Case Study of Expected Loss Failure Mode and Effect Analysis Model Based on Maintenance Data

Seungsik Min,Hyeonae Jang

doi:10.3390/app11167349

Seungsik Min, Hyeonae Jang

Open Access

https://doi.org/10.3390/app11167349

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Journal: Applied Sciences	Publication Date: Aug 10, 2021
Citations: 1	License type: CC BY 4.0

Affiliation: Korea Naval Academy, Jeonju University

Abstract

Failure mode and effect analysis (FMEA) is one of the most widely employed pre-evaluation techniques to avoid risks during the product design and manufacturing phases. Risk priority number (RPN), a risk assessment indicator used in FMEA, is widely used in the field due to its simple calculation process, but its limitations as an absolute risk assessment indicator have been pointed out. There has also been criticism of the unstructured nature and lack of systematicity in the FMEA procedures. This work proposes an expected loss-FMEA (EL-FMEA) model that organizes FMEA procedures and structures quantitative risk assessment metrics. In the EL-FMEA model, collectible maintenance record data is defined and based on this, the failure rate of components and systems and downtime and uptime of the system are calculated. Moreover, based on these calculated values, the expected economic loss is computed considering the failure detection time. It also provides an alternative coefficient to evaluate whether or not a detection system is installed to improve the expected loss of failure. Finally, a case study was conducted based on the maintenance record data, and the application procedure of the EL-FMEA model was presented in detail, and the practicality of this model was verified through the results.

Highlights

Failure mode and effect analysis (FMEA) is an efficient qualitative analysis method adopted in safety system engineering
This section explains in detail variables and calculation processes that can quantitatively perform risk evaluation based on the expected loss-FMEA (EL-FMEA) model
The prerequisite data is defined as a variable necessary for calculating the expected loss based on the maintenance record data that can be collected in the industrial field

Summary

Introduction

FMEA is an efficient qualitative analysis method adopted in safety system engineering. The failure modes, failure effects, potential accidents, and the consequence of accidents can be systematically identified and evaluated by using the powerful tool [1]. The results of the FMEA can help analysts identify and correct the failure modes that have a detrimental effect on the system and improve its performance during the design and production stages [2]. Since its introduction as a methodology for preventing failures, FMEA has been broadly used in various industries, including the aerospace, automotive, semiconductor, aircraft, chemical plant, and steel industries [1,3,4,5,6,7,8]

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