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Technical Safety > Asset Integrity

Failure Mode Effect Analysis (FMEA)

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Failure Mode Effect Analysis (FMEA) is a systematic and structured approach to identify potential failures in a system, process, or component and analyze their effects. It helps organizations predict what might go wrong, assess the severity of consequences, and determine ways to eliminate or reduce the chances of failure. This analysis is documented in a table for easy review and updates.

Steps in FMEA

1

Define Scope and Objectives

Identify the system, process, or equipment to analyze. Define the boundaries and focus (e.g., safety or reliability).

2

Identify Failure Modes

List possible ways components or systems can fail (e.g., rupture, leakage, failure to start or stop).

3

Analyze Effects of Failures

Determine the impact of each failure mode on the system or process (e.g., loss of function, safety risks).

4

Evaluate Risk

i-Rate each failure mode using:

  • Severity (S): How severe are the effects
  • Occurrence (O): How likely is the failure?
  • Detection (D): How likely is it to detect the failure before it happens?

ii-Calculate the Risk Priority Number (RPN):
RPN=S×O×D\text{RPN} = S \times O \times D

5

Recommend Actions

Propose controls or improvements to reduce high-risk failure modes (e.g., design changes, inspections)

6

Document and Review

Record findings in a table and regularly update based on changes or new information.

Key Components of FMEA

1. Failure Modes

  • Specific ways a component or process can fail.

2. Causes

  • Underlying reasons for the failure.

3. Effects

  • Consequences of the failure on the system or operation.

4. Controls

  • Existing measures to prevent or detect the failure

5. RPN

  • A priority score to guide corrective actions.

Importance of FMEA

1. Enhances Safety

  • Identifies and mitigates potential risks early.

2. Improves Reliability

  • Ensures systems and processes function as intended.

3. Reduces Costs

  • Avoids costly failures by addressing issues proactively.

4. Supports Compliance

  • Helps meet safety and quality standards.

What Storm Technical Can Do For Clients

As a desktop-based engineering consultancy, Storm Technical can provide:

Customized FMEA Analysis

Conduct detailed failure analysis using client-provided data, system diagrams, and process details.

Preparation of FMEA Table

Document all identified failure modes, effects, and recommendations in clear and professional formats.

Risk Assessment:

Evaluate and prioritize risks using the RPN method and suggest risk mitigation strategies.

Design Review Support

Analyze design documents to identify potential failure points and recommend improvements.

Process Optimization

Assess operational procedures to enhance safety and reliability.

Training and Workshops

Provide guidance on FMEA techniques and how clients can implementthem effectively.

Storm Technical’s expertise ensures clients have a thorough understanding of their system risks and practical strategies to minimize failures, all while adhering to industry standards.