Reliability Analysis
FMEA
Development program for Preventive Maintenance Engineers
P05 Reliability Analysis FOR INTERNAL USE ONLY © LafargeHolcim 2015
Objectives
• Understand the importance and concept of Reliability Analysis and how
to apply it in preventive maintenance
• To be able to replicate the FMEA process in the specific plant conditions
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Have you heard this expression?
“Why is there always enough time to do it over, but
never enough time to do it right the first time?”
Restated in a maintenance context,
“Why is there always enough time (and money) to
fix a broken machine but never enough time (or
money) to prevent it from failing?”
Jim Fitch (Noria Corporation).
WS06 Preventive Maintenance Strategy, CM, 2015-05-21
Driver: Preventive Maintenance Strategy
Coupling failure of the bucket elevator
322BE1
Lack of lubrication in
hydraulic coupling
Geared
couplings
damaged
Proactive action: Complete hydraulic
Condition
Preventive maintenance coupling damaged
routine to re-grease. Shaft of
Aprox. Cost of proactive gearbox
task 500 USD damaged
Motor
Time damaged
++
+ Total cost: Functional
- failure
-- 45 kUSD
Cost to repair
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Bearing failure in a bucket elevator
Possible Bearing
contamination clearance above Excessive Approx. total cost of the failures:
wear
of bearing normal 50 kUSD
Unusual noise
PROACTIVE Bearing inspection:
TASK internal clearance and
lubricant condition New bearing inspection Excessive heat
(Approx. cost of
(Notification: 81246630 564-BE1
the PROACTIVE
Mech Insp 6 Month
TASK to avoid
03.30.2011
the problem:
Condition
(There has been a notification in
1 kUSD)
the system for several months to
replace these bearings.)
81345529 564-BE1 INSP D.E. head shaft bearing. 09/27/2011
(During inspection I found the drive end head shaft brg. hot and
making an unusual noise. Temp. was at 110deg. C and brg.
making a grinding noise on 9/27/11.)
Time
+ WO 10640994 – 09/30/2011 564-BE1
- INSP D.E. head shaft bearing
(Replaced both bearings and drive
WO 10656060 04/03/2012
564-BE1 OEE Replace
-- Cost to repair shaft complete- $24,883.46) gearbox output shaft
(Installed new gear box. Job
complete- $23,425.98)
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Agenda
Reliability Process - FMEA
FMEA and measures
Decision process
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Failure Mode Effect Analysis (FMEA)
• … is a review technique that focuses on defining possible failure modes
and their effects on the system
• … provides basis to determine the preventive maintenance actions,
contingency plans to be implemented and spare parts requirements
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Reliability analysis process
1. Risk Analysis 2. FMEA 3. Measures
• Definition of risk matrix • Perform FMEA for all / most • Measures to reduce
for each process area “A” critical equipment probability / severity
• Definition of operation loss • Allocate failure causes in risk ✓ Preventive Maintenance
and impact on revenue matrix Routines
cost related to probability • Measures required if ✓ Contingency plan
of occurrence located outside predefined ✓ Hold Critical spare parts
protection level
P05 Reliability Analysis FOR INTERNAL USE ONLY © LafargeHolcim 2015 8
Template
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Equipment and equipment function
The equipment name
must include the
proper ACS code
Equipment: _______________________
Equipment Function: _______________________
_______________________
Include all the functions of the
equipment such as e.g.
- Primary
- Secondary
- Protection Devices
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Sub-systems
Start
#‘s
Divide equipment into
sub-systems to
increase focus of
analysis
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Failure modes
Do not list all
Sequential #‘s possibilities
reset for each regardless of it
sub-system likelihood
• When brainstorming failure modes try to stick to...
• Failure modes which have occurred before
• Failure modes which are already the subject of proactive maintenance routines
• Failure modes which have not yet occurred, but which are considered to be real
possibilities
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Causes
List possible
Letter in alphabetical causes for each
order, reset it for failure mode
each failure mode
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Effects
• Failure effects describe what happens for occurance of each
single failure mode
• The effect of the failure should be considered in the worst case
scenario and that there are no current efforts being performed to
prevent it
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Severity and probability
Probability
Severity
• According to the failure mode and the effect, severity and
probability are determined
• Assess each failure mode and its effect according to the risk
profile for the area the equipment is located
• Correlation to aspect impacted (e.g. production loss, safety, etc.)
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Assumptions and explanations
• Finally, document any and all assumptions or explanations for the
evaluation
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Completed sheet
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Feed back to risk profile
• Example: Failure modes of belt 332-FB6
• Drive pulley:
• 1: Bearing failure
• 2: Broken shaft
• Drive:
• 3: Gear box bearing failure
• 4: Gear box gear wheel failure
• 5: Gear box shaft failure
• 6: Electrical motor bearing failure
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Example: Belt 332-FB6, NO Actions considered
6
1
2 3 4 5
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Agenda
Reliability Process - FMEA
FMEA and measures
Decision process
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FMEA - Measures to be taken
• As part of an FMEA the following type measures can be defined
• Preventive maintenance
• Contingency plan
• Hold critical spare part
Probability
A
B
C
D
E
F
IV III II I Severity
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Impact of decisions taken
• Holding spare parts can reduce severity by eliminating lead time of
spare parts
• Having a contingency plan can reduce severity – being prepared
Probability
A
B
C
D
E
F
IV III II I Severity
P05 Reliability Analysis FOR INTERNAL USE ONLY © LafargeHolcim 2015 22
Impact of decisions taken
• Proper alignment, clean working environment, proper lubrication etc.
can reduce probability by guaranteeing optimal working conditions
Probability
A
B
C
D
E
F
IV III II I Severity
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Impact of decisions taken
Condition monitoring reduces both,
probability and severity
Probability
C
D
E
F
IV III II I Severity
P05 Reliability Analysis FOR INTERNAL USE ONLY © LafargeHolcim 2015 24
Agenda
Reliability Process - FMEA
FMEA and measures
Decision process
P05 Reliability Analysis FOR INTERNAL USE ONLY © LafargeHolcim 2015 25
Decision process
QUESTION
Is the detection of the potential failure
during operation both technically TASK
feasible and economically justified? CONDITION MONITORING
1
• Vibration Analysis A
NO • Temperature measurement
YES
Is the detection of the potential failure • Human sense
during stand -still both technically
feasible and economically justified ?
2 INSPECTION Would a spare part on
• Specific measurement stock be economically
NO • NDT (Non destructive Tests) justified ?
YES
Is an age -related overhaul or exchange
task both technically feasible and
economically justified ?
3 Decision if corrective
NO SCHEDULED OVERHAUL OR EXCHANGE maintenance task is of
YES high or low cost.
Is a task to detect a hidden failure both
technically feasible and economically
justified ?
4 FAILURE FINDING TASK
• Actuate Safety Circuit
NO Check in the risk
YES • Functional Test
Are the failure consequences still in profile for
5 acceptance
an unacceptable zone? RE-DESIGN COMPULSORY
YES
6 NO PREVENTATIVE MAINTENANCE
Re-design if both technically feasible
NO and economically justified.
A Is a servicing task (lubrication, cleaning,
tightening) economically justified ?
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Capture action and decisions in the worksheet
Corresponds to
New New
coding system in
severity probability
FMEA Sheet.
(e.g. 1.1.A)
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Step 8: Feed back to risk profile
Example: Failure Modes of Belt 332-FB6
• Drive pulley:
• 1: Bearing failure
• 2: Broken shaft
• Drive:
• 3: Gear box bearing failure
• 4: Gear box gear wheel failure
• 5: Gear box shaft failure
• 6: Electrical motor bearing failure
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Example: Belt 332-FB6, NO Actions considered
6
1
2 3 4 5
P05 Reliability Analysis FOR INTERNAL USE ONLY © LafargeHolcim 2015 29
Example: Failure modes of Belt 332-FB6 - Actions
• Drive pulley:
• 1: Bearing failure ➔
Action: buy bearing
• 2: Broken shaft ➔
Action: weld temporary
• Drive:
• 3: Gear box bearing failure ➔ Action: buy bearing
• 4: Gear box gear wheel failure ➔ Action: vibration analysis
• 5: Gear box shaft failure ➔ Action: weld temporary
• 6: Electrical motor bearing failure ➔ Action: hold bearing
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Example: Belt 332-FB6, actions considered
6 6
1 1
2 3 5 2 3 4 4 5
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Risk matrix
Reduce severity
Probability Eliminate repetition and/or probability
D Look for the
root cause
E
F
Severity
No action
IV III II I
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Where to start?
This can entail a massive
amount of work if every asset
in the plant is examined,
therefore we need to examine
only
Critical assets
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Questions / Comments …
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