Working on presentation while ill (have not eaten for 54+ hours)
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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
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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
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%.png:%.dia
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%.png:%.dia
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dia -t png $<
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dia -t png $<
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@ -22,7 +22,9 @@
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\frametitle{FMEA}
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\frametitle{FMEA}
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%\tableofcontents[currentsection]
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%\tableofcontents[currentsection]
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\end{frame}
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\end{frame}
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This talk introduces Failure Mode Effects Analysis, and the different ways it is applied.
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These techniques are discussed, and then
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a refinement is proposed, which is essentially a modularisation of the FMEA process.
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\begin{frame}
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\begin{frame}
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\frametitle{FMEA}
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\frametitle{FMEA}
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\begin{itemize}
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\begin{itemize}
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@ -129,13 +131,13 @@ We need to look at a large number of failure scenarios
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to do this completely (all failure modes against all components).
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to do this completely (all failure modes against all components).
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This is represented in the equation below. %~\ref{eqn:fmea_state_exp},
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This is represented in the equation below. %~\ref{eqn:fmea_state_exp},
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where $N$ is the total number of components in the system, and
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where $N$ is the total number of components in the system, and
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$cfm$ is the number of failure modes per component.
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$f$ is the number of failure modes per component.
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\begin{equation}
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\begin{equation}
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\label{eqn:fmea_single}
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\label{eqn:fmea_single}
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N.(N-1).cfm % \\
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N.(N-1).f % \\
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%(N^2 - N).cfm
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%(N^2 - N).f
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\end{equation}
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\end{equation}
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\end{frame}
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\end{frame}
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@ -159,11 +161,14 @@ $N^3$.
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\begin{equation}
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\begin{equation}
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\label{eqn:fmea_double}
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\label{eqn:fmea_double}
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N.(N-1).(N-2).cfm % \\
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N.(N-1).(N-2).f % \\
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%(N^2 - N).cfm
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%(N^2 - N).f
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\end{equation}
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\end{equation}
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$100*99*98*3=2,910,600$.
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$100*99*98*3=2,910,600$.
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\pause
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.\\
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The European Gas burner standard (EN298:2003), demands the checking of
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The European Gas burner standard (EN298:2003), demands the checking of
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double failure scenarios (for burner lock-out scenarios).
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double failure scenarios (for burner lock-out scenarios).
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@ -438,6 +443,7 @@ against all safe and dangerous failure probabilities.
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Again this is usually expressed as a percentage.
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Again this is usually expressed as a percentage.
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$$ SFF = \big( \Sigma\lambda_S + \Sigma\lambda_{DD} \big) / \big( \Sigma\lambda_S + \Sigma\lambda_D \big) $$
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$$ SFF = \big( \Sigma\lambda_S + \Sigma\lambda_{DD} \big) / \big( \Sigma\lambda_S + \Sigma\lambda_D \big) $$
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\pause
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SFF determines how proportionately fail-safe a system is, not how reliable it is ! \pause
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SFF determines how proportionately fail-safe a system is, not how reliable it is ! \pause
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Weakness in this philosophy; \pause adding extra safe failures (even unused ones) improves the SFF.
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Weakness in this philosophy; \pause adding extra safe failures (even unused ones) improves the SFF.
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@ -577,12 +583,12 @@ judged to be in critical sections of the product.
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% to do this completely (all failure modes against all components).
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% to do this completely (all failure modes against all components).
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% This is represented in equation~\ref{eqn:fmea_state_exp},
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% This is represented in equation~\ref{eqn:fmea_state_exp},
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% where $N$ is the total number of components in the system, and
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% where $N$ is the total number of components in the system, and
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% $cfm$ is the number of failure modes per component.
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% $f$ is the number of failure modes per component.
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%
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%
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% \begin{equation}
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% \begin{equation}
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% \label{eqn:fmea_state_exp}
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% \label{eqn:fmea_state_exp}
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% N.(N-1).cfm % \\
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% N.(N-1).f % \\
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% %(N^2 - N).cfm
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% %(N^2 - N).f
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% \end{equation}
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% \end{equation}
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@ -606,6 +612,8 @@ This creates an analysis hierarchy.
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\pause \item Collect Symptoms.
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\pause \item Collect Symptoms.
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\pause \item Create a '{\dc}', where its failure modes are the symptoms of the {\fg} from which it was derived.
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\pause \item Create a '{\dc}', where its failure modes are the symptoms of the {\fg} from which it was derived.
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\pause \item The {\dc} is now available to be used in higher level {\fgs}.
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\pause \item The {\dc} is now available to be used in higher level {\fgs}.
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\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.
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\pause \item i.e. $ \bowtie ( FunctionalGroup ) \rightarrow {DerivedComponent} $
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\end{itemize}
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\end{itemize}
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\end{frame}
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\end{frame}
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@ -623,7 +631,7 @@ This creates an analysis hierarchy.
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We can return to the milli-volt amplifier as an example to analyse.
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We can return to the milli-volt amplifier as an example to analyse.
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\pause
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\pause
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We can begin by looking for functional groups.\pause
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We can begin by looking for functional groups.\pause
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The resistors would together to perform a fairly common function in electronics, that of the potential divider.
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The resistors perform a fairly common function in electronics, that of the potential divider.
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So our first functional group is $\{ R1, R2 \}$.\pause
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So our first functional group is $\{ R1, R2 \}$.\pause
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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).
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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).
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@ -652,6 +660,7 @@ Resistor and its failure modes represented as a directed graph.
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\begin{table}
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\begin{table}
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\textbf{Failure Scenario} & & \textbf{Pot Div Effect} & & \textbf{Symptom} \\
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\textbf{Failure Scenario} & & \textbf{Pot Div Effect} & & \textbf{Symptom} \\
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\textbf{ / test case } & & \textbf{ } & & \textbf{ } \\
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\hline
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\hline
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FS1: R1 SHORT & & $LOW$ & & $PDLow$ \\ \hline
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FS1: R1 SHORT & & $LOW$ & & $PDLow$ \\ \hline
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FS2: R1 OPEN & & $HIGH$ & & $PDHigh$ \\ \hline
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FS2: R1 OPEN & & $HIGH$ & & $PDHigh$ \\ \hline
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@ -782,6 +791,7 @@ how the levels work and converge to a top or system level.
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\caption{Functional Group Tree example}
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\caption{Functional Group Tree example}
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\label{fig:three_tree}
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\label{fig:three_tree}
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\end{figure}
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\end{figure}
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\end{frame}
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\end{frame}
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\begin{frame}
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\begin{frame}
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@ -789,29 +799,42 @@ how the levels work and converge to a top or system level.
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The fact FMMD analyses small groups of components at a time, and organises them
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The fact FMMD analyses small groups of components at a time, and organises them
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into a hierarchy
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into a hierarchy
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addresses the state explosion problem. \pause
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addresses the state explosion problem. \pause
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Where $O$ is order
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of complexity $O(N^2)$ in the equation below.
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For FMEA where we check every component failure mode rigorously
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against all the other components (we could call this \textbf{RFMEA})
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Where $N$ is the number of components, we can determine the order
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of complexity $ O(N^2) $ thus.
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% %
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\begin{equation}
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\begin{equation}
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\label{eqn:fmea_single2}
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\label{eqn:fmea_single2}
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N.(N-1).cfm % \\
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N.(N-1).f
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%(N^2 - N).cfm
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\end{equation}
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\end{equation}
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%
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% %\end{frame}
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\end{frame}
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\begin{frame}
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\frametitle{FMMD - comparing number of checks RFMEA $\ldots$ FMMD}
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%\end{frame}
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If we consider $c$ to be the number of components in a {\fg}, $f$ is the number of failure modes per component, and
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$L$ to be the number of levels in the hierarchy of FMMD analysis.
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%\begin{frame}
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We can represent the number of failure scenarios to check in an FMMD hierarchy
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We can represent the number of failure scenarios to check in an FMMD hierarchy
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with equation~\ref{eqn:anscen}.
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with equation~\ref{eqn:anscen}.
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\pause
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\begin{equation}
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\begin{equation}
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\label{eqn:anscen}
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\label{eqn:anscen}
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\sum_{n=0}^{L} {fgn}^{n}.fgn.cfm.(fgn-1)
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\sum_{n=0}^{L} {c}^{n}.c.f.(c-1)
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\end{equation}
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\end{equation}
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Where $fgn$ is the number of components in each functional group,
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% Where $c$ is the number of components in each functional group,
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and $cfm$ is the number of failure modes per component
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% and $f$ is the number of failure modes per component
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and L is the number of levels, the number of
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% and L is the number of levels, the number of
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analysis scenarios to consider.
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% analysis scenarios to consider.
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~\ref{eqn:fmea_state_exp}.
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%%~\ref{eqn:fmea_state_exp}.
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\end{frame}
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\end{frame}
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@ -833,18 +856,18 @@ analysis scenarios to consider.
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% In other words, we have three components in our functional group,
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% In other words, we have three components in our functional group,
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% and nine failure modes to consider.
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% and nine failure modes to consider.
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% So taking each failure mode and looking at how that could affect the functional group,
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% So taking each failure mode and looking at how that could affect the functional group,
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% we must compare each failure mode against the two other components (the `$fgn-1$' term).
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% we must compare each failure mode against the two other components (the `$c-1$' term).
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%
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%
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% For the one `zero' level FMMD case we are doing the same thing as FMEA type analysis
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% For the one `zero' level FMMD case we are doing the same thing as FMEA type analysis
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% (but on a very simple small sub-system).
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% (but on a very simple small sub-system).
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% We are looking at how each failure~mode can effect the system/top level.
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% We are looking at how each failure~mode can effect the system/top level.
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% We can use equation~\ref{eqn:fmea_state_exp44} to represent
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% We can use equation~\ref{eqn:fmea_state_exp44} to represent
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% the number of checks to rigorously perform FMEA, where $N$ is the total
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% the number of checks to rigorously perform FMEA, where $N$ is the total
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% number of components in the system, and $cfm$ is the number of failures per component.
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% number of components in the system, and $f$ is the number of failures per component.
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%
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%
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% Where $N=3$ and $cfm=3$ we can see that the number of checks for this simple functional
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% Where $N=3$ and $f=3$ we can see that the number of checks for this simple functional
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% group is the same for equation~\ref{eqn:fmea_state_exp22}
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% group is the same for equation~\ref{eqn:fmea_state_exp22}
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% and equation~\ref{eqn:anscen}.
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% and equation~\ref{eqn:anscen}.
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% \clearpage
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% \clearpage
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@ -855,7 +878,7 @@ analysis scenarios to consider.
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To see the effects of reducing `state~explosion' we can use an example.
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To see the effects of reducing `state~explosion' we can use an example.
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% with fixed numbers
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% with fixed numbers
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%for components in a functional group, and failure modes per component.
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%for components in a functional group, and failure modes per component.
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Let us take a system with 4 levels (with a top/system 0 level),
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Let us take a system with 3 levels of FMMD analysis,
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with three components per functional group and three failure modes per component,
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with three components per functional group and three failure modes per component,
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and apply these formulae.
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and apply these formulae.
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Having 4 levels (in addition to the top zeroth level)
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Having 4 levels (in addition to the top zeroth level)
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@ -865,14 +888,14 @@ $$
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%\begin{equation}
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%\begin{equation}
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\label{eqn:fmea_state_exp22}
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\label{eqn:fmea_state_exp22}
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81.(81-1).3 = 19440 % \\
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81.(81-1).3 = 19440 % \\
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%(N^2 - N).cfm
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%(N^2 - N).f
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%\end{equation}
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%\end{equation}
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$$
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$$
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$$
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$$
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%\begin{equation}
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%\begin{equation}
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% \label{eqn:anscen}
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% \label{eqn:anscen}
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\sum_{n=0}^{4} {3}^{n}.3.3.(2) = 2178
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\sum_{n=0}^{3} {3}^{n}.3.3.(2) = 720
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%\end{equation}
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%\end{equation}
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$$
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$$
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\end{frame}
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\end{frame}
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@ -884,10 +907,10 @@ $$
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\begin{itemize}
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\begin{itemize}
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\pause \item Thus for FMMD we needed to examine 2178 failure~modes against functionally adjacent components, and for traditional FMEA
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\pause \item Thus for FMMD we needed to examine 720 failure~modes against functionally adjacent components, and for traditional FMEA
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type analysis methods, the number rises to 19440.
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type analysis methods, the number rises to 19440.
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\pause \item 19440 `checks' is not practical
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\pause \item 19440 `checks' is not practical
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\pause \item 2178 checks is alot, but...
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\pause \item 720 checks is quite alot, but...
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\pause \item Modules in FMMD can be re-used...
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\pause \item Modules in FMMD can be re-used...
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\end{itemize}
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\end{itemize}
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% In practical example followed through, no more than 9 components have ever been required for a functional
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% In practical example followed through, no more than 9 components have ever been required for a functional
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@ -907,22 +930,31 @@ To determine all possible double simultaneous failures for rigorous FMEA
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\begin{equation}
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\begin{equation}
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\label{eqn:fmea_state_exp2}
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\label{eqn:fmea_state_exp2}
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N.(N-1).(N-2).cfm % \\
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N.(N-1).(N-2).f % \\
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%(N^2 - N).cfm
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%(N^2 - N).f
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\end{equation}
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\end{equation}
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Or express in terms of the level
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\begin{equation}
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\label{eqn:fmea_state_exp2}
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c^{L+1}.(c^{L+1}-1).(c^{L+1}-2).f % \\
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%(N^2 - N).f
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\end{equation}
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\pause
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\pause
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The FMMD case (equation~\ref{eqn:anscen2}), is cubic within the functional groups only,
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The FMMD case (equation~\ref{eqn:anscen2}), is cubic within the functional groups only,
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not all the components in the system.
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not all the components in the system.
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\begin{equation}
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\begin{equation}
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\label{eqn:anscen2}
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\label{eqn:anscen2}
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\sum_{n=0}^{L} {fgn}^{n}.fgn.cfm.(fgn-1).(fgn-2)
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\sum_{n=0}^{L} {c}^{n}.c.f.(c-1).(c-2)
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\end{equation}
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\end{equation}
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\end{frame}
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\end{frame}
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\begin{frame}
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\begin{frame}
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\frametitle{FMMD - Failure Mode Modular De-Composition}
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\frametitle{FMMD - Failure Mode Modular De-Composition}
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\textbf{Traceability}
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\textbf{Traceability}
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Because each reasoning stage contains associations ($FailureMode \mapsto Symptom$)
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Because each reasoning stage contains associations ($FailureMode \rightarrow Symptom$)
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we can trace the `reasoning' from base level component failure mode to top level/system
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we can trace the `reasoning' from base level component failure mode to top level/system
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failure, by traversing the tree/hierarchy. This is in effect providing a `framework' of the reasoning.
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failure, by traversing the tree/hierarchy. This is in effect providing a `framework' of the reasoning.
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