FMECA

Introduction

Failure Modes, Effects, and Criticality Analysis (FMECA) is a systematic technique designed to identify and evaluate potential failures and failure modes in complex assets, and to determine the probability and consequences of those failures. This allows for the creation and adjustment of maintenance strategies to minimize such failures.

A Criticality Matrix is used with FMECA to assess and prioritize potential failure modes based on their severity, occurrence, and detectability.

This process helps achieve the business goals associated with Asset Performance Management (APM), enabling the prioritization and delivery of maintenance actions to increase asset availability and reliability.

FMECA Process

Including defining Basic Data, the main functionalities of FMECA are to Initiate FMECA, Prepare FMECA, Publish FMECA, Apply FMECA, and View and Manage FMECA Analysis results.

The main functionalities of FMECA include:

Define Basic Data & Master Data

The following basic data and master data are prerequisites for performing FMECA:

Basic Data

Item Classes: A general equipment classification, e.g., a Crane.
Process Classes: Contexts for item placement, either geographical (e.g., Artic, Tropic) or system-based (e.g., Control System).
Failing Components: Subparts of an Item Class, e.g., a Trolley motor within a Crane.
Failure Modes: Description of a specific way an asset might fail, e.g., Reduced trolley speed.
Symptoms: Indicators associated with failure modes, e.g., Audible differences in motor operation, such as unusual noises or changes in pitch, Load takes longer to reach the specified distance.
Causes: The root reason or factor that leads to a failure mode, e.g., Material fatigue.
FMECA Decisions: Actions derived for FMECA analysis to mitigate or address failure modes, e.g., Implementing Corrective Maintenance, Switching to Run to Failure.
Criticality Matrix Standards: Defined by a set of categories of criticality ratings (Severity, Probability Detectability), for instance related to:
- Personnel Injury
- Environmental Spill
- Equipment/Material Damages
- Production Losses

Master Data

Equipment Objects: Registered as either Functional or Serial Objects, these can form structures (e.g., Sites, Locations, Machines).
Work Task Templates (WTT): Templates for work tasks, centralized but adaptable for specific sites, connected to an Item Class category.
PM Programs: A collection of work task templates that outline how a specific type of equipment is maintained. PM programs enable the reuse of preventive maintenance information when creating new PM actions, ensuring consistency and efficiency.

Initiate FMECA: Define Item Class, Process Class, and Criticality Matrix (CM) standards against which the FMECA should be performed. Apply revision control to the analysis to ensure the correct analysis with the correct combinations is used.

Prepare FMECA: Identify the facilitator for the FMECA and determine the status of the analysis within its lifecycle. Define the Functions, Functional Failures, and Failure Modes. Describe the effects of these failure or degradation modes and combine them with affected components. Apply the values of the modes to a risk matrix and identify the appropriate maintenance decision according to the failure or degradation mode for the combination of item class and process class.

Publish FMECA: Summarize the results of the analysis to determine an overall maintenance strategy for the combination of Item Class and Process Class. Activate and make the latest version of the analysis available for application.

Apply FMECA: Apply the FMECA results to individual objects, leading to the creation of new Preventive Maintenance (PM) actions and Corrective Actions as needed. Additionally, update PM Programs accordingly.

View and Manage FMECA Analysis Results: Provide summarized results from the FMECA on the assets and a lobby page to support and evaluate the FMECA process.

FMECA

Introduction

FMECA Process

Pages

Activity Diagrams