Lecture 08: Failure Modes and Effects

Analysis (FMEA)- Identification of Failure

Modes

1
 Outline
• Introduction
• System breakdown concept
• Methodology
• Example

2
 Introduction
• Failure Modes: the way that an element of a system can fail
to achieve its intended function
Switch Failure Modes Motor Failure Modes Human Failure Modes

• Open • Fails to start • Fails to perform task

• Partially open • Fails off while running • Perform tasks in the 
• Close • Starts prematurely  wrong sequence 
• Partially closed • Operates too long • Performs an additional 
• Operates at degraded  task 
torque/rotational  • Performs the wrong 
speed task

3
 System Breakdown Concept
• Hardware approach (bottom – up)
– When every component of the system must be reviewed

• Functional Approach (top – down)

– Hardware cannot be uniquely identified
– System complexity requires progressive analysis

• Hybrid
4
 System Breakdown Concept
• Part
• Part Components
Sub‐sub system
• Part 
Sub 
• Part
Components system
• Part
• Part
• Part
• Part Components System
• Part Sub‐sub system
• Part
Components
• Part
• Part
• Part Components Sub 
• Part
system
• Part
• Part Components
5
 System Breakdown Concept - An Example

• Intended Functions
– F1: Provide compressed air at
100psig
– F2: Removes moisture and
contaminants from air
– F3: Contain the compressed air

6
7
 Identify Failure Modes of Compressor
Subsystem
• Compressor (C)
– External leak
– External rupture
– Fails to start
– Fails off while running
– Starts prematurely
– Operates too long
– Operates at degraded
head/flow performance (too
fast, too slow etc.)
• Pipe
– External leak
– External rupture
– Plugged
• Pressure control (PC)
– Fails with no output signal
– Fails with low output signal
– Fails with high output signal
– Fails to respond to an input
change
– Spurious output signal
• Relieve valve
– External leak
– External rupture
– Plugged
– Fails to open on demand
– Fail to reset
– Opens prematurely
– Closes prematurely
8
Methodology