Transcript No Slide Title

FMECA Lab
Last revised 08/14/2014
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Introduction
This lab will walk the user through the steps involved in
performing a FMECA using ASENT. In this lab the user will
perform the FMECA that was shown in the Introduction to
FMECA presentation.
First, a new project will be created in ASENT and then the
product tree structure and failure rates will be entered. Next, the
reliability tree will be imported into the FMECA. The end
effects and severities, failure modes, next higher effects and
other FMECA data will then be entered, and reports will be
generated.
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Step 1: Creating A New Project
The first thing we will do is create a new project in
ASENT. This is accomplished in the ASENT Session
Manager. The slides that follow will guide you
through these steps.
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Create the New Flashlight Project
Create a new flashlight
project. From ASENT’s
Session Manager select
the Project menu option
and select the ‘New’
option.
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Create New Flashlight Project
For the project name enter
your <last name>_flashlight.
For example, if your last
name is Smith, then enter
smith_flashlight for your
project name. Fill in the other
information as shown in this
example, then click on the
Save button.
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Step 2: Creating A Product Tree Structure
The next thing we will do is create a product tree
structure in ASENT. This is accomplished in the
ASENT Reliability Manager.
Here, we will build the product tree structure and
assign failure rates. Later, we will use this information
as we perform the FMECA. The slides that follow will
guide you through these steps.
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Invoke the Reliability Manager
Now that the project has been created,
our next step is to build the product
tree structure for our flashlight. We do
this in the Reliability Manager.
To invoke the Reliability Manager,
right-click on your flashlight project
and select the ‘Reliability Manager’
from the drop-down menu.
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Building the Flashlight Product Tree
Initially, only a project node will appear in
the product tree structure when the
Reliability Manager appears.
Right-click on the project node and select
the ‘Add SubAssy / Board’ option from the
drop-down menu.
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Adding the Bulb
To add the bulb to the product
tree, enter the information as
shown, and click on the Save
button.
To user set the failure rate to
50, be sure and check the
checkbox, and then you can
enter a failure rate.
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Adding the Switch
To add the switch to the
product tree, right-click on the
project node and select the
‘Add Subassy / Board’ option,
then enter the information as
shown, and click on the Save
button.
To user set the failure rate to
10, be sure and check the
checkbox, and then you can
enter a failure rate.
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Adding the Contact
To add the contact to the
product tree, right-click on the
project node and select the
‘Add Subassy / Board’ option,
then enter the information as
shown, and click on the Save
button.
To user set the failure rate to
10, be sure and check the
checkbox, and then you can
enter a failure rate.
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Adding the Battery
To add the battery to the
product tree, right-click on the
project node and select the
‘Add Subassy / Board’ option,
then enter the information as
shown, and click on the Save
button.
To user set the failure rate to
40, be sure and check the
checkbox, and then you can
enter a failure rate.
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Calculate Failure Rates
The product tree has now been constructed, and it is
time to calculate the failure rates. In this example, we
are merely summing them up since we supplied user
set values.
Right-click on the project node and select the
‘Calculate Failure Rates’ option from the dropdown menu.
When the Failure Rate
Calculator window
appears, click on the
Calculate button.
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Step 3: Performing a FMECA
In the Reliability Manager click on the
icon to exit the tool.
Finally, we will perform a FMECA for the flashlight
example that was discussed in the Introduction to
FMECA presentation. This is accomplished in the
ASENT FMECA Manager.
The slides that follow will guide you through these
steps.
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Invoking the FMECA Manager
So far we have created a
new project, built a
product tree structure and
calculated failure rates.
Now, we are ready to
start performing the
FMECA. The tool in
ASENT that performs
FMECAs is the FMECA
Manager.
From the Session
Manager, right-click on
your flashlight project
and select ‘FMECA
Manager’ from the
drop-down menu.
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Select Start-up Project Libraries
The first time that you enter the FMECA Manager for a project it will
have you select the default project to be used to initialize the
FMECA. Select the ‘COMMON_FMD97’ project and click the OK
button.
Leave all of the checkboxes
checked and click the OK
button.
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Defining a Function / Phase
Data in the FMECA is
organized by Function
and Phase. Fill in your
Function/Phase data as
shown, and click on the
Save button.
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Importing the Reliability Prediction Tree
A normal starting point for the
FMECA is to begin with the product
tree structure that was used for the
reliability prediction. To start our
FMECA we will import the
Reliability tree.
To do this, right-click on the project
node and select the Import | from
ASENT options. When the Import
screen appears make sure that
‘Reliability Manager Trees’ is
selected and click on the OK button.
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Select the Project to Import
Find your flashlight
project in the list of
projects. Select your
project and click on the
OK button.
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Importing the Product Tree
The product tree for your project appears.
Initially, it appears fully collapsed so that
only the project node is displayed.
Since we want to import the entire
product tree, merely select the project
node and click on the OK button.
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Importing the Product Tree
Click on the ‘Yes’ button to overwrite the
FMECA tree, and click on the ‘No’ button
when asked about importing parts.
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The FMECA Tree
This screen shows the result
after we have imported the
product tree from the
Reliability Manager.
Here, in the FMECA
Manager, we see the
product tree structure for
our flashlight example.
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Defining End Effects – Step 1
There will be a FMs container for each
item in the FMECA product tree. This is a
holder for failure modes/effects. The FMs
container directly below the project node
is used to hold system level effects or end
effects.
To add end effects, click on the ‘+’
symbol next to your project node to
expand the tree, then right-click on the
FMs container, and select the ‘Add’
option from the drop-down menu.
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Defining End Effects – Step 2
This slide shows the FMECA
Manager screen for adding a
new end effect. You can either
click on the pull-down list in
the Failure Mode field to select
one from the library or you can
click on the
icon to enter
one on the fly.
Click on the
one on the fly.
icon to add
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Defining End Effects – Step 3
Enter ‘constant flashlight output’ for the
name and click on the OK button.
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Defining End Effects – Step 4
The ‘constant flashlight
output’ value that you entered
now appears in the Failure
Mode field. Move down to the
Severity field and select ‘1’ for
the severity level, from the pick
list. Click on the Save button to
record your inputs. After the
Save button is clicked you will
see the new end effect appear
under the FMs container of the
project node.
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Repeat Prior Steps to Add Another End Effect
To add a second End Effect,
merely repeat the prior steps,
and enter the information as
shown here.
Here, we define a second end
effect of ‘flashlight output
dim’ with a severity level of
‘3’.
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All End Effects Are Now Defined
Create two additional end
effects. Create one called
‘flashlight sometimes will not
turn on’ with a severity of ‘3’,
and create one called ‘no
flashlight output’ with a
severity of ‘2’.
When you have entered all of
the end effects and click on the
FMs container directly below
the project node, then your
screen should look like this.
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Adding FMs for the Bulb – Step 1
To add failure modes for the
bulb, click on the ‘+’ symbol
next to the bulb. Right-click on
the FMs container and select
the ‘Add’ option from the dropdown menu.
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Adding FMs for the Bulb – Step 2
This slide shows the FMECA
Manager screen for adding a
new failure mode. You can
either click on the pull-down
list in the Failure Mode field to
select one from the library or
you can click on the
icon
to enter one on the fly.
Click on the
one on the fly.
icon to add
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Adding FMs for the Bulb – Step 3
Enter ‘dim light’ for the name and click on the
OK button.
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Adding FMs for the Bulb – Step 4
The ‘dim light’ value that you
entered now appears in the
Failure Mode field. Move down
to the Failure Mode Ratio field
and enter ‘0.1’. Click on the
Save button to record your
inputs. After the Save button is
clicked you will see the new
failure mode appear under the
FMs container of the bulb.
Note:
failure mode ratios are only entered at the lowest level
in the product tree structure. The failure mode ratios for all
intermediate level nodes can be left blank and ASENT will
calculate these for you.
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Adding FMs for the Bulb – Step 5
Repeat steps 1-4 and add a
second failure mode for the
Bulb. Add one called ‘no light’
and give it a failure mode ratio
of ‘0.9’.
After you have added this
second failure mode and
clicked on the FM’s container,
your screen should appear as
shown here.
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Adding FMs for the Switch – Repeat Previous Steps
Repeat the same procedure that
was used to add failure modes
to the bulb, to add failure
modes for the switch.
Here we will enter three failure
modes for the switch. These
failure modes along with their
failure mode ratios are shown
here.
both the ‘Stuck closed’ and ‘Stuck open’ failure modes
exist in the failure mode library. For these two failure modes,
enter these by selecting them from the failure mode library
pick list instead of clicking on the
icon to add them on the
fly.
Note:
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Adding FMs for the Contact – Repeat Previous Steps
Repeat the same procedure that
was used to add failure modes
to the bulb and switch, to add
failure modes for the contact.
Here we will enter three failure
modes for the contact. These
failure modes along with their
failure mode ratios are shown
here.
the ‘intermittent’ failure mode was added to the failure
mode library when we added it for the switch. For this failure
mode, enter it by selecting it from the failure mode library pick
list instead of clicking on the
icon to add it on the fly.
Note:
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Adding FMs for the Battery – Repeat Previous Steps
Repeat the same procedures
that were used earlier, to add
failure modes for the battery.
Here we will enter two failure
modes for the battery. These
failure modes along with their
failure mode ratios are shown
here.
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Defining NHEs for the Bulb – Step 1
To define the Next Higher
Effects for the bulb failure
modes we will do the following.
Click on the ‘dim light’ failure
mode, as shown, and click on
the ‘Next Effects’ tab.
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Defining NHEs for the Bulb – Step 2
The Next Effects screen
consists of two parts. The left
side displays a list of all of the
modes at the Next Higher
Assembly that have not been
selected as a Next Effects for
this failure mode.
The right side of the screen will
display the next effects and
their corresponding beta values.
The sum of the beta values
should add up to 1.0.
Select ‘flashlight output dim’
from the Parent Failure Modes
list and click on the
button.
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Defining NHEs for the Bulb – Step 3
After the
button was
selected, the ‘flashlight output
dim’ appeared in the next
effects list with a beta value of
1.0. Often, there is only one
next effect, so the beta is
automatically defaulted to 1.0.
If you assigned more than one
next effect for a failure mode,
then you would have to adjust
the beta values, accordingly, so
that they sum up to 1.0.
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Defining NHEs for the Bulb – Step 4
Next, we select the bulb’s ‘no
light’ failure mode. Click on
the ‘no flashlight output’
mode from the Parent Failure
Modes list, and click on the
button to assign it as a next
effect for this failure mode.
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Defining NHEs for the Bulb – Step 5
This screen shows the end
result. ‘no flashlight output’ is
assigned as a next effect for the
‘no light’ failure mode for the
bulb.
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Defining NHEs for the Switch – Repeat Previous Steps
Follow the same steps that were used when defining next higher effects for the bulb, to assign next
higher effects for the failure modes of the switch. The failure modes along with their corresponding
next effects are listed below. Navigate down to the switch and enter the next effects shown below:
Failure Mode
Next Effect
Beta
Intermittent
flashlight sometimes will not turn on
1.0
Stuck closed
constant flashlight output
1.0
Stuck open
no flashlight output
1.0
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Defining NHEs for the Contact – Repeat Previous Steps
Follow the same steps that were used when defining earlier next higher effects, to assign next higher
effects for the failure modes of the contact. The failure modes along with their corresponding next
effects are listed below. Navigate down to the contact and enter the next effects shown below:
Failure Mode
Next Effect
Beta
Intermittent
flashlight sometimes will not turn on
1.0
No contact
no flashlight output
1.0
Poor contact
flashlight output dim
1.0
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Defining NHEs for the Battery – Repeat Previous Steps
Follow the same steps that were used when defining earlier next higher effects, to assign next higher
effects for the failure modes of the battery. The failure modes along with their corresponding next
effects are listed below. Navigate down to the battery and enter the next effects shown below:
Failure Mode
Next Effect
Beta
Low power
flashlight output dim
1.0
No power
no flashlight output
1.0
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Roll-up Failure Mode Ratios
We have now finished defining
the failure modes and effects.
Now, we are going to calculate
the failure mode ratios for any
intermediate nodes in our
structure. Right-click on the
project node and select the
‘Roll-up Failure Mode Ratios’
option from the drop-down
menu.
Click on the ‘OK’ button when
the window below appears.
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Calculate Criticality Numbers
Next, we will calculate the
criticality numbers. Right-click
on the project node and select
the ‘Calculate Criticality’
option from the drop-down
menu
Click on the ‘OK’ button when
the window below appears.
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Assign Failure Mode Indicators
Failure Mode Indicators are
identifiers that are commonly used in
the Logistics LSAR database, but
they can also be helpful in sorting
and identifying failure modes in
reports. ASENT will automatically
generate these for you. Right-click
on the project node and select the
‘Create FMIs’ option from the dropdown menu.
Click on the ‘Yes’ button when the
window below appears.
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Generating a FMECA Report
To generate a FMECA report, rightclick on the project node and select
the ‘Reports | FMECA’ option from
the drop-down menu.
Click on the ‘OK’ button when the
window below appears.
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FMECA Report Output
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