Working on presentation while ill (have not eaten for 54+ hours)

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Robin Clark 2011-10-27 17:14:15 +01:00
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DIAPNG= component.png fmmd_env_op_uml.png fmmd_exm_h.png master_uml.png mvampcircuit.png mvamp.png n_inv_dc.png pd.png pd_euler2.png pd_euler.png DIAPNG= three_tree.png component.png fmmd_env_op_uml.png fmmd_exm_h.png master_uml.png mvampcircuit.png mvamp.png n_inv_dc.png pd.png pd_euler2.png pd_euler.png
%.png:%.dia %.png:%.dia
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@ -22,7 +22,9 @@
\frametitle{FMEA} \frametitle{FMEA}
%\tableofcontents[currentsection] %\tableofcontents[currentsection]
\end{frame} \end{frame}
This talk introduces Failure Mode Effects Analysis, and the different ways it is applied.
These techniques are discussed, and then
a refinement is proposed, which is essentially a modularisation of the FMEA process.
\begin{frame} \begin{frame}
\frametitle{FMEA} \frametitle{FMEA}
\begin{itemize} \begin{itemize}
@ -129,13 +131,13 @@ We need to look at a large number of failure scenarios
to do this completely (all failure modes against all components). to do this completely (all failure modes against all components).
This is represented in the equation below. %~\ref{eqn:fmea_state_exp}, This is represented in the equation below. %~\ref{eqn:fmea_state_exp},
where $N$ is the total number of components in the system, and where $N$ is the total number of components in the system, and
$cfm$ is the number of failure modes per component. $f$ is the number of failure modes per component.
\begin{equation} \begin{equation}
\label{eqn:fmea_single} \label{eqn:fmea_single}
N.(N-1).cfm % \\ N.(N-1).f % \\
%(N^2 - N).cfm %(N^2 - N).f
\end{equation} \end{equation}
\end{frame} \end{frame}
@ -159,11 +161,14 @@ $N^3$.
\begin{equation} \begin{equation}
\label{eqn:fmea_double} \label{eqn:fmea_double}
N.(N-1).(N-2).cfm % \\ N.(N-1).(N-2).f % \\
%(N^2 - N).cfm %(N^2 - N).f
\end{equation} \end{equation}
$100*99*98*3=2,910,600$. $100*99*98*3=2,910,600$.
\pause
.\\
The European Gas burner standard (EN298:2003), demands the checking of The European Gas burner standard (EN298:2003), demands the checking of
double failure scenarios (for burner lock-out scenarios). double failure scenarios (for burner lock-out scenarios).
@ -438,6 +443,7 @@ against all safe and dangerous failure probabilities.
Again this is usually expressed as a percentage. Again this is usually expressed as a percentage.
$$ SFF = \big( \Sigma\lambda_S + \Sigma\lambda_{DD} \big) / \big( \Sigma\lambda_S + \Sigma\lambda_D \big) $$ $$ SFF = \big( \Sigma\lambda_S + \Sigma\lambda_{DD} \big) / \big( \Sigma\lambda_S + \Sigma\lambda_D \big) $$
\pause
SFF determines how proportionately fail-safe a system is, not how reliable it is ! \pause SFF determines how proportionately fail-safe a system is, not how reliable it is ! \pause
Weakness in this philosophy; \pause adding extra safe failures (even unused ones) improves the SFF. Weakness in this philosophy; \pause adding extra safe failures (even unused ones) improves the SFF.
@ -577,12 +583,12 @@ judged to be in critical sections of the product.
% to do this completely (all failure modes against all components). % to do this completely (all failure modes against all components).
% This is represented in equation~\ref{eqn:fmea_state_exp}, % This is represented in equation~\ref{eqn:fmea_state_exp},
% where $N$ is the total number of components in the system, and % where $N$ is the total number of components in the system, and
% $cfm$ is the number of failure modes per component. % $f$ is the number of failure modes per component.
% %
% \begin{equation} % \begin{equation}
% \label{eqn:fmea_state_exp} % \label{eqn:fmea_state_exp}
% N.(N-1).cfm % \\ % N.(N-1).f % \\
% %(N^2 - N).cfm % %(N^2 - N).f
% \end{equation} % \end{equation}
@ -606,6 +612,8 @@ This creates an analysis hierarchy.
\pause \item Collect Symptoms. \pause \item Collect Symptoms.
\pause \item Create a '{\dc}', where its failure modes are the symptoms of the {\fg} from which it was derived. \pause \item Create a '{\dc}', where its failure modes are the symptoms of the {\fg} from which it was derived.
\pause \item The {\dc} is now available to be used in higher level {\fgs}. \pause \item The {\dc} is now available to be used in higher level {\fgs}.
\pause \item We can represent this process as a function which converts a {\fg} into a {\dc} and use the symbol $ \bowtie $ to represet it.
\pause \item i.e. $ \bowtie ( FunctionalGroup ) \rightarrow {DerivedComponent} $
\end{itemize} \end{itemize}
\end{frame} \end{frame}
@ -623,7 +631,7 @@ This creates an analysis hierarchy.
We can return to the milli-volt amplifier as an example to analyse. We can return to the milli-volt amplifier as an example to analyse.
\pause \pause
We can begin by looking for functional groups.\pause We can begin by looking for functional groups.\pause
The resistors would together to perform a fairly common function in electronics, that of the potential divider. The resistors perform a fairly common function in electronics, that of the potential divider.
So our first functional group is $\{ R1, R2 \}$.\pause So our first functional group is $\{ R1, R2 \}$.\pause
We can now take the failure modes for the resistors (OPEN and SHORT EN298) and see what effect each of these failures will have on the {\fg} (the potential divider). We can now take the failure modes for the resistors (OPEN and SHORT EN298) and see what effect each of these failures will have on the {\fg} (the potential divider).
@ -652,6 +660,7 @@ Resistor and its failure modes represented as a directed graph.
\begin{table} \begin{table}
\begin{tabular}{|| l | l | c | c | l ||} \hline \begin{tabular}{|| l | l | c | c | l ||} \hline
\textbf{Failure Scenario} & & \textbf{Pot Div Effect} & & \textbf{Symptom} \\ \textbf{Failure Scenario} & & \textbf{Pot Div Effect} & & \textbf{Symptom} \\
\textbf{ / test case } & & \textbf{ } & & \textbf{ } \\
\hline \hline
FS1: R1 SHORT & & $LOW$ & & $PDLow$ \\ \hline FS1: R1 SHORT & & $LOW$ & & $PDLow$ \\ \hline
FS2: R1 OPEN & & $HIGH$ & & $PDHigh$ \\ \hline FS2: R1 OPEN & & $HIGH$ & & $PDHigh$ \\ \hline
@ -782,6 +791,7 @@ how the levels work and converge to a top or system level.
\caption{Functional Group Tree example} \caption{Functional Group Tree example}
\label{fig:three_tree} \label{fig:three_tree}
\end{figure} \end{figure}
\end{frame} \end{frame}
\begin{frame} \begin{frame}
@ -789,29 +799,42 @@ how the levels work and converge to a top or system level.
The fact FMMD analyses small groups of components at a time, and organises them The fact FMMD analyses small groups of components at a time, and organises them
into a hierarchy into a hierarchy
addresses the state explosion problem. \pause addresses the state explosion problem. \pause
Where $O$ is order
of complexity $O(N^2)$ in the equation below.
For FMEA where we check every component failure mode rigorously
against all the other components (we could call this \textbf{RFMEA})
Where $N$ is the number of components, we can determine the order
of complexity $ O(N^2) $ thus.
% %
\begin{equation} \begin{equation}
\label{eqn:fmea_single2} \label{eqn:fmea_single2}
N.(N-1).cfm % \\ N.(N-1).f
%(N^2 - N).cfm
\end{equation} \end{equation}
%
% %\end{frame}
\end{frame}
\begin{frame}
\frametitle{FMMD - comparing number of checks RFMEA $\ldots$ FMMD}
%\end{frame}
If we consider $c$ to be the number of components in a {\fg}, $f$ is the number of failure modes per component, and
$L$ to be the number of levels in the hierarchy of FMMD analysis.
%\begin{frame}
We can represent the number of failure scenarios to check in an FMMD hierarchy We can represent the number of failure scenarios to check in an FMMD hierarchy
with equation~\ref{eqn:anscen}. with equation~\ref{eqn:anscen}.
\pause
\begin{equation} \begin{equation}
\label{eqn:anscen} \label{eqn:anscen}
\sum_{n=0}^{L} {fgn}^{n}.fgn.cfm.(fgn-1) \sum_{n=0}^{L} {c}^{n}.c.f.(c-1)
\end{equation} \end{equation}
Where $fgn$ is the number of components in each functional group, % Where $c$ is the number of components in each functional group,
and $cfm$ is the number of failure modes per component % and $f$ is the number of failure modes per component
and L is the number of levels, the number of % and L is the number of levels, the number of
analysis scenarios to consider. % analysis scenarios to consider.
~\ref{eqn:fmea_state_exp}. %%~\ref{eqn:fmea_state_exp}.
\end{frame} \end{frame}
@ -833,18 +856,18 @@ analysis scenarios to consider.
% In other words, we have three components in our functional group, % In other words, we have three components in our functional group,
% and nine failure modes to consider. % and nine failure modes to consider.
% So taking each failure mode and looking at how that could affect the functional group, % So taking each failure mode and looking at how that could affect the functional group,
% we must compare each failure mode against the two other components (the `$fgn-1$' term). % we must compare each failure mode against the two other components (the `$c-1$' term).
% %
% For the one `zero' level FMMD case we are doing the same thing as FMEA type analysis % For the one `zero' level FMMD case we are doing the same thing as FMEA type analysis
% (but on a very simple small sub-system). % (but on a very simple small sub-system).
% We are looking at how each failure~mode can effect the system/top level. % We are looking at how each failure~mode can effect the system/top level.
% We can use equation~\ref{eqn:fmea_state_exp44} to represent % We can use equation~\ref{eqn:fmea_state_exp44} to represent
% the number of checks to rigorously perform FMEA, where $N$ is the total % the number of checks to rigorously perform FMEA, where $N$ is the total
% number of components in the system, and $cfm$ is the number of failures per component. % number of components in the system, and $f$ is the number of failures per component.
% %
% Where $N=3$ and $cfm=3$ we can see that the number of checks for this simple functional % Where $N=3$ and $f=3$ we can see that the number of checks for this simple functional
% group is the same for equation~\ref{eqn:fmea_state_exp22} % group is the same for equation~\ref{eqn:fmea_state_exp22}
% and equation~\ref{eqn:anscen}. % and equation~\ref{eqn:anscen}.
% \clearpage % \clearpage
@ -855,7 +878,7 @@ analysis scenarios to consider.
To see the effects of reducing `state~explosion' we can use an example. To see the effects of reducing `state~explosion' we can use an example.
% with fixed numbers % with fixed numbers
%for components in a functional group, and failure modes per component. %for components in a functional group, and failure modes per component.
Let us take a system with 4 levels (with a top/system 0 level), Let us take a system with 3 levels of FMMD analysis,
with three components per functional group and three failure modes per component, with three components per functional group and three failure modes per component,
and apply these formulae. and apply these formulae.
Having 4 levels (in addition to the top zeroth level) Having 4 levels (in addition to the top zeroth level)
@ -865,14 +888,14 @@ $$
%\begin{equation} %\begin{equation}
\label{eqn:fmea_state_exp22} \label{eqn:fmea_state_exp22}
81.(81-1).3 = 19440 % \\ 81.(81-1).3 = 19440 % \\
%(N^2 - N).cfm %(N^2 - N).f
%\end{equation} %\end{equation}
$$ $$
$$ $$
%\begin{equation} %\begin{equation}
% \label{eqn:anscen} % \label{eqn:anscen}
\sum_{n=0}^{4} {3}^{n}.3.3.(2) = 2178 \sum_{n=0}^{3} {3}^{n}.3.3.(2) = 720
%\end{equation} %\end{equation}
$$ $$
\end{frame} \end{frame}
@ -884,10 +907,10 @@ $$
\begin{itemize} \begin{itemize}
\pause \item Thus for FMMD we needed to examine 2178 failure~modes against functionally adjacent components, and for traditional FMEA \pause \item Thus for FMMD we needed to examine 720 failure~modes against functionally adjacent components, and for traditional FMEA
type analysis methods, the number rises to 19440. type analysis methods, the number rises to 19440.
\pause \item 19440 `checks' is not practical \pause \item 19440 `checks' is not practical
\pause \item 2178 checks is alot, but... \pause \item 720 checks is quite alot, but...
\pause \item Modules in FMMD can be re-used... \pause \item Modules in FMMD can be re-used...
\end{itemize} \end{itemize}
% In practical example followed through, no more than 9 components have ever been required for a functional % In practical example followed through, no more than 9 components have ever been required for a functional
@ -907,22 +930,31 @@ To determine all possible double simultaneous failures for rigorous FMEA
\begin{equation} \begin{equation}
\label{eqn:fmea_state_exp2} \label{eqn:fmea_state_exp2}
N.(N-1).(N-2).cfm % \\ N.(N-1).(N-2).f % \\
%(N^2 - N).cfm %(N^2 - N).f
\end{equation} \end{equation}
Or express in terms of the level
\begin{equation}
\label{eqn:fmea_state_exp2}
c^{L+1}.(c^{L+1}-1).(c^{L+1}-2).f % \\
%(N^2 - N).f
\end{equation}
\pause \pause
The FMMD case (equation~\ref{eqn:anscen2}), is cubic within the functional groups only, The FMMD case (equation~\ref{eqn:anscen2}), is cubic within the functional groups only,
not all the components in the system. not all the components in the system.
\begin{equation} \begin{equation}
\label{eqn:anscen2} \label{eqn:anscen2}
\sum_{n=0}^{L} {fgn}^{n}.fgn.cfm.(fgn-1).(fgn-2) \sum_{n=0}^{L} {c}^{n}.c.f.(c-1).(c-2)
\end{equation} \end{equation}
\end{frame} \end{frame}
\begin{frame} \begin{frame}
\frametitle{FMMD - Failure Mode Modular De-Composition} \frametitle{FMMD - Failure Mode Modular De-Composition}
\textbf{Traceability} \textbf{Traceability}
Because each reasoning stage contains associations ($FailureMode \mapsto Symptom$) Because each reasoning stage contains associations ($FailureMode \rightarrow Symptom$)
we can trace the `reasoning' from base level component failure mode to top level/system we can trace the `reasoning' from base level component failure mode to top level/system
failure, by traversing the tree/hierarchy. This is in effect providing a `framework' of the reasoning. failure, by traversing the tree/hierarchy. This is in effect providing a `framework' of the reasoning.

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