Failure Mode Effect Research Articles

Optimizing Operations: Evaluating Overall Equipment Effectiveness (OEE) And Failure Mode Effect Analysis (FMEA) For Muratec Qpro Ex Winding Machines at PT XYZ

Optimizing Operations: Evaluating Overall Equipment Effectiveness (OEE) And Failure Mode Effect Analysis (FMEA) For Muratec Qpro Ex Winding Machines at PT XYZ

Evaluation of the performance and effect of steel fiber reinforced cellular concrete for underwater blast protection under contact explosion loading

The reinforced concrete structure is more likely to be destroyed under the action of underwater explosion load, which makes the overall structure have the risk of instability. The purpose of this paper is to study the underwater anti-explosion protection performance of steel fiber reinforced cellular concrete protective layer. The FEM-SPH coupling method was used to study the underwater damage process, dynamic response, failure mode and protection effect of the protected structure strengthened by eight different proportions of protective layers. The results show that the addition of steel fiber reinforced cellular concrete protective layer can effectively improve the anti-explosion performance of the protected structure, and its anti-explosion performance is directly related to the volume fraction of steel fiber in the protective layer. Under different ratio protection schemes, the total energy absorption and protection rate of the protective layer increase first and then decrease with the increase of the volume fraction of steel fiber in the protective layer, while the peak pressure of the protected structure at the measuring point and the failure volume rate of the whole structure decrease first and then increase. Among them, the underwater wave attenuation and energy consumption effect of SAP10S15 protective layer is the most prominent, and its total energy absorption is 20 % higher than that of other protective layers. Under this ratio protection scheme, the shock wave pressure of the protected structure is greatly attenuated, and the peak pressure of each measuring point is reduced by about 35.8 %, 37.9 %, 23.7 %, 27.9 % and 35.1 % respectively compared with the unprotected scheme. The damage degree of the protected structure under the SAP10S15 ratio protection scheme is significantly reduced. The failure volume rate and damage index are 8.03 % and 0.21, respectively, which are 37.7 % and 42.5 % lower than those of the unprotected scheme. The damage level is reduced from serious damage to moderate damage. In addition, the damage grade prediction curve of the protected structure is constructed, and the predicted value of the curve is in good agreement with the simulation results, which can provide a reference for the rapid evaluation of the underwater explosion-proof performance of the steel fiber reinforced cellular concrete protective layer.

A fault hierarchical propagation reliability improvement method for CNC machine tools based on spatiotemporal factors coupling

Clarifying the fault propagation mechanism is one of the key methods for improving the machine tool's reliability. However, current modeling methods usually overlook the impact of spatiotemporal coupling factors on fault propagation, leading to a limited understanding of the fault propagation mechanism. Therefore, this paper proposes a fault hierarchical propagation reliability improvement method based on spatiotemporal factors coupling. Considering the coupling effects of component comprehensive importance, fault tolerance, and failure modes on the machine tool system, a spatiotemporal fault hierarchical propagation topological directed graph model was established. Based on this, an improved method for calculating fault propagation strength was proposed to identify weak links and critical fault propagation paths. The proposed method effectively addresses the critical path identification problem across CNC machine tool systems. Comparison results demonstrate that the proposed method can accurately identify critical fault propagation paths. Furthermore, the influence of various factors on these path sequences is studied in this paper. It extends the traditional modeling methods and theories to enhance the transparency of the fault propagation process within the machine tool system. This work provides theoretical support for maintenance decision-making.

Optimization of Maintenance Strategies in an Oil and Gas Production Facility to Minimize Maintenance Cost

Abstract: In this study, maintenance strategies in an oil and gas production facility were optimized to minimize maintenance costs. The centrifugal pump system in Port Harcourt Refinery was selected for this study because it significantly impacts on the productivity of the refining plant. The pump system’s failure mode effects and criticality analysis (FMECA) were examined, and an optimized maintenance task was developed for the system. The exponential reliability method was employed to analyse the pump’s failure data to determine the pump systems' failure rate and reliability while reliability centred maintenance (RCM) and linear programming (LP) model were employed to optimize the pump’s maintenance strategies and the pump’s maintenance labour force respectively. Broad-based results of the optimized maintenance strategies consisted of on-condition-directed (CD) maintenance, preventive maintenance (PreM), and Proactive maintenance (ProM) strategies to be carried out monthly. The optimized maintenance labour force result revealed that approximately three engineers and two technicians should be employed for the pump’s maintenance task with a minimum of N2, 585, 700 as cost of salaries for the labour force monthly as against the current maintenance labour force requiring fourteen engineers and thirteen technicians monthly. The results showed that the labour cost decreased from N180,000,000 per year to N31,028,400 per year (approximately 82.76% reduction) using the proposed optimized maintenance task compared to the current maintenance plan. Conclusion and recommendation were made that the maintenance optimization technique presented in this work should be adopted by the oil and gas processing and production companies in order to minimize maintenance cost.

Application of Healthcare Failure Mode and Effect Analysis in the Management of Patients With Intrathecal Morphine Pump Implantation

BackgroundIntrathecal morphine pump helps alleviate pain in the advanced stages of cancer, and thus, ensuring safe intrathecal morphine pump infusion is important. In this study, we investigated the effect of healthcare failure mode and effects analysis (HFMEA) in the management of patients with intrathecal morphine pump implantation. MethodsWe included 112 cancer patients with severe pain who met the inclusion criteria for intrathecal morphine pump implantation treatment in the pain department of our hospital from November 2021 to October 2022. We analyzed the severity, likelihood, and crisis of potential failure modes, causes, and results of intrathecal morphine pumps during this period, compiled the records, and formulated the appropriate improvement measures based on the results of the analysis. From November 2022 to October 2023, the HFMEA model was applied to 125 patients in the department, and the effectiveness of the model was evaluated by assessing the patients’ VAS (visual analog scale) score, SAS (self-rating anxiety scale) score, SDS score, PSQI (Pittsburgh Sleep Quality Index) score and quality of life (QOL) (self-rating depression scale) score. ResultsThe occurrence of adverse events (6 cases vs. 2 cases, p < .05), and the total incidence of adverse events (8.9% vs. 1.6%, X2= 6.600, p = .010) was significantly different before and after HFMEA was applied. For patients who received intrathecal morphine pump implantation, the VAS scores and the related pain indices were significantly lower after HFMEA than before. Additionally, the score of SAS (48.91 ± 6.03 vs. 47.02 ± 6.77), PSQI (37.30 ± 5.78 vs. 39.63 ± 5.64), and QOL (9.93 ± 3.04 vs. 8.98 ± 2.31) of patients improved significantly. ConclusionsWith the application of the HFMEA model, a multidisciplinary team assessed the risks associated with the use of intrathecal morphine pumps and prioritized measures to reduce them. By implementing the improvement measures, potential errors decreased significantly during the intrathecal morphine pump process. It allowed nursing managers to change the safety incidents related to drug administration using an intrathecal morphine pump from negative treatment after the event to active prevention before the event, greatly improved the level of drug use safety management, reflected the continuous improvement of nursing quality, and ensured nursing safety.

Failure Mode Effects Analysis of Re-triage of Injured Patients to Receiving High-Level Illinois Trauma Centers.

This study identified failures in emergency inter-hospital transfer, or re-triage, at high-level trauma centers receiving severely injured patients. The re-triage process averages four hours despite the fact timely re-triage within two hours mitigates injury-associated mortality. Non-trauma and low-level trauma centers reported most critical failures were in finding an accepting high-level trauma center. Critical failures at high-level trauma centers have not been assessed. This was an observational cross-sectional study at nine high-level adult trauma centers and three high-level pediatric trauma centers. Failure Modes Effects Analysis (FMEA) of the re-triage process was conducted in four phases. Phase 1 purposively sampled trauma coordinators followed by snowball sampling of clinicians, operations, and leadership to ensure representative participation. Phase 2 mapped each re-triage step. Phase 3 identified failures at each step. Phase 4 scored each failure on impact, frequency, and safeguards for detection. Standardized rubrics were used in Phase 4 to rate each failure's impact (I), frequency (F), and safeguard for detection (S) to calculate their Risk Priority Number (RPN) (I x F x S). Failures were rank ordered for criticality. A total of 64 trauma coordinators, surgeons, emergency medicine physicians, nurses, operations and quality managers across twelve high-level trauma centers participated. There were 178failures identified at adult and pediatric high-level trauma centers. The most critical failures were: Insufficient trained transport staff (RPN=648); Issues transmitting imaging from sending to receiving centers (RPN=400); Incomplete exchange of clinical information(RPN=384). The most critical failures were limited transportation and incomplete exchange of clinical, radiological and arrival timing information. Further investigation of these failures that includes several regions is needed to determine the reproducibility of these findings.

Analisis Pemeliharaan Menggunakan Metode Reliability pada Sistem Gas Turbine Engine untuk Mengetahui Kinerja Engine Turbofan CFM56-3 pada Pesawat Boeing 737-500

In carrying out structured maintenance, a method is needed to increase the durability of an aircraft component, one of the methods used is the reliability method. The reliability of aircraft components is very necessary to ensure that each aircraft component is serviceable and runs according to its function in the aircraft system, so to increase the reliability of an aircraft component, the reliability method is very important to do. This study aims to determine the critical life time limit of the asset or system or equipment function and identify the failure mode that occurs in the Gas Turbine Engine component of the Boeing 737-500 aircraft because if this engine fails, it can result in flight delays and if not handled immediately can cause the aircraft to experience Aircraft on Ground (AOG) conditions, because it has the potential to disrupt airworthiness and threaten safety. This study uses exploratory research which aims to simplify problems to make them easier to solve. This study uses the Pareto diagram method to determine the highest type of failure in components, then analyzes it using the failure mode effect analysis (FMEA) method. Based on FMECA and FTA analysis, there are 3 failure modes, the failure modes include mechanical system (Bleed Valve), pneumatic system (Butterfly Shaft), electrical system (actuator). The failure was due to the occurrence of the top event part consumable, namely the bleed valve part with an RPN value of 192, followed by the butterfly shaft part with an RPN value of 75 and the Actuator part with an RPN value of 72. The pneumatic system and electrical system categories are prioritized to carry out preventive maintenance, which means it is a solution from industry players in an effort to maximize maintenance of the turbofan engine system accompanied by technical or economic analysis to ensure a system in extending the service life of parts in the aircraft system.

Risk Management in Production using Quality Risk Approach and FMEA

Abstract: The production process of 600ml AQUA at PT Tirta Investama (AQUA) Pandaan faces significant risks, including non-compliance with standards in bottle density, incorrect packaging labels, unreadable bottle codes, box failures, and barcode rework. These issues pose challenges in maintaining product quality and operational efficiency. Specific Background: With 247 bottles failing density standards and 18 packaging errors occurring daily, effective risk management is crucial. Knowledge Gap: Previous studies have not integrated Quality Risk Management (QRM) and Failure Mode Effect and Criticality Analysis (FMECA) to address production risks in the context of AQUA's operations. Aims: This study aims to identify the highest critical risk points and propose mitigation strategies. Results: Utilizing QRM and FMECA, 42 risks were identified, categorized into 20 acceptable, 21 tolerable, and 1 unacceptable risk, specifically related to pallets stuck on conveyors due to substandard quality. Novelty: The application of these integrated methodologies provides a systematic approach to identifying and mitigating risks in the production process, highlighting the necessity for in-depth inspections by logistics and machine operators. Implications: The findings underscore the importance of rigorous quality control and proactive risk management in manufacturing to enhance product quality and minimize operational disruptions, thus ensuring customer satisfaction and competitiveness in the market. Highlights: Effective risk management is crucial to ensure product quality and operational efficiency. Integration of QRM and FMECA identifies critical risk points in the production process. Regular inspections and quality control can significantly reduce unacceptable risks. Keywords: Risk Management, Production Process, QRM, FMECA, AQUA

Zero Produced Water Discharge Innovation in Production Fluid Management for Sustainability and Financial Efficiency

This paper will present the sustainability initiatives of PHI Tanjung Field obtained from the evaluation of existing oil and gas production activities. Through the Plan-Do-Check Action (PDCA) approach, based on the results of life cycle assessment and focus group discussions from managers and engineers in Tanjung Field, the identification of priority problems is related to the management of production fluid generated from outside the existing production facility process. Through a fishbone diagram approach to find out the root of the problem followed by Failure Mode Effect Analysis (FMEA) including Pareto diagrams and risk map analysis to get priority risk problems in the form of production fluid processing methods. Furthermore, through the Analytic Hierarchy Process (AHP) approach, the alternative solution taken is to modify the production fluid processing with CSSR (Contain, Sediment, Separate, Recovery) innovation. The results of this CSSR innovation are no more produced water is discharged into the environment so that the Tanjung Field Manager’s policy of moving towards zero produced water discharge is achieved. With this innovation, the processing efficiency of the production fluid in 2nd year (prediction) after innovation is 97.5%, up from 66.6% in initial year before innovation. By optimizing the use of produced water, the need for clean water for the injection program can be minimized. The reduction of clean water usage from Initial year to 2nd year (prediction) is 83.1%. The efficiency ratio of this innovation is 11.10 &gt; 1 indicates that the program generates more savings and revenue than its cost, making it a worthwhile investment. In energy reduction, the effectiveness of this innovation from Initial year to 2nd year (prediction) is reducing energy by 94.96%. In emission reduction, the reduction of CO2 emission load from Initial year to 2nd year (prediction) is 95%. This innovation contributes to the 6th Sustainable Development Goal (SDGs) “Clean Water and Sanitation,” the 7th SDGs “Clean and Affordable Energy,” the 12th SDGs “Responsible Consumption and Production,” 13th SDGs “Handling Climate Change,” and the 14th SDGs “Ocean Ecosystems.”

A New Method of Failure Mode and Severity Effects Analysis for Hydrogen-Fueled Combustion Systems

A New Method of Failure Mode and Severity Effects Analysis for Hydrogen-Fueled Combustion Systems

Preventive Maintenance Planning for Machines Computer Numerical Control (CNC) Type Hurco Vmx24 to Improve Reliability Using the Reability Centered Maintenance (RCM) Method (Case Study)

Abstract: This paper presents the results of the analysis of Computer Numerical Control (CNC) machine components that result in decreased machine efficiency in the production system with the Reliability Centered Maintenance (RCM) approach. Utilized to improve the performance of machine components. The machine has not been maintained regularly so that at any time the machine can experience damage which results in losses to the company's income. so that an analysis is designed for maintenance planning management activities with the methodology of identifying and analyzing failure factors using the Failure Mode Effect Analysis (FMECA) worksheet, Logic Tree Analysis (LTA), and finally the Action Road Map. The results of the analysis carried out are divided into three categories of maintenance actions, namely, Condition Direction (CD) maintenance, Time Directed (TD) maintenance, Finding Failure (FF) maintenance with a periodic checking interval of 2 times within a period of 12 days.

Cross-contamination Risk Assessment using FMEA tool

In pharmaceutical manufacturing facilities, products with different therapeutic properties and potencies are manufactured in shared spaces, which poses a potential risk for cross-contamination. During the manufacturing process, cross-contamination may occur due to the uncontrolled release of dust, gases/vapors, mix-ups with other materials, residues on equipment, and contamination from operator’s clothing. By implementing adequate facility design and manufacturing operations aligned with Quality Risk Management principles, the risk of cross-contamination can be controlled. If a shared facility is used for manufacturing pharmaceutical products, strategic controls for identifying and managing the risks of cross-contamination should be in place. This article provides a structured and systematic framework for the risk-based identification of the worst-case product and manufacturing process among the products manufactured in the solid oral facility, addressing the high risk of cross-contamination. Keywords: Cross-contamination, Contamination, Risk Assessment, Formal risk assessment, Quality Risk Management (QRM), Failure Mode Effect Analysis (FMEA), Oral Solid Dosage (OSD), Worst case, Contamination Control Strategies (CCS)

Analyse de risques appliquée au suivi des concentrations des immunosuppresseurs chez les patients transplantés pulmonaire

Mastering and monitoring immunosuppressant concentrations is central to the care of lung transplant patients and involves multiple stakeholders. The objective is to conduct a risk analysis to evaluate the impact of various actions taken. The lung transplantation team was convened to carry out a failure mode effect analysis. The process was divided into stages where different risks were identified. The risk priority number (RPN) (severity, frequency, detectability) and risk level of criticality (frequency, severity) were established before implementation of actions (before 2009) and then after (in 2022) to classify risks according to four levels of criticality. The implemented actions included the establishment of a quality assurance process, computerization of monitoring, and double analysis by a physician/pharmacist pair. Thirty-two risks were identified during the four stages of the process: biological sampling (n=13), reception (n=3), analysis and treatment of levels (n=5), transmission of information/prescriptions to the patient (n=11). The total raw RPN (before 2009) was 839, with 12 major risks. The current total RPN (in 2022) was 452 (a decrease of 46.1%), with 7 major risks identified. The analysis enabled the objective evaluation of the effectiveness of the actions taken. The most secure stage of the process is the reception of residual level results. Efforts should focus on empowering and involving patients, as well as engaging local stakeholders in collaboration with the specialized transplantation team.

Maintenance Resources Optimization Using Pareto Analysis

Managing resource allocation for optimum effectiveness at various levels of maintenance activities is always a challenging task. Optimizing maintenance resources enables an organization to set priorities towards achieving certain goals which are availability and reliability of the equipment for operational excellence. The purpose of this analysis is to determine the optimum resources allocation proportions among the failure modes and to identify the failure modes that have the greatest cumulative effect on the equipment's downtime. This paper presents a methodology using the Pareto analysis in conjunction with failure mode effect and criticality Analysis in maintenance resources optimization. The approach is based on ensuring all failure mode criticality number are considered to obtain the significant failures mode that you should focus on as a priority. The analysis shows that failure mode; FM5, FM 3, FM 2, FM 12, FM 7 and FM 13 are confirmation to the Pareto principle, identifying that most of the downtime of the Instrumentation Air Compressors originated from these failure modes.

Eliminating Production Process Waste with Lean Six Sigma in the Gresik Ceramic Industry

The Gresik Ceramic Industry is a company operating in the ceramic industry. In the ceramic production area at PT XYZ, waste is still found, namely waste defects, safety health environment (SHE), excess processing. and motion. This research aims to identify and reduce waste in the ceramic production process using the Lean six sigma (LSS) method and Failure Mode Effect and Analysis (FMEA) as proposed recommendations for improvement. Lean six sigma uses 5 stages, namely define, measure, analyze, improve, control. However, research is carried out to the improvement stage to provide recommendations for improvement. The results of reducing the lead time value in the ceramic production process, which was originally 1880 minutes, changed to 1816 minutes or decreased by 64 minutes, thereby reducing the cycle time in the ceramic production process. Then the DPMO value obtained was13311 with a sigma level of 3.71. The research results show that crack defects have the highest RPN value of 576 with the cause being that the punches on the press machine have reached their useful life, causing the printing process to be less than perfect. The proposed recommendation for improvement is replacing the punches components on the press machine

Integrated Application of Risk Management Techniques in Developing an Analysis Method for Traditional Chinese Medicine: A Case Study of a Percolation Solution for Xiaochaihu Capsules

Risk management should run through the entire process of method development, utilization, and maintenance. Based on the analytical quality by design (AQbD) concept, various integrated risk management techniques were used in this study to develop an analysis method for the percolation solution of Xiaochaihu capsules. During the development of the analysis method, risk assessment was conducted using an Ishikawa diagram and failure mode effects analysis, followed by method optimization using experimental design. The probability of nonconformance calculated via an exhaustive Monte Carlo method quantitatively characterized the risk magnitude of method parameter failures, leading to the establishment of a operable design region method based on risk magnitude. Validation experiments and robustness tests of the data were utilized for model refinement and initial risk review. Methodological validation of the developed method was performed, and control strategies for the analysis method were presented through a decision tree. Stability experiments demonstrated that the samples remained stable at 4 °C for 24 h. The average recovery rate fell between 98.8% and 105%, with relative standard deviations ranging from 2.73% to 4.48%. The results showed that the established analysis method exhibited robustness. This analysis method can simultaneously determine the contents of uridine, adenine, 5-hydroxymethylfurfural, and guanosine. This method can also be employed for process control during percolation. This study integrated various risk management techniques to develop and maintain the analysis method, and this approach can potentially be extended to other analytical methods.

Identification of Intra and Inter Subsystems Failure Propagation Path for Incorporation of Preventive Measures in A Spacecraft - A Case Study

All failure modes down to individual part level needs to be addressed for a space system as there is a great deal of concern not only with the probability of failure of parts but also with the potential consequences of different modes of failure. It is more so in space related systems as they are non repairable after launch. Towards this, Failure mode effects analysis needs to be carried out at system level for a spacecraft to identify intra and inter subsystems failure propagation paths to incorporate preventive measures in the design. A case study on interplanetary mission is provided in this paper to explain the significance and necessity of system level failure mode effects analysis. This paper critically addressed the effects of a failure on built-in autonomy and fault tolerant design of interplanetary mission considered for the case study.

Failure Mode Effect Analysis (FMEA) At Good Manufacturing Practice (GMP) of Nata De Coco

Failure Mode Effect Analysis (FMEA) At Good Manufacturing Practice (GMP) of Nata De Coco

Risk Assessment Framework for Reverse Logistics in Waste Plastic Recycle Industry: A Hybrid Approach Incorporating FMEA Decision Model with AHP-LOPCOW- ARAS Under Trapezoidal Fuzzy Set

In this study, a novel risk assessment framework designed for evaluating the challenges of plastic packaging waste management in the context of reverse logistics is introduced. The framework leverages Failure Mode Effect Analysis (FMEA) to address decision-making in a fuzzy environment. To augment the traditional FMEA risk criteria, encompassing severity (S), occurrence (O), and detection (D), three additional essential risk criteria are introduced: cost of failure (C), complexity of failure resolution (H), and impact on business (I). These newly incorporated criteria significantly enhance the capacity to convey the multifaceted risks inherent in reverse logistics for the plastic recycling sector. Furthermore, a comprehensive literature review and expert validation are conducted to identify ten distinct failure modes. To subjectively and objectively determine the risk criteria weightings, a combination of Analytic Hierarchy Process (AHP) and LOgarithmic Percentage Change-driven Objective Weighting (LOPCOW) is employed. Finally, the Additive Ratio Assessment (ARAS) approach is applied to prioritize such failure modes. Recognizing the inherent imprecision and uncertainty associated with human decision-making, the trapezoidal fuzzy set (TrFS) is adopted throughout all decision-making processes. To showcase the proposed framework effectiveness, the framework is applied as a case study to a waste plastic recycling manufacturer in Thailand.

Integrasi Statistical Quality Control dan Failure Mode and Effect Analysis Dalam Menganalisis Defect Pada Proses Produksi

One of the companies that make tools for printing at one of the printing companies in Jakarta has a product in the form of Offset Roller Printing, where Offset Roller Printing is a mainstay product with the highest sales. The company promises a declining trend in the rejection rate in 2024, with the rejection rate not exceeding 2%. For that, an analysis of the cause of the problem will be carried out until a repair proposal is obtained by using an integrated method which is Statistical Quality Control (SQC) with Failure Mode Effect Analysis (FMEA). Based on the check sheet, it shows the total production in January - December 2023 of 5699. On the overall operational map, there is no point that is outside the upper or lower operational limits. From the results of the FMEA analysis, it can be seen that the highest RPN is the cover for the method factor with the first priority having an RPN value of 252 which means that the vulcanization temperature is not reached or the temperature of the maturity point is not reached. unable to. There is a need to renew the vulcanization recipe so that the rubber matures perfectly and avoids the occurrence of oblong or closed defects. In addition, improvement proposals as a form of evaluation results are given related to the operator's attention factor, operator's skill, various types of materials, working environment temperature, no machine control, comfortable work environment, hostap plastic setting.