2012ars eu t1s2 ganot
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2012 ARS, Europe: Warsaw, Poland
Track 1, Session 2Begins at 10:30 AM, Wednesday, March 28th
Prerequisites for a
Comprehensive and Successful
FMEAAmnon Ganot, CREGertron Ltd. CTO
RAMS Consulting Services
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PRESENTATION SLIDESPRESENTATION SLIDES
The following presentation was delivered at the:
International Applied Reliability Symposium, Europe
March 28 - 30, 2012: Warsaw, Polandhttp://www.ARSymposium.org/europe/2012/
The International Applied Reliability Symposium (ARS) is intended to be a forum for reliability and maintainability practitionerswithin industry and government to discuss their success stories and lessons learned regarding
the application of reliability techniques to meet real world challenges. Each year, the ARS issues an open
"Call for Presentations" at http://www.ARSymposium.org/europe/presenters/index.htm and the presentations
delivered at the Symposium are selected on the basis of the presentation proposals received.
Although the ARS may edit the presentation materials as needed to make them ready to print, the content of the
presentation is solely the responsibility of the author. Publication of these presentation materials in the
ARS Proceedings does not imply that the information and methods described in the presentation have been
verified or endorsed by the ARS and/or its organizers.
The publication of these materials in the ARS presentation format isCopyright 2012 by the ARS, All Rights Reserved.
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ALT Accelerated Life Test
ATM Automatic Teller Machine
CFMEA Concept FMEA
DFM Design For Maintainability DFMEA Design FMEA
EMI Electromagnetic Interference
FFMEA Functional FMEA
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FMEA Failure Mode & Effect Analysis
FRU Field Replicable Unit
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HALT Highly Accelerated Life Test I/O Input / Output
e
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PFMEA Process FMEA
Amnon Ganot, Gertron Ltd. Slide Number: 2Session 2Track 1Applied
RAMS Reliability, Availability, Maintainability & Safety
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Time MinTo ic
8Motivation
FMEA Definition
ypes
FMEA The Lean Way
40System Engineering
System Mission(s)
System Boundaries
Functional Structure Dia ram
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Functional Analysis
Components Function
mposium, n er ace agram
Operation Modes
State Diagrams
e
liabilityS Functions & Parameters
2FMEA Tips
Summar
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10Questions
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demanding
Development cycles become shorter
As a result, we have to implement more
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methodologies.>
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e
liabilityS
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is a systematic method ofidentifying and
preventing product and process problems.
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e
liabilityS
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CFMEA is used to analyze concepts in the early
s ages e ore ar ware s e ne mos o en asystem and subsystem).
It focuses on potential failure modes associated
with the proposed functions of a concept
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proposal.
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multiple systems and interaction between the
e
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Functional FMEA
FFMEA examines the intended functions that a product,rocess or service is to erform rather than the
characteristics of the specific implementation.
When a functional FMEA is develo ed a functional blockdiagram is typically used to identify the top-level failures
for each block in the diagram.
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Interface FMEA
An IFMEA anal sis focuses on determinin the
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characteristics of failures in the interconnections betweensubs stem elements. Cables, lumbin , fiber o tic links,
e
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mechanical linkages and other interconnections between
subs stem modules rovide the basis for the ostulated
Amnon Ganot, Gertron Ltd. Slide Number: 7Session 2Track 1Applied failure modes.
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DFMEA is used to analyze product detailed designs
.on potential failure modes associated with the parts of
.
Process FMEA
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PFMEA is used to analyze the already developed or
existing processes. PFMEA focuses on potential failure
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modes associated with both the processsafety/effectiveness/efficiency, and the functions of a
e
liabilityS product caused by the process problems.
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--William James, American Philosopher
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Functional ApproachParts ApproachAttributes
Functional dia ramDetailed drawinPrere uisites
Difficult to establishBased on parts listCompleteness criterion
Examination of functionPast experienceKnowledge of failure modes
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Top-downBottom-upUsual progression
mposiu
m,
Low / ShortHigh / LongRelative cost
e
liabilityS Early (system level)Late (detailed design)Project stage
Can be doneNot PossibleSoftware Analysis
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engineering design: the bottom-up and top-
down approaches.
e mos common me o o ogy o
en ineerin desi n is rovided usin the
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systems approach, which is actually based
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system.
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The process is self-consistent.
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the primary function or purpose of the unit. A
mission is a brief description of the units,
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m,
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To wash laundry 1910 advertisement
Rinsing
pnnng
.
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the internal components of a system from external
en es. Those external entities can also be thou ht and be
called as actors.
urope201 n a use case agram, a sys em oun ary s
represented by a rectangle that is drawn to
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enclosed the internal components of a system. Anyentities outside the rectan le i.e. the s stem
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boundary) are hence the actors.
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mposiu
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mposiu
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analyzing the functional structure of a system.
usually comes after the elaboration of the specification and
.
It presents the design solution independent of the specific
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The functions should be in the form a verb-noun
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m, com na on. e ver s ou e an ac on ver o ,
protect, rotate, move, control, directetc.). The noun should
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operation takes place (density, noise, color, etc.). For
Amnon Ganot, Gertron Ltd. Slide Number: 17Session 2Track 1Applied examp e: genera e co or, re uce no se e c.
E g : Washing Machine FunctionalE g : Washing Machine Functional
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E.g.: Washing Machine FunctionalE.g.: Washing Machine Functional
Structure DiagramStructure Diagram
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mposiu
m,
eliabilityS
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E g : Washing Machine FunctionalE g : Washing Machine Functional
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E.g.: Washing Machine FunctionalE.g.: Washing Machine Functional
Structure DiagramStructure Diagram
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mposiu
m,
eliabilityS
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E g : Washing Machine FunctionalE g : Washing Machine Functional
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E.g.: Washing Machine FunctionalE.g.: Washing Machine Functional
Structure DiagramStructure Diagram
urope201
mposiu
m,
eliabilityS
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E g : Washing Machine FunctionalE g : Washing Machine Functional
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E.g.: Washing Machine FunctionalE.g.: Washing Machine Functional
Structure DiagramStructure Diagram
urope201
mposiu
m,
eliabilityS
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E g : Washing Machine FunctionalE g : Washing Machine Functional
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E.g.: Washing Machine FunctionalE.g.: Washing Machine Functional
Structure DiagramStructure Diagram
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mposiu
m,
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interconnections between the parts. This will be used to
.
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mposiu
m,
eliabilityS
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E g : Window Cleaning FunctionalE g : Window Cleaning Functional
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E.g.: Window Cleaning FunctionalE.g.: Window Cleaning Functional
nayssnayss
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mposiu
m,
eliabilityS
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To be able to anal ze all the otential failure that mi ht cause a
component failure, one has to analyze each of the components failures
composing the sub-system.
The list should include all hardware components as well as softwaremodules. In case a human is controlling the sub-system (e.g.,
, - .
For example: a flashlight is composed of the following sub-assemblies:
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, , , .
The case can further be decomposed into its sub-
assemblies/com onents and it is the decision of the FMEA erformer
mposiu
m,
to decide down to what level the sub-system should be decomposed. In any case, the decomposition should be at least down to the
eliabilityS FRU (Spare Part) level.
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E.g.: Washing Machine ComponentsE.g.: Washing Machine Components
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E.g.: Washing Machine ComponentsE.g.: Washing Machine Components
unc onsunc onsFRUCom onentFunctionSub-Ass
YesEMI Filter????
YesWater Supply ValveControl Water Supply
YesDrain ValveControl Water DrainYesSoftener SupplyControl Softener
YesPower Factor
Correction Assy
????
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Drum
mposiu
m,
YesBeltNoDrum????
eliabilityS
YesFront Panel????
YesWater Level SensorMonitor Water Level
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is composed of the relation between the
system/sub-system/sub-assemblies to the.
It alwa s includes the missions of the unit as
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well as the influences of the unit on the
mposium, .
eliabilityS
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eliabilityS
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E.g.: Washing Machine InterfacesE.g.: Washing Machine Interfaces
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E.g.: Washing Machine InterfacesE.g.: Washing Machine Interfaces
DiagramDiagram
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eliabilityS
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,
exposed to different stress levels which lead to
mechanisms.
It is important to determine all the operational modes
of each unit.
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Modes of operation that dominant most of the time will
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operating modes are: Off, Startup, Shutdown,
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Idle Display Please Insert Card
Serving Customer
Reading PIN
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Choosing Transaction
Performing Transaction
mposium,
Eject Card
eliabilityS
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science and related fields to describe the behavior of
State diagrams require that the system described is,
this is indeed the case, while at other times this is a
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In some cases, system states and operating modes
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mode has several states.
eliabilityS
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do we need the unit? the functions describes the way
.
While a mission is non measurable, functions have
measurable results and unique definitions of failure.
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passengers from one place to another, one of the
mposium, .
In some cases, functions and missions are coincident.
eliabilityS
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are controlled by the function .
E.g., function = "set pressure" / parameters =ressure & rate
For each Sub-Assembly, write its Function(s).
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For each Function, write its Parameter(s).
mposium,
Parameter.
eliabilityS
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E.g.: Washing MachineE.g.: Washing Machine
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unc ons arame ersunc ons arame ers
Rel. DataCriticalParametersFunctionSub-Assy
YesYesDisplay IntegrityControl Panel (I/O) [Display,
YesYesInput Signal Integrity
YesYesState IntegrityControl Water Supply [Water
Supply Valve]
NoNoPressure Drop
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NoYesOut Leak Rate
mposi
um,
Sensor]
YesYesState IntegrityMonitor Cover State [Cover
eliabilityS
YesNoHeating PowerHeat Water [Heating Element]
..
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parameters.
Add Failure Modes due to illegal transitione ween s a es.
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interruption at any state.
mposi
um,
Add Failure Modes due to interfaces issue.
eliabilityS a ure o es ue o uman error.
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Reliabilit oals become more and more demandin
Development cycles become shorter
,
reliability methodologies.>
using the systems approach, which is actually based on a top-down
approach to the design.
urope201
The mission is a concise statement outlining the primary function or
purpose of the unit - Why do we need the unit?
mposi
um,
A system boundary is a boundary that separates the internal
components of a system from external entities.
eliabilityS
Functional Structure Diagram presents the design solution
independent of the specific technical methods to be involved.
Amnon Ganot, Gertron Ltd. Slide Number: 38Session 2Track 1Applied
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A Functional Anal sis is needed to be able to evaluate the
interconnections between the parts. This will be used to light up the
functions of the parts.
Make a list that includes all hardware components as well assoftware modules and their functions. In case a human is controlling
the sub-system (e.g., operating panel), the human is a sub-system.
Interface Diagram is an important data as it is composed of the
urope201 re a on e ween e sys em su -sys em su -assem es o e nex
level entity.
mposi
um, s mpor an o e erm ne a e opera ona mo es o eac un .
State diagrams require that the system described is composed of a
eliabilityS , ,
other times this is a reasonable abstraction.
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Statcharts: A Visual Formalism for Com lex S stems. David Harel
Fundamentals of Failure Modes and Effects Analysis. John B.
Bowles
Standard for Performing a Failure Mode and Effects Analysis(FMEA) and Establishing a Critical Items List (CIL) (DRAFT). Flight
Assurance Procedure (FAP) 322 209
Functional Clues. Aleksey Pinyayev
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Washing machine. Wikipedia
System Reliability & Failure Prevention. Herbert Hecht
mposium,
Handbook of Performability Engineering. Krishna B. Misra Reliabilit Centered Maintenance. John Moubra
eliabilityS
The Basic of FMEA. Robin E. McDermott, Raymond J. Mikulak,
Michael R. Beauegard
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RAMS Expert at ORBOTECH Ltd. & CTO at GERTRON Ltd. RAMS Consulting Services
Amnon Ganot is the RAMS expert at Orbotech ltd. Amnon is working at Orbotech for the
last 22 years. Prior to being the RAMS expert, Amnon was the RAMS & Standard
Com liance mana er of Orbotech.
During his cadence as the RAMS & Standard Compliance manager, he concentrated ondeveloping methodologies for RAMS such as ALT, FMEA (Quick & Extended), DFM, DFR,
25 years, a project manager and system engineer in multidisciplinary projects in the
medical, communication and industrial field.
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consulting services.
Amnon holds a B.Sc in Electrical Engineering from the Technion Israel Institute of
mposium, , . - , .
an ASQ Certified Reliability Engineer (CRE) as well as ISQ Certified Reliability Engineer(CREI)
eliabilityS on ac n .: er ron ., . . ox , avne, srae
Phone: +972 54 4942373 Fax: +972 3 9410685
E-Mail: [email protected]
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Thank you for your attention.
urope201 o you ave any ques ons
mposium,
eliabilityS
Amnon Ganot, Gertron Ltd. Slide Number: 42Session 2Track 1Applied