Failure Analysis Methods

What, Why and How

MEEG 466 Special Topics in Design

Jim Glancey
Spring, 2006
 Failure Analysis Methods
Every product or process has modes of
failure.
An analysis of potential failures helps
designers focus on and understand the
impact of potential process or product
risks and failures.
Several systematic methodologies have
been develop to quantify the effects and
impacts of failures.
 Failure Analysis Methods . . .
Why perform failure analysis?
Product Development:
Prevent product malfunctions.
Insure product life.
Prevent safety hazards while using the product.
Process Development:
Insure product quality
Achieve process reliability
Prevent customer dissatisfaction
Prevent safety or environmental hazards
 Common Failure Analysis
Techniques
Cause-Consequence Analysis Hazard & Operability Analysis
Checklist (HAZOP)
Event Tree Analysis Human Reliability
Failure Modes & Effects Preliminary Hazard Analysis
Analysis (FMEA) (PHA)
Failure Modes, Effects and Relative Ranking
Criticality Analysis (FMECA) Safety Review
Fault Tree Analysis (FTA) What-If / Checklist Analysis
What-If Analysis

For the purpose of this class, two common but

fundamentally different techniques will be presented in
detail:
1. Failure Modes Effects Analysis (FMEA)
2. Fault Tree Analysis
Part 1: Failure Modes Effect
Analysis
 Failure Modes & Effects Analysis
(FMEA)
Tabulation of equipment/components and their associated
single point failure modes, consequences and safeguards.
Identification/assessment of risk is derived from looking at
each component (or machine in the case of multi-unit
manufacturing).
This is commonly referred to as a bottom-up approach.
Simple Example: Car
Failure
Item Identification Description Modes Effects Safeguards Actions

1 Car Tire -Supports Weight Flat -Stranded Spare Tire Acceptable

-Traction -Loose Control In Trunk as is
-Cornering
-Smooth Ride

Gas Tank Holds fuel -Empty -Stall -Fuel Gage Acceptable

2 -Blows up -Car Destroyed -Locate away as is
from Engine
 Implementing FMEA
An FMEA can be implemented using a
hardware or functional approach, and
often due to system complexity, be
performed as a combination of the two
methods.
Hardware = loss of a component
Functional = loss of a function or feature
 Failures
Need to understand failures which can be
any of the following:
Failure is any loss that interrupts the continuity of production.
Failure is a loss of asset availability.
Failure is the unavailability of equipment.
Failure is a deviation from the status quo.
Failure is not meeting target expectations.
Failure is any secondary defect
 Failures . . .
Failures can be:
pump not working
seized valve
broken wire
software crash
system down
reactor melt down
no money in a checking account
(inevitable for college student)
 Failures . . .
Defining the possible (and relevant)
failures is the key for the analysis to
produce meaningful results.
For instance, if all we care about are
failures that cause injuries or death, then
the analysis would be much different than
one that was interested in economical
problems.
 FMEA Procedure
Review and understand product or process design; breakdown into components
(product) or steps (process).

Brainstorm modes of failure.

Rate the severity of each effect of failure.

Rate the likelihood of occurrence for each failure.

Rate the likelihood of detection for each cause of failure (i.e. the likelihood of
detecting the problem before it reaches the customer or operator).

Compute the Risk Priority Number, RPN = Severity x Occurrence x Detection

Implement corrective actions to minimize the occurrence of the more significant

failure modes (i.e. the highest RPNs).

Re-assess the product or process by another cycle of FMEA after the actions
have been completed.

Perform regular (re)assessments of failures as needed.

 FMEA Table
Example: Hydraulic Hose Failure

Severity, Occurance and Detection ratings are based on a 1 = low to

10 = high scale.

The FMEA results clearly show the greatest risk is associated with over-
pressure failure, and the lowest risk is due to weathering-related failure.

The excel template shown is above is available at:

http://research.me.udel.edu/~jglancey/FMEA_Template.xls
Part 2: Fault Tree Analysis
 Fault Tree Analysis (FTA)
Graphical model that displays the various
combinations of equipment failures and
human errors that can result in the main
system failure of interest.
Identification/assessment of risk is derived
by first identifying faults/hazards.
A top down approach.
 Definitions
FAULT
An abnormal undesirable state of a system or a system
element* induced 1) by presence of an improper
command or absence of a proper one, or 2) by a
failure (see below). All failures cause faults; not all
faults are caused by failures. A system which has
been shut down by safety features has not faulted.
FAILURE
Loss, by a system or system element*, of functional
integrity to perform as intended, e.g., relay contacts
corrode and will not pass rated current closed, or the
relay coil has burned out and will not close the
contacts when commanded the relay has failed; a
pressure vessel bursts the vessel fails.
Fault Tree Example
Explosion

Relief valve 1 Relief valve 2

does not open does not open

Operator does
not know to
open valve 2

Computer
does not
open valve 1
 Fault Tree Construction
Each node in the tree can be represented by a
combination of events that cause the
occurrence of the event, by means of logic
gates
Each gate has inputs and outputs
An input can be a basic event or an output of
another gate
The development of a fault tree model relies
on the analysts understanding of the system
being analyzed
It is very important to understand the system
first in order to build a unbiased fault tree
 Logic (Boolean) Gates

TOP Event- , undesirable event,

towa.rd which all faultlog paths
Intermediate event- describing
roduced antecedent
"Or" Gate- prod output if any input
ex:1:sts. Any input, individuaL ust
ecessary and (2) sufficient to

ru'r1nu<:::es OUtput a Inputs CO-eXI:SI Inputs,

individually and sufficient to vCUJ.:><;;;; the
output event

Basic Event- I
(Called "Leaf,'' "I Basic. The Basic Event marks
limit resolution of the nalysis.
Events and Gates not component parts of the system being analyzed. They
the
 Standard Symbols for FTA
Construction
AND GATE OR GATE

Next level failure if ALL Next level failure if ANY

inputs fail. inputs fail.
Table- FTA
 FTA Structure

------""10 Identify undesirable TOP event

~=------@ Li n k contributors to TOP by logic gates
l-4
.------~-..., ~ Identify first-level contributors

....------- Link second-level contributors

to TOP by logic gates

Baste Event (" Leaf," "Initiator. or

"Baste") tndtcates limit of analyltcal L...---::;;:::::!..'- - - - - Repeat/continue
resolulton. :..
12 JACOBS
SVI!.RDRUP
""
 Identifying TOP Events

Explore historical records (own and others).

Look to energy sources.
Identify potential mission failure contributors.
Development what-if scenarios.
Use shopping lists.
 FTA Example

Consider lamp failing to illuminate when the fluid level is too low.
Battery fuse float switch Indicator 18lflp
 Fault Tree Constraints and
Shortcomings

Undesirable events must be foreseen and are only analyzed

singly.
All significant contributors to fault/failure must be anticipated.
Each fault/failure initiator must be constrained to two conditional
modes when modeled in the tree.
Initiators at a given analysis level beneath a common gate must
be independent of each other.
Events/conditions at any analysis level must be true, immediate
contributors to next-level events/conditions.
Each Initiators failure rate must be a predictable
 FTA vs. FMEA
Preferred
Selection Characteristic
FTA FMECA
Safety .of public/.operating/m aintenance personnel ~
Small number/clearly defined TOP ev~, 1b
Indistinctly defined TOP events
Full-Mission completion critically imp.ort.ant
"
~
'
Many, potentially successful missions possible
"All possible" failure modes are of concern ""
"
High potential for "human error" contributions
High ;::;e!ential for "software error'' contributions ~

Numerical "risk evaluation" nc"'~"'1 ~

Very complex system architecture/many functional parts

Linear system architecture with little/human software influence
System irreparable after mission starts
" "
~
"Fault Develop!nent Center.
 Preparation of a FTA
SYSTEM BLOCK DIAGRAM
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FMEA
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'---

FTA
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