FMEA Presentation V1.1

Murphy’s Law Buster FMEA Improves System Reliability and Saves Costs Presented by Ernie Borgoyne

Ernie Borgoyne - Biography ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Agenda ,[object Object],[object Object],[object Object],[object Object]

Background What is an FMEA and how did it originate?

FMEA is an acronym for Failure Modes and Effects Analysis ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],* ASQ CQE Reference Material

FMEA History ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

FMEA is a “Bottom-Up” Analysis Complements other Reliability Analysis Methods * ASQ CQE Reference Material * Failure Modes and Effects Analysis (FMEA FMEA for Critical Components (FMECA) Fault Tree Analysis (FTA) Type of Analysis ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Type of use ,[object Object],[object Object],[object Object]

Application to an Actual System ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Application to an Actual System (cont’d) Subsystem Action Electrical System ,[object Object],[object Object],[object Object],[object Object],Deep Well / Shallow Well ,[object Object],Water Storage System ,[object Object],[object Object],Central Water Pressure Control System ,[object Object],[object Object],Water Distribution System ,[object Object],[object Object],[object Object],[object Object]

Application to an Actual System (cont’d) Subsystem Action Water Distributed Pressure Control System ,[object Object],[object Object],Wastewater Influent Collection System ,[object Object],[object Object],[object Object],Wastewater Treatment Plant ,[object Object],[object Object],Effluent Pond ,[object Object]

Develop System Description Identify Major System Components ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Could go further but then the list of components to analyze becomes unmanageable

Develop System Description Identify Potential Failure Modes, Triggers and Effects ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Remember Murphy’s Law: If it CAN go wrong, it WILL go wrong Failure Mode Trigger Effects Catastrophic Transformer Failure Overheat or overvoltage Complete loss of water pressure, impacting fire suppression in the community Pressure reducing valve fails OPEN Internal diaphragm failure Full downstream Pressure ,[object Object],25+ year flood conditions ADEQ illegal discharge violation

Develop System Description Identify Current Controls ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Perform Risk Analysis Rate the Severity of the Effect on the Customer ,[object Object],[object Object],[object Object],[object Object],Rating Severity of Effect 10 Result in Injury 9 May be Illegal 8 Render product or service unfit for use 7 Cause extreme customer dissatisfaction 6 Result in partial malfunction 5 Cause a loss of performance which is likely to result in a complaint 4 Cause minor performance loss 3 Cause a minor nuisance but can be overcome with no performance loss 2 Be unnoticed and have only minor effect on performance 1 Be unnoticed and not affect the performance

Perform Risk Analysis Identify Probability of Occurrence for each Cause ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Rating Occurrence Probability 10 More than once per day > 30% 9 Once every 3-4 days 30% 8 Once every week 5% 7 Once per month 1% 6 Once every 3 months 0.03% 5 Once every 6 months 1 per 10,000 4 Once per year 6 per 100,000 3 Once every 1-3 years 6 per million 2 Once every 3-6 years 3 per 10 million 1 Once every 6-9 years 2 per billion

Perform Risk Analysis Identify Probability of Detection ,[object Object],[object Object],[object Object],[object Object],[object Object],Rating Detectability 10 Defect caused by failure is not detectable 9 Partial system shutdown required to reveal defect 8 Units are systematically sampled and inspected to reveal defect 7 Cursory inspection of system reveals defect 6 Process is monitored and manually inspected at the site 5 Defect is obvious when operator arrives at the site 4 Defect is auto detected and recorded but not alarmed 3 Defect can be detected by casual observer who calls operator 2 Defect is auto detected and audibly or visibly alarmed 1 Defect is auto detected and alarm is sent to operator

Perform Risk Analysis Calculate Risk Priority Number (RPN) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],Quiz: What is the most common source of error in generating FMEAs? ,[object Object],[object Object],[object Object],[object Object],Source: Motorola Black Belt Certification Exam

Quiz: Which of the following would result in the HIGHEST value of DETECTABILTY for FMEA? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Source: Motorola Black Belt Certification Exam

Develop Risk Mitigation and Control Plan Identify system upgrades and/or controls for high risk areas ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Develop Risk Mitigation and Control Plan Perform Risk Analysis on Proposed Controls ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Develop Risk Mitigation and Control Plan Deploy Risk Mitigations and Controls ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Wrap-up A Failure Modes and Effects Analysis is only one tool in an organization’s comprehensive Quality Management System

ISO-9000 Global Industrial Standardization (1988) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],A highly overlapping and Continuous Process

ISO-14000 Global Environmental Management Standardization (1996) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],How will ISO-14000 affect your business going forward? ,[object Object]

Ceptara Can Help Your Organization Bring Excellence into Focus ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

If you would like a copy of the complete FMEA report for PCCDWID please complete your opinion survey and give to me along with your business card Questions?

FMEA Presentation V1.1

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