successful FMEA V1.1m

Page 27

Key Points
Important to keep process
manageable
Ask questions which can easily
be answered
Focus on known failure modes
Use approximations
Use simple understandable
models

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 28

CM41 Successful FMEA V1.1m

Page 14

www.avtechnology.co.uk

References
ISO 17359:2011, Condition monitoring and diagnostics of machines General guidelines

Developing a Maintenance Strategy and Setting Performance Targets,

Simon Mills

Presented at Maintec 2008

Published in ME Maintenance & Asset Management, Vol 23 no 5, Sept/Oct
2008

Understanding Maintenance Key Performance Indicators, Simon Mills

Presented at Maintec 2010

Key Steps to Implementing Condition-Based Maintenance, Simon Mills

Presented at Maintec 2011

Websites

British Standards web site www.bsigroup.com

ISO web site www.iso.org
AV Technology Ltd www.avtechnology.co.uk

AV Technology Ltd

AV Technology Ltd

02.2012

02.2012

CM41 Successful FMEA V1.1m

Page 29

CM41 Successful FMEA V1.1m

Page 15