2012ars Eu t1s2 Ganot

7/31/2019 2012ars Eu t1s2 Ganot

1/43

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

7/31/2019 2012ars Eu t1s2 Ganot

2/43

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.

7/31/2019 2012ars Eu t1s2 Ganot

3/43

ALT Accelerated Life Test

ATM Automatic Teller Machine

CFMEA Concept FMEA

DFM Design For Maintainability DFMEA Design FMEA

EMI Electromagnetic Interference

FFMEA Functional FMEA

urope201

FMEA Failure Mode & Effect Analysis

FRU Field Replicable Unit

mposium,

HALT Highly Accelerated Life Test I/O Input / Output

e

liabilityS n er ace

PFMEA Process FMEA

Amnon Ganot, Gertron Ltd. Slide Number: 2Session 2Track 1Applied

RAMS Reliability, Availability, Maintainability & Safety

7/31/2019 2012ars Eu t1s2 Ganot

4/43

Time MinTo ic

8Motivation

FMEA Definition

ypes

FMEA The Lean Way

40System Engineering

System Mission(s)

System Boundaries

Functional Structure Dia ram

urope201

Functional Analysis

Components Function

mposium, n er ace agram

Operation Modes

State Diagrams

e

liabilityS Functions & Parameters

2FMEA Tips

Summar


10Questions

7/31/2019 2012ars Eu t1s2 Ganot

5/43

demanding

Development cycles become shorter

As a result, we have to implement more

urope201

methodologies.>

mposium,

e

liabilityS


7/31/2019 2012ars Eu t1s2 Ganot

6/43

is a systematic method ofidentifying and

preventing product and process problems.

urope201

mposium,

e

liabilityS


7/31/2019 2012ars Eu t1s2 Ganot

7/43

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

urope201

proposal.

mposium,

multiple systems and interaction between the

e

liabilityS .


7/31/2019 2012ars Eu t1s2 Ganot

8/43

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.

urope201

Interface FMEA

An IFMEA anal sis focuses on determinin the

mposium,

characteristics of failures in the interconnections betweensubs stem elements. Cables, lumbin , fiber o tic links,

e

liabilityS

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.

7/31/2019 2012ars Eu t1s2 Ganot

9/43

DFMEA is used to analyze product detailed designs

.on potential failure modes associated with the parts of

.

Process FMEA

urope201

PFMEA is used to analyze the already developed or

existing processes. PFMEA focuses on potential failure

mposium,

modes associated with both the processsafety/effectiveness/efficiency, and the functions of a

e

liabilityS product caused by the process problems.


7/31/2019 2012ars Eu t1s2 Ganot

10/43

urope201

mposiu

m,

--William James, American Philosopher

e

liabilityS


7/31/2019 2012ars Eu t1s2 Ganot

11/43

Functional ApproachParts ApproachAttributes

Functional dia ramDetailed drawinPrere uisites

Difficult to establishBased on parts listCompleteness criterion

Examination of functionPast experienceKnowledge of failure modes

urope201

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


7/31/2019 2012ars Eu t1s2 Ganot

12/43

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

urope201

systems approach, which is actually based

mposiu

m, - .

e

liabilityS

system.


The process is self-consistent.

7/31/2019 2012ars Eu t1s2 Ganot

13/43

the primary function or purpose of the unit. A

mission is a brief description of the units,

urope201

mposiu

m,

e

liabilityS


7/31/2019 2012ars Eu t1s2 Ganot

14/43

To wash laundry 1910 advertisement

Rinsing

pnnng

.

urope201

mposiu

m,

e

liabilityS


7/31/2019 2012ars Eu t1s2 Ganot

15/43

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

mposiu

m,

enclosed the internal components of a system. Anyentities outside the rectan le i.e. the s stem

e

liabilityS

boundary) are hence the actors.


7/31/2019 2012ars Eu t1s2 Ganot

16/43

urope201

mposiu

m,

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

17/43

urope201

mposiu

m,

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

18/43

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

urope201 .

The functions should be in the form a verb-noun

mposiu

m, com na on. e ver s ou e an ac on ver o ,

protect, rotate, move, control, directetc.). The noun should

eliabilityS e escr p ve an genera ; s e operan on w c e

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

7/31/2019 2012ars Eu t1s2 Ganot

19/43

E.g.: Washing Machine FunctionalE.g.: Washing Machine Functional

Structure DiagramStructure Diagram

urope201

mposiu

m,

eliabilityS



7/31/2019 2012ars Eu t1s2 Ganot

20/43



urope201

mposiu

m,

eliabilityS



7/31/2019 2012ars Eu t1s2 Ganot

21/43



urope201

mposiu

m,

eliabilityS



7/31/2019 2012ars Eu t1s2 Ganot

22/43



urope201

mposiu

m,

eliabilityS



7/31/2019 2012ars Eu t1s2 Ganot

23/43



urope201

mposiu

m,

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

24/43

interconnections between the parts. This will be used to

.

urope201

mposiu

m,

eliabilityS


E g : Window Cleaning FunctionalE g : Window Cleaning Functional

7/31/2019 2012ars Eu t1s2 Ganot

25/43

E.g.: Window Cleaning FunctionalE.g.: Window Cleaning Functional

nayssnayss

urope201

mposiu

m,

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

26/43

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:

urope201

, , , .

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.


E.g.: Washing Machine ComponentsE.g.: Washing Machine Components

7/31/2019 2012ars Eu t1s2 Ganot

27/43

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

????

urope201 YesMotorSupply Motion to

Drum

mposiu

m,

YesBeltNoDrum????

eliabilityS

YesFront Panel????

YesWater Level SensorMonitor Water Level


7/31/2019 2012ars Eu t1s2 Ganot

28/43

is composed of the relation between the

system/sub-system/sub-assemblies to the.

It alwa s includes the missions of the unit as

urope201

well as the influences of the unit on the

mposium, .

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

29/43

urope201

mposium,

eliabilityS


E.g.: Washing Machine InterfacesE.g.: Washing Machine Interfaces

7/31/2019 2012ars Eu t1s2 Ganot

30/43

E.g.: Washing Machine InterfacesE.g.: Washing Machine Interfaces

DiagramDiagram

urope201

mposium,

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

31/43

,

exposed to different stress levels which lead to

mechanisms.

It is important to determine all the operational modes

of each unit.

urope201

Modes of operation that dominant most of the time will

mposium, .

operating modes are: Off, Startup, Shutdown,

eliabilityS , , , , .


7/31/2019 2012ars Eu t1s2 Ganot

32/43

Idle Display Please Insert Card

Serving Customer

Reading PIN

urope201

Choosing Transaction

Performing Transaction

mposium,

Eject Card

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

33/43

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

urope201 .

In some cases, system states and operating modes

mposium, ,

mode has several states.

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

34/43

urope201

mposium,

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

35/43

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.

urope201 . .,

passengers from one place to another, one of the

mposium, .

In some cases, functions and missions are coincident.

eliabilityS


7/31/2019 2012ars Eu t1s2 Ganot

36/43

are controlled by the function .

E.g., function = "set pressure" / parameters =ressure & rate

For each Sub-Assembly, write its Function(s).

urope201

For each Function, write its Parameter(s).

mposium,

Parameter.

eliabilityS


E.g.: Washing MachineE.g.: Washing Machine

7/31/2019 2012ars Eu t1s2 Ganot

37/43

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

urope201 oesne ea a e

NoYesOut Leak Rate

mposi

um,

Sensor]

YesYesState IntegrityMonitor Cover State [Cover

eliabilityS

YesNoHeating PowerHeat Water [Heating Element]

..


7/31/2019 2012ars Eu t1s2 Ganot

38/43

parameters.

Add Failure Modes due to illegal transitione ween s a es.

urope201

interruption at any state.

mposi

um,

Add Failure Modes due to interfaces issue.

eliabilityS a ure o es ue o uman error.


7/31/2019 2012ars Eu t1s2 Ganot

39/43

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.


7/31/2019 2012ars Eu t1s2 Ganot

40/43

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.


7/31/2019 2012ars Eu t1s2 Ganot

41/43

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

urope201

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


7/31/2019 2012ars Eu t1s2 Ganot

42/43

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.

urope201 , .,

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]


7/31/2019 2012ars Eu t1s2 Ganot

43/43

Thank you for your attention.

urope201 o you ave any ques ons

mposium,

eliabilityS


Documents

2012ars Eu t1s2 Ganot