1. FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA) Module 4 UNIT II RCM PROCESS " Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

2. Introduction Module Preview: FMECA IntroductionIntroduction References References FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA) Review and Summary

3. Module Objective: IntroductionIntroduction 1. Introduce the concept of Failure Mode, Effects, and Criticality Analysis (FMECA). 2. Define the following FMECA terms: Function Function Functional Failure Functional Failure Failure Mode Failure Mode Failure Effect Failure Effect Failure Detection Failure Detection Severity Classification Severity Classification Mean Time Between Failure (MTBF) Mean Time Between Failure (MTBF) 3. Identify FMECA reference materials FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

4. 1. Identify Team and responsibilities 4. Identify and document Review Process 2. Identify analysis items 5. Orientation/Training 3. Prioritize Items 6. Ground Rules and Assumptions PLANNING AND PREPARATION ANALYSIS RCM Process Analysis Approac h/ RCM Plan Analysis MaintenanceRequirementsMaintenanceRequirements MaintenanceProgramMaintenanceProgram DataData 1.Equipment Kick-off Meeting 2.Initial Data Gathering 3.Hardware Partition 4.Function 5.Functional Failure 6.Failure Mode 7.Failure Effects 8.Failure Consequences 9.Task Evaluation 10.Task Selection 1.Package Maintenance Task 2.Implement Other Actions Results IMPLEMENT RESULTS 1.Emergent Issues 2.Age Exploration 3.Hardware Changes 4.Trend/degrader analysis 5.Document Reviews SUSTAIN FMECAFMECA FMECA

5. FMECA Definition: Process used to determine the functions, functional failures, and failure modes of equipment; and the associated effects, severity, and frequency of each failure modes: Steps involve identifying... Functions Functions Functional Failures Functional Failures Failure Modes Failure Modes Failure Effects Failure Effects Severity of Failure effects Severity of Failure effects Frequency of occurrence Frequency of occurrence … as they apply to the equipment under analysis in its operating context FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

6. FMECA Terms: Hydraulic Pump Assembly FUNCTION What the user expects the asset or system to do within a required standard of performance. Provides hydraulic fluid at a pressure of 3000 psi +/- 200 psi FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

7.  Consider all functions of an item  Describe functions in terms of specific limits when possible  State functions in terms of what the item is needed for, not its capability  Do not combine functions Function descriptions should include a verb, object, and applicable limits Function descriptions should include a verb, object, and applicable limits Identifying Functions Identifying Functions: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

8. All equipment has primary and secondary functions FMECA for RCM analysis should identify ALL primary AND secondary functions. Typical Secondary Functions:  Control  Warning or status indication  Environmental protection  Physical support or attachment  Safety or protective functions  Fluid Containment  Comfort and Aesthetics Identifying Functions: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

9. Identifying Functions: FMECAFMECA Function sources:  Maintenance Manual description/theory of operation  Operating Manuals  Other tech data providing system descriptions Common Errors:  Missing secondary functions  Listing functions of lower level hardware items items FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

10. NAVAIR 00-25-403 RCM adds a categorization process to function identification called “significant function identification” Intended to: Intended to: 1)eliminate analysis of inconsequential functions 2)Ensure all significant functions are identified Not technically part of the FMECA process Not technically part of the FMECA process Identifying Functions: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

11. A SIGNIFICANT FUNCTION is one whose failure will have adverse effect on the end item with respect to: Safety Safety Environmental Health Environmental Health Operations Operations Economics Economics Identifying Functions: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

12. SIGNIFICANT FUNCTION (SF) IDENTFCATION FUNCTION SIGNIFICANTFUNCTIONNON-SIGNIFICANTFUNCTION YES YES YES YES NO NO NO NO DOES THE LOSS OF FUNCTION HAVE AN ADVERSE EFFECT ON SAFETY OR ENVIRONMENT? DOES THE LOSS OF FUNCTION HAVE AN ADVERSE EFFECT ON OPERATIONS? DOES THE LOSS OF FUNCTION HAVE AN ADVERSE ECONOMIC IMPACT? IS THE FUNCTION PROTECTED BY AN EXISTING PM TASK? FUNCTION 5 Fly-ins

13. Class Exercise FMECAFMECA Objective: List the functions of a Coffee Maker Identifying Functions: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

14. Function Exercise: 3 Fly Ins HOT PLATE SUBSYSTEM 1B4 PWR SWITCH SUBSYSTEM 1B1 CLOCK PROGRAMMER SUBSYSTEM 1B2 WATER HEATING SUBSYSTEM 1B3 FILTRATION SUBSYSTEM 1A2 CARAFE SUBSYSTEM 1A3 WATER RESERVOIR SUBSYSTEM 1A1 COFFEE MAKER 1 ELECTRICAL SYSTEM 1B BREWING SYSTEM 1A Analyze at this level Analyze at this level

15. Remember Secondary Functions:  Control  Warning or status indication  Environmental protection  Physical support or attachment  Safety or protective functions  Fluid Containment  Comfort and Aesthetics Function Exercise:

16. Coffee Maker Functions 1.Brew 1 to 12 cups of coffee 2.Maintain coffee at 120°f  5°f 3. Automatically start brewing process within 15 minutes of time specified by user 4. Automatically shut down coffee maker 4 hours after brew cycle is completed 5. Contain coffee in carafe 6. Contain 1 carafe of water in reservoir 7. Provides safe handling of hot coffee FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

17. FMECA Terms: Fails to provide hydraulic fluid at a pressure of 3000 psi +/- 200 psi Hydraulic Pump Assembly FUNCTIONAL FAILURE The inability of an item to perform a specific function within specified limits. FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

18.  Note that functional failure may not be a complete loss of the function  Separate functional failures should be listed where the effects of less than total loss of the function are different from total loss  Ensure functional failure addresses the function as defined  Common Errors: - Confusion with failure modes of hardware - Confusion with potential failures Identifying Functional Failures: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

19. Identifying FMECA Terms: FMECAFMECA Class Exercise Objective: Identify and list the coffee maker’s Functional Failures FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

20. FUNCTION 1 – Brew 1 to 12 cups of coffee FUNCTIONAL FAILURE A - Fails to brew coffee FUNCTION 2 - Maintain coffee temperature at 120°f  5° f FUNCTIONAL FAILURE A – Doesn't keep coffee warm(< 100°f) FUNCTIONAL FAILURE B – Heats Coffee too hot (>125° f) FUNCTIONAL FAILURE C – Partial warm coffee (>100 °f but 100 °f but < than 115°f) Coffee Maker Functional Failures FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

21. FUNCTION 3 - Automatically brew coffee within 15 minutes of time specified by user FUNCTIONAL FAILURE A - Does not brew coffee at all FUNCTIONAL FAILURE B - Brews coffee more than 15 minutes earlier than specified FUNCTIONAL FAILURE C - Brews coffee more than 15 minutes after time specified by user Coffee Maker Functional Failures FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

22. FMECA Terms: FAILURE MODE A specific physical condition that causes a particular functional failure. Scored Bearing Worn Impeller Bent Linkage FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

23.  When possible list failure cause or mechanism, ex. “cracked spar due to fatigue”  List all failure modes that are “reasonable”.  Be as descriptive as possible  Do not combine failure modes where failure effects, rates, or possible failure management solutions may be different  Methods to identify “significant” failures vary by project. FMECAFMECA Identifying Failure Modes: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

24. Failure mode sources:  Existing PM Tasks  Operating/Maintenance Manuals  Operator/Maintainer Input  Prior FMECA, RCM or other analyses  Failure Databases (Age Exploration)  Engineer/SME input  3M/CMMS data*** FMECAFMECA Identifying Failure Modes: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

25. Common Errors:  Over dependence on CMMS or other “non- specific” failure data  Lack of specificity in the failure mechanism, (“broken”) or of the failed part/location  Worrying about identifying all failures vice the “important ones”  Confusing potential failures (e.g. “cracks”), induced damage, or secondary damage from failure causes  Failure to apply common sense or analyst/SME knowledge to data FMECAFMECA Identifying Failure Modes: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

26. FMECA Terms: SYSTEM1ASYSTEM1C GEAR BOX 1B3B SUBSYSTEM 1B2 1B2 SUBSYSTEM1B4SUBSYSTEM1B1 MOTOR1B3A PRESSURE REG 1B3E SUB-ASSY ITEM UNDER ANALYSIS NEXT HIGHER END ITEMHYDRAULIC SYSTEM 1B AIRCRAFT1 HYD PUMP 1B3D CENT PUMP 1B3C Impeller worn (FM) FMECAFMECA FAILURE EFFECT The result of a failure mode and it’s functional failure on surrounding items, the functional capability of the end item, and hazards to personnel and environment. HYD PUMP ASSY 1B3 FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

27. When listing effects:  List most severe effects  Should be reasonable  Qualify less likely effects with terms such as “possible” or “potential”  Include restorative actions, as appropriate  Consider compensating provisions  Effects should be identified at point of functional failure FMECAFMECA Identifying Failure Effects: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

28. FMECAFMECA Identifying Failure Effects: When properly identified:  Makes the rest of the analysis much easier  Effects must address functional failure but should also consider secondary damage  Hidden failures must assume the condition that makes them evident has occurred  Effects must be clearly related to operational scenarios FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

29. Pay attention to level of effects:  Local: effect on the failed part: “Loss of Impeller effectiveness.”  Next higher: effect on the function of the system/subsystem being analyzed, often synonymous with functional failure: “Loss of Hydraulic Sys #1 pressure.”  End: what the failure means to the asset: “Loss of mission.” FMECAFMECA Identifying Failure Effects: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

30. Sources: Operating Manuals Operating Manuals Maintenance Manuals Maintenance Manuals Operator/maintainer/engineer input Operator/maintainer/engineer input Troubleshooting charts Troubleshooting charts SME/Analyst knowledge SME/Analyst knowledge Accident/Incident/Hazard reports Accident/Incident/Hazard reports Failure/Engineering Investigations Failure/Engineering Investigations Test reports Test reports FMECAFMECA Failure Effects Sources: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

31. FMECAFMECA Failure Effects Errors Common errors: Common errors: Assuming PM in place Assuming PM in place Incorrect levels Incorrect levels Ignoring secondary damage Ignoring secondary damage Improper treatment of hidden failures Improper treatment of hidden failures FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

32. Identifying FMECA Terms: FMECAFMECA Class Exercise Objective: Identify and list the Coffee Maker’s Failure Modes Failure Modes Failure Effects Failure Effects Extra Credit Describe how operating context impacts failure effects (Residential vs Commercial Use) Describe how operating context impacts failure effects (Residential vs Commercial Use) Failure Modes/Effects next... FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

33. FUNCTION 1- Brew 1 to 12 cups of coffee FUNCTIONAL FAILURE A – Fails to brew coffee FAILURE MODE 1 - Clogged heating chamber tubing due to excessive calcium build-up. FAILURE EFFECT - No coffee FAILURE MODE 2 - Shorted wiring due to frayed insulation. FAILURE EFFECT - Possible fire FAILURE MODE 3 - Open On/Off switch due to corrosion. FAILURE EFFECT - No coffee Coffee Maker Failure Modes and Effects FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

34. FUNCTION 2 - Maintain coffee temperature at 120°f  5°f. FUNCTIONAL FAILURE A - Fails to heat coffee (< 100°f) FUNCTIONAL FAILURE A - Fails to heat coffee (< 100°f) FAILURE MODE 1 – Broken power supply wire to heating element connection. FAILURE EFFECT - Cold coffee FAILURE EFFECT - Cold coffee FAILURE MODE 2 – Heating plate thermostat internal failure. FAILURE MODE 2 – Heating plate thermostat internal failure. FAILURE EFFECT - Cold coffee FAILURE EFFECT - Cold coffee FUNCTIONAL FAILURE B- Heats coffee to hot (>125° f) FUNCTIONAL FAILURE B - Heats coffee to hot (>125° f) FAILURE MODE 1 – Corroded heating plate thermostat. FAILURE EFFECT - Possible damage to coffee maker. Possible fire. FAILURE EFFECT - Possible damage to coffee maker. Possible fire. Coffee Maker Failure Modes and Effects FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

35. FUNCTION 2 - Maintain coffee at 120°f  5°f. (continued) FUNCTION 2 - Maintain coffee at 120°f  5°f. (continued) FUNCTIONAL FAILURE C - Partially warm coffee (>100°f but 100°f but < than 115°f) FAILURE MODE 1 - Corroded heating plate thermostat. FAILURE MODE 1 - Corroded heating plate thermostat. FAILURE EFFECT – Lukewarm coffee FAILURE EFFECT – Lukewarm coffee Coffee Maker Failure Modes and Effects FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

36. FUNCTION 3 - Automatically brew coffee within 15 minutes of time specified by user FUNCTIONAL FAILURE A - Does not brew coffee at all FAILURE MODE 1 - Inoperative Clock due to internal failure FAILURE EFFECT - No coffee FUNCTIONAL FAILURE B - Brews coffee more than 15 minutes earlier than specified FAILURE MODE 1 - Clock operation too fast due to internal failure FAILURE EFFECT - Old, bitter coffee Coffee Maker Failure Modes and Effects FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

37. FUNCTION 3 - Automatically brew coffee within 15 minutes of time specified by user FUNCTIONAL FAILURE C - Brews coffee more than 15 minutes after time specified by user FAILURE MODE 1 - Slow clock operation due to internal failure FAILURE EFFECT - No coffee until more than 15 minutes after time specified Coffee Maker Failure Modes and Effects FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

38. A note on “human error” failure modes: RCM may be used to address human error… Example: “Operator forgot to add water to coffee pot” Solution: “Post checklist by coffee pot” However… Care should be taken not to overcompensate for human error where other processes (human factors engineering) or common sense should preside FMECAFMECA Identifying Failure Modes: FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

39. FMECA Terms: FAILURE DETECTION Describes method(s) by which functional failures are detected and failure modes are identified. Failure Detection Visual alarms Visual alarms Audible alarms Audible alarms Gauges/Indicators Gauges/Indicators Operating characteristics Operating characteristics Identifying Failure Modes Voltage checks Voltage checks Continuity checks Continuity checks Visual inspections Visual inspections PHM systems PHM systems FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

40. FMECAFMECA Failure Detection  Address both operator and maintainer For operator: detection of FUNCTIONAL FAILURE (or effects) For operator: detection of FUNCTIONAL FAILURE (or effects) For maintainer: detection of FAILURE MODE For maintainer: detection of FAILURE MODE FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

41. FMECAFMECA Failure Detection Sources:  Operator/maintainer interviews  Maintenance/Operator’s Manuals  Troubleshooting charts  Accident/Incident/Hazard reports  Failure/Engineering Investigations  Test reports Common Errors:  Not addressing both operator and maintainer  Listing specific PM FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

42. FMECA Terms: SEVERITY CLASSIFICATION A category assigned to a failure mode based on the impacts if its potential effects. Categories are defined by the organization performing the analysis Categories for the same failure mode may be different in different operating phases or scenarios FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

43. SEVERITY CATEGORY Category ICatastrophic Aircraft example: “Death, Permanent Disability, destruction of equipment/system, damage in excess of $1M, significant breach of environmental regulation. Aircraft example: “Death, Permanent Disability, destruction of equipment/system, damage in excess of $1M, significant breach of environmental regulation. Critical equipment example: “Death, Permanent Disability, destruction of equipment/system,damage in excess of $1M, significant breach of environmental regulation, Down-time > 2 days Critical equipment example: “Death, Permanent Disability, destruction of equipment/system, damage in excess of $1M, significant breach of environmental regulation, Down-time > 2 days FMECA Terms: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

44. SEVERITY CATEGORY Category ICatastrophic Category IICritical Aircraft example: “Personal Injury, Damage more than $100K but less than $1M, Inability to perform a critical mission” Aircraft example: “Personal Injury, Damage more than $100K but less than $1M, Inability to perform a critical mission” Critical equipment example: “Personal Injury, Damage more than $100K but less than $1M, Down- time more than 24 hours but less than two days” Critical equipment example: “Personal Injury, Damage more than $100K but less than $1M, Down- time more than 24 hours but less than two days” FMECA Terms: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

45. Aircraft example: “Damage more than $1K but less than $100K, Degraded ability to perform a critical mission” Aircraft example: “Damage more than $1K but less than $100K, Degraded ability to perform a critical mission” Critical Equipment example: “Damage more than $1K but less than $100K, Down-time more than 8 hours but less than 24 hours” Critical Equipment example: “Damage more than $1K but less than $100K, Down-time more than 8 hours but less than 24 hours” SEVERITY CATEGORY Category ICatastrophic Category IICritical Category IIIMarginal FMECA Terms: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

46. SEVERITY CATEGORY Aircraft example: “Damage less than $1K, Unscheduled Maintenance or Repair” Aircraft example: “Damage less than $1K, Unscheduled Maintenance or Repair” Equipment example: “Damage less than $1K, Down-time less than 8 hours” Equipment example: “Damage less than $1K, Down-time less than 8 hours” Category ICatastrophic Category IICritical Category III Marginal Category IV Minor FMECA Terms: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

47. FMECA Terms: MEAN TIME BETWEEN FAILURE (MTBF MEAN TIME BETWEEN FAILURE (MTBF) Basic measure of reliability for an item. Average time between failure occurrences during a specified period with no preventive measures in place Average time between failure occurrences during a specified period with no preventive measures in place Usually: Total operating time in given period divided by number of failures that have occurred Usually: Total operating time in given period divided by number of failures that have occurred Inverse of the failure rate Inverse of the failure rate Adjustment required if PM is already in-place Adjustment required if PM is already in-place Used in RCM for prioritizing failure modes, performing cost analysis and Failure Finding Task Interval Calculations FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

48. CALCULATING MTBF (Method 1)  Total operating time/number of failures (mature populations in a specified time period)  When no failures have occurred use a conservative estimate  Evaluate like and similar equipment  Consider possibility of failure in short period of time Calculating MTBF: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

49. Calculating MTBF: FMECAFMECA Sources: CMMS data CMMS data Third party repair records Third party repair records Supply usage data Supply usage data Artisan/Maintainer anecdotal estimates Artisan/Maintainer anecdotal estimates FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

50. Method 1 Cautions:  Need data specific to item  Understand difference between potential failures and functional failures Note: MTBF based on potential failures may need adjustment  Adjustments may be required to establish MTBF where PM is already in place  Make sure time period chosen is representative (steady-state)  Assumes constant failure rate of the population  May require periodic monitoring/update Calculating MTBF: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

51. CALCULATING MTBF (Method 2) Use Design or predicted values Data sources: Data sources: Design/vendor specs Design/vendor specs “Like and similar” equipment “Like and similar” equipment Analytical/handbook predictions Analytical/handbook predictions Caution: Often inaccurate Caution: Often inaccurate Verify with real data if possible Verify with real data if possible Adjust with conservatism where necessary Adjust with conservatism where necessary Monitor/Update when field data becomes available Monitor/Update when field data becomes available Calculating MTBF: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

52. CALCULATING MTBF (Method 3) Statistical Modeling methods Beyond scope of this course Beyond scope of this course Requires specialized training and knowledge Requires specialized training and knowledge May be most accurate if properly performed May be most accurate if properly performed Calculating MTBF: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

53. CriticalityCriticalityFMECAFMECA Combination of Severity and Frequency (MTBF) Combination of Severity and Frequency (MTBF) Hazard Risk Index (HRI) Hazard Risk Index (HRI) Risk Priority Number (RPN) Risk Priority Number (RPN) FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA) FREQUENCY SEVERITY FREQUENT (A) > 1 per 1,000 Hours PROBABLE (B) > 1 per 10,000 Hours OCCASIONAL (C) > 1 per 100,000 Hours REMOTE (D) > 1 per 1,000,000 Hours IMPROBABLE (E) < 1 per 1,000,000 Hours CATASTROPHIC (I) CRITICAL (II) MARGINAL (III) MINOR (IV) Death or Permanent disability Death or Permanent disability Significant Environmental breach Significant Environmental breach Damage > $1M, Downtime>2 days Damage > $1M, Downtime>2 days Destruction of system/equipment Destruction of system/equipment Personal Injury Personal Injury Damage >$100K and $100K and < $1M Loss of availability > 24 hrs and Loss of availability > 24 hrs and < 7 days < 7 days Damage >$10K and $10K and < $100K Loss of availability > 4 hrs and Loss of availability > 4 hrs and < 24 hrs < 24 hrs Damage <$10K Damage <$10K Loss of availability < 4 hrs Loss of availability < 4 hrs 1HIGH 3HIGH 4HIGH 2HIGH 5HIGH 8MED 6MED 7MED 9MED 10LOW 12ACCEPT 13ACCEPT 15ACCEPT 16ACCEPT 17ACCEPT 20 ACCEPT19 14 11LOW 18ACCEPT

54. Item – What it is Item – What it is Functions – What you want item to do Functions – What you want item to do Functional Failures – How it fails to do it Functional Failures – How it fails to do it Failure Modes – Why it fails to do it Failure Modes – Why it fails to do it Failure Effects – What happens Failure Effects – What happens Severity of Failure – How bad it is Severity of Failure – How bad it is Failure Frequency – How often it happens Failure Frequency – How often it happens Criticality – Severity + Frequency Criticality – Severity + Frequency Item – What it is Item – What it is Functions – What you want item to do Functions – What you want item to do Functional Failures – How it fails to do it Functional Failures – How it fails to do it Failure Modes – Why it fails to do it Failure Modes – Why it fails to do it Failure Effects – What happens Failure Effects – What happens Severity of Failure – How bad it is Severity of Failure – How bad it is Failure Frequency – How often it happens Failure Frequency – How often it happens Criticality – Severity + Frequency Criticality – Severity + Frequency FMECA Summary: FMECAFMECA FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

55. Guidance:Guidance:ReferencesReferences NAVAIR 00-25-403: Guidelines for the Naval Aviation RCM process NAVAIR 00-25-403: Guidelines for the Naval Aviation RCM process SAE JA1012: Society of Automotive Engineers Guide to RCM Standard SAE JA1012: Society of Automotive Engineers Guide to RCM Standard RAC-HDBK-1120: FMECA - Failure Mode, Effects and Criticality Analysis RAC-HDBK-1120: FMECA - Failure Mode, Effects and Criticality Analysis MIL-STD-1629A: Procedures for Performing a Failure Mode, Effects, and Criticality Analysis MIL-STD-1629A: Procedures for Performing a Failure Mode, Effects, and Criticality Analysis MIL-HDBK-217: Reliability Prediction of Electronic Equipment. MIL-HDBK-217: Reliability Prediction of Electronic Equipment. MIL-STD-882D: Standard Practice For System Safety MIL-STD-882D: Standard Practice For System Safety NAVAIRINST 5100.11: Research and Engineering Review of Risk Process and Procedures for Processing Grounding Bulletins NAVAIRINST 5100.11: Research and Engineering Review of Risk Process and Procedures for Processing Grounding Bulletins FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

56. Sources:Sources: ReferencesReferences Useful Data Sources For Identifying FMECA Information are: Maintenance/Operators Manuals Maintenance/Operators Manuals Troubleshooting Guides/Charts Troubleshooting Guides/Charts Drawings Drawings Operators/Maintainers/Engineers/OEM Tech Reps Operators/Maintainers/Engineers/OEM Tech Reps Work Orders/CMMS or other failure data Work Orders/CMMS or other failure data Block Diagrams/Schematics Block Diagrams/Schematics Existing PM Tasks Accident/Incident/Hazard reports Accident/Incident/Hazard reports Engineering/Failure Investigations/Test reports Engineering/Failure Investigations/Test reports FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)

57. Review and summary Provided an understanding of the Failure Modes, Effects, and Criticality Analysis (FMECA). IntroductionIntroduction Learning Objectives FMECAFMECA Definition of a FMEA Definition of a FMEA Purpose of a FMECA Purpose of a FMECA Definitions & Identification Process Definitions & Identification Process ReferencesReferences FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (FMECA) Module Objective

58. End of Module up next…….. RCM Decision Logic End of Module up next…….. RCM Decision Logic