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FMECA: Failure Mode, Effect, and Criticality Analysis in Process Industries

This assignment explores the methodology of Failure Mode, Effect, and Criticality Analysis (FMECA) and its applications in process industries. It covers the background, uses, types, and approaches to FMECA, as well as the main steps involved in conducting an FMECA study.

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FMECA: Failure Mode, Effect, and Criticality Analysis in Process Industries

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  1. SAFETY AND HEALTH IN PROCESS INDUSTRIES(MKKK1653)2015/2016 ASSIGNMENT Failure mode, effect and critical analysis (FMECA) By Yahya Gambo (MKK152006) SUBMITTED TO: Ir. Dr. ZAKI YAMANI

  2. PRESENTATION HIGHLIGHTS INTRODUCTION BACKGROUND USES OF FMECA FMECA AT GLANCE ITS TYPES APPROACHES TO FMECA MAIN STEPS INVOLVED

  3. INTRODUCTION • What is FMECA? • Failure modes, effects, and criticality analysis (FMECA) is a methodology to identify and analyze: • All potential failure modes of the various parts of a system • The effects these failures may have on the system • How to avoid the failures, and/or mitigate the effects of the failures on the system • FMECA is a technique to “resolve potential problems in a system before they occur” – SEMATECH (1992)

  4. Background • FMECA was developed by the U.S. Military in November 9, 1949 • FMECA is the most widely used reliability analysis technique in the initial stages of product/system development • Performed during the conceptual and initial design phases of the system in order to assure that all potential failure modes have been considered and the proper provisions have been made to eliminate these failures

  5. Uses of FMECA • Assist in selecting design alternatives with high reliability and high safety potential during the early design phases • Ensure that all conceivable failure modes and their effects o n operational success of the system have been considered • List potential failures and identify the severity of their effects • Develop early criteria for test planning and requirements for test equipment • Provide historical documentation for future reference to aid in analysis of field failures and consideration of design changes • Provide a basis for maintenance planning

  6. FMECA at glance FMECA can be summarized as follows:

  7. Types of FMECA • Design FMECA • Process FMECA • System FMECA

  8. Two approaches to FMECA • Bottom-up approach • The bottom-up approach is used when a system concept has been decided. Each component on the lowest level of indenture is studied one-by-one. The bottom-up approach is also called hardware approach. • Top-down approach • The top-down approach is mainly used in an early design phase before the whole system structure is decided. The analysis is usually function oriented. The analysis starts with the main system functions - and how these may fail

  9. FMECA main steps 1. FMECA prerequisites 2. System structure analysis 3. Failure analysis and preparation of FMECA worksheets 4. Team review 5. Corrective actions (Design changes, Engineered safety features, Safety devices, Warning devices & Procedures/training)

  10. THANK YOU ALL

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