The Problem: The Systems-driven approach to design and increasing complexity of equipment (combining electronic, hydraulic, mechanical and pneumatic systems) makes the traditional manual approach to failure identification and analysis difficult to conduct and validate. This makes it difficult to accurately or consistently perform a Failure Mode Effects Analysis (FMEA) using the traditional ‘brainstorming’ process (with the outputs recorded in spreadsheets). These problems are compounded by the requirement to update the FMEA as engineering changes are proposed during the design lifecycle.
Solution: The model-based FMEA available in MADE introduces automation (e.g. dependency mapping of failure propagation), objectivity (results are derived from the model attributes) and consistency (standardised taxonomies of functions / failure concepts). MADE FMEAs use a structured approach that is consistent with international standards and guidelines (MIL, SAE, ISO) to generate a consistent and repeatable FMEA analysis directly from a system model. A key benefit of this model-based approach is that the FMEA analysis is generated ‘on-demand’, enabling the user to analyse the impact of potential changes rather than simply document the design state.
Figure 1: A simulated failure propagation for a driveline transfer case.
MADe generates the FMEA reports directly from the Functional Block Diagrams (system model) – the functions of each element in the system and their connections to other model elements are used to identify the causal relationships and the propagate failure effects in the system. Once the core failure modes are identified MADE uses the Failure Diagram to add extra detail to determine failure causes, detection methods or compensating provisions.
Complex engineering requires a model-based approach to consistently and accurately perform analysis, using a graphical approach provides many key benefits:
A MADE based FMEA means that the user can maximize the consistency and effectiveness of the failure analysis process. The failure analysis information is consistent and current, so the FMEA can be used to drive additional future analyses (e.g. Fault Tree Analysis, Classic RCM, PHM Analysis and Sensor Set Design) at each stage of the product lifecycle.
Figure 2: Failure Diagram of a Fuel Filter Component.