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<div id="breadcrumbs"><a href="http://www.paragonrx.com/" title="Home">Home</a> <span class="arrow">»</span> <a href="http://www.paragonrx.com/experience/">Experience</a> <span class="arrow">»</span> <a href="http://www.paragonrx.com/experience/white-papers/">White Papers</a> <span class="arrow">»</span> <span class="lastitem">Effective Risk Management and Quality Improvement by Application of FMEA and Complementary Techniques</span></div><h2 class="page_header">Effective Risk Management and Quality Improvement by Application of FMEA and Complementary Techniques</h2>
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<div style="float: left; width: 50%; text-align: left;"><em>Benjamin A. Berman</em></div>
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<div style="float: right; width: 50%; text-align: right;"><em>November 2003</em></div>
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<br>
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<h3>Introduction</h3>
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<p>This paper provides my expert opinion of the use and effectiveness of
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Failure Modes and Effects Analysis (FMEA) for managing risks and
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improving quality in several industrial domains. I also consider and
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evaluate several other analytical techniques as complementary extensions
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of FMEA.<span style="vertical-align: super; font-size: 70%;"><a href="http://www.paragonrx.com/experience/white-papers/effective-risk-management-and-quality-improvement/#1">[1]</a></span></p>
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<p>The opinions that I express in this paper are based on a thorough
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review that I conducted of industry standards and procedures for risk
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management, FMEA techniques, and FMEA applications in aviation and other
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industries. I also base these opinions on my 25 years of experience in
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transportation management and analysis, airline flight operations,
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safety investigation management, safety research, and airline accident
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investigation. I have ten years of experience on the staff of the U.S.
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National Transportation Safety Board (NTSB), concluding my service there
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as the Chief of the Major Investigations Division. In that position, I
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managed the overall investigative effort for U.S. air carrier accidents
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from the field investigation to the public board meeting and final
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accident report. I also managed the U.S. Government’s participation in
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foreign aviation accidents. My previous NTSB experience included
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||
management of flight operations, air traffic control, and meteorological
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aspects of air carrier accident investigations; on-scene and follow-up
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investigations of flight operations for several major accident
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||
investigations including the USAir flight 427 Boeing 737 accident near
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||
Pittsburgh and ValuJet flight 592 DC-9 accident in the Everglades; and
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||
management of research programs on flight crew human factors and
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regional air safety issues, both of which were adopted and published by
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the NTSB. I am a pilot for a major U.S. air carrier, qualified in the
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Boeing 737 and two other transport category aircraft types. I have
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consulted with the National Aeronautics and Space Administration (NASA),
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the World Bank, the European Bank for Reconstruction and Development,
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the U.S. President’s Aviation Safety Commission, and several airlines,
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financial institutions, airport authorities, and other private entities
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on safety and analytical matters. I received the A.B. degree <em>summa cum laude</em> in Economics from Harvard College and am a member of the Phi Beta Kappa Society.</p>
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<h3>FMEA—Summary and Definition</h3>
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<p>According to the Society of Automotive Engineers (SAE) International Aerospace Recommended Practice (ARP) 5580, <em>Recommended Failure Modes and Effects (FMEA) Practices for Non-Automobile Applications</em>,
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FMEA is “a formal and systematic approach to identifying potential
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system failure modes, their causes, and the effects of the failure mode
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occurrence on the system operation…FMEA provides a basis for identifying
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potential system failures and unacceptable failure effects that prevent
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achieving design requirements from postulated failure modes…FMEA is
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used in many system design analyses including assessing system safety,
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planning system maintenance activities, defining provisions for fault
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recovery, fault tolerance, and failure detection and isolation, and
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identifying design modifications and corrective actions needed to
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mitigate the effects of a failure on the system.”</p>
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<p>The basic FMEA process involves examining each basic hardware,
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software, personnel, or functional element of a system, identifying all
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the ways in which that element can fail (failure modes), assessing the
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effects of each failure mode upon the function of other elements of the
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system and the entire system (failure effects), and then assessing the
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criticality of the failure effects. Integral to the FMEA process is the
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specification of corrective actions that will prevent critical failures
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or restore critical functions.</p>
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<p>FMEA typically uses a worksheet for analyzing data and documenting
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the results. The worksheet proceeds, left to right, from the component
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identification, to the associated failure modes, to the failures’
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effects at various levels of the system (including detectability of the
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failure modes/effects), to their risk, reliability, or quality
|
||
consequences. The following is an example of an FMEA worksheet that was
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||
prepared by the SAE for analysis of a fictitious aerospace application:</p>
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<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-sae-table.gif" alt="" height="840" width="484"></p>
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<p style="padding-left: 30px;"><em>Source:SAE ARP926B, p. 32.</em></p>
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<p>The criticality or level of risk, from a failure is a combination of
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the severity of the effect and the probability of its occurrence. Under
|
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FMEA the severity is estimated qualitatively with each effect assigned
|
||
to one of several categories ranging from none to catastrophic, and the
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probability is assessed either qualitatively or quantitatively (the
|
||
latter if failure rate data are available from previous experience or
|
||
from laboratory or field experimentation). The severity and probability
|
||
assessments are combined into an overall assessment of the risk level of
|
||
the failure effect as being acceptable or unacceptable, along the lines
|
||
of the following graphic from Federal Aviation Administration (FAA)
|
||
guidance material:</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-faa-chart.gif" alt="" height="345" width="497"></p>
|
||
<p style="padding-left: 30px;"><em>Source:FAA Advisory Circular 25.1309-1A, System Design and Analysis, p. 7</em></p>
|
||
<p>One aspect of the FMEA process that is often ignored in discussions
|
||
of the methodology (perhaps because it is not represented on the FMEA
|
||
worksheet) is the importance of documenting and retaining all
|
||
assumptions, including rationales for failure rates and effects
|
||
categorization that underlie the FMEA worksheet entries. This is
|
||
specifically cited by the SAE in its recommended standard ARP4761,
|
||
appendix G, section 3.2.1.</p>
|
||
<p>My review of FMEA utilization in aerospace and several other fields
|
||
suggests that the most common applications of FMEA are in product design
|
||
and manufacturing processes. FMEA has not typically been applied to the
|
||
post-manufacturing environment (such as product distribution and field
|
||
usage by providers, operators, maintainers, and customers); however,
|
||
post-manufacturing applications are not specifically excluded in FMEA
|
||
standards. In fact, in SAE ARP5580 section 6.1.1 (5), “failure
|
||
conditions caused by the operational and maintenance environment” are
|
||
specifically cited among the failure modes to be considered.</p>
|
||
<h3>Cross-industry acceptance and use of FMEA</h3>
|
||
<p>FMEA is firmly established as a risk analysis and risk management
|
||
methodology. Originating in the U.S. military during the 1940s and
|
||
supported by military specification beginning in 1949 (MIL-P-1649, <em>Procedures for Performing a Failure Mode, Effects, and Criticality Analysis</em>),
|
||
FMEA methods and applications were officially accepted as a recommended
|
||
practice for aerospace engineering by the SAE beginning in 1967 under
|
||
ARP926, <em>Fault/Failure Analysis Procedure</em>. FMEA had become a
|
||
standard part of the design process in the aerospace industry by the
|
||
1980s and has been in continuous use through the present. For example,
|
||
the Boeing Commercial Airplane Group relied upon FMEA to substantiate
|
||
the safety and reliability of design changes for two generations of the
|
||
Boeing 737 commercial airliner: the 737-300/400/500 series, first
|
||
produced in the mid-1980s, and the “next generation” 737-600/700/800/900
|
||
series, first produced in the late 1990s and early 2000s. I have
|
||
personally examined numerous FMEA documents and FMEA-based safety
|
||
analyses prepared by aircraft manufacturers for original and modified
|
||
transport-category aircraft designs (these FMEA applications are
|
||
proprietary to the manufacturers). In addition to these aviation
|
||
applications of FMEA, the late 1980s saw the application of FMEA to
|
||
design and manufacturing processes by a major U.S. automobile
|
||
manufacturer, and these practices were recognized by the automotive
|
||
industry under the auspices of the Automotive Industry Action Group
|
||
(AIAG) and the SAE (Surface Vehicle Recommended Practice J-1739, first
|
||
issued in 1994). Currently, FMEA is recognized by the SAE (ARP5580, <em>Recommended Failure Modes and Effects Analysis (FMEA) Practices for non-Automobile Applications</em>), the FAA (Advisory Circular 25.1309-1A, <em>System Design and Analysis</em>), and the National Aeronautics and Space Administration (NPA 8715.3, <em>NASA Safety Manual</em>, and NSTS 22206, <em>Instructions for Preparation of FMEA and CIL</em>).
|
||
In a subsequent section of this paper, I will provide an example of a
|
||
successful government-sponsored (and therefore non-proprietary) aviation
|
||
industry application of FMEA that resulted in a significant improvement
|
||
in commercial air carrier flight safety.</p>
|
||
<p>FMEA has also been applied successfully in a wide range of other
|
||
domains. For example, FMEA is being used to analyze design and
|
||
maintenance issues in building structures (Anker Nielson, Ph.D., “Use of
|
||
FMEA, Failure Modes Effects Analysis on Moisture Problems in
|
||
Buildings,” <em>Building Physics 2002—6<sup>th</sup> Nordic Symposium</em>).
|
||
Also, engineers have applied FMEA to design and manufacturing processes
|
||
in the semiconductor industry (Steven Martin and Bedwyr Humphreys,
|
||
“FMEA Speeds Time to Market in Photonic IC Manufacturing”, <em>Compound Semiconductor</em>,
|
||
November 2002). The authors concluded, “The FMEA technique has been
|
||
successfully implemented at MetroPhotonics, aiding in the rapid
|
||
development and the successful launch of the SurePath product suite…Time
|
||
to market and development costs were greatly reduced through the
|
||
selection of optimum system alternatives (through FMEA), resulting in a
|
||
successful product launch within four months of concept” (Martin and
|
||
Humphreys, p. 69).</p>
|
||
<p>FMEA has become established as a standard methodology for risk
|
||
management in the healthcare industry. Under Joint Commission on
|
||
Accreditation of Healthcare Organizations (JCAHO) Standard LD.5.2,
|
||
adopted July 1, 2000, healthcare organizations are required to
|
||
proactively identify and manage potential risks to patient safety, using
|
||
FMEA and root cause analysis to analyze at least one high-risk process
|
||
annually. The U.S. Veteran’s Administration has developed and begun
|
||
implementation of an application of FMEA that the agency customized for
|
||
healthcare delivery (Joseph DeRosier, Erik, Stalhandske, James P.
|
||
Bagian, and Tina Nudell, “Using Health Care Failure Mode and Effect
|
||
Analysis™: The VA National Center for Patient Safety’s Prospective Risk
|
||
Analysis System,” <em>The Joint Commission Journal on Quality Improvement</em>,
|
||
Vol 28. No 5, May 2002). Private health care organizations (for
|
||
example, Kaiser Permanente) have begun to implement FMEA-based processes
|
||
(Kaiser Permanente, <em>Failure Modes and Effects Analysis Team Instruction Guide</em>,
|
||
March 2002). Although healthcare-related applications of FMEA have
|
||
considered some aspects of pharmaceutical delivery (for example,
|
||
Institute for Healthcare Improvement, “<em>Sample FMEA: Comparison of Five Medication Dispensing Scenarios</em>,”
|
||
2003), I am not aware that a comprehensive analysis of pharmaceutical
|
||
distribution, delivery, and use, treating all post-manufacture
|
||
activities as an integrated system, has been performed to date using
|
||
FMEA or any alternative, formal risk-management methodology.</p>
|
||
<h3>Advantages of FMEA</h3>
|
||
<p>I suggest that FMEA has several general advantages for organizations seeking to improve quality and safety:</p>
|
||
<p>First, FMEA is a structured process that promotes disciplined
|
||
elicitation of ideas about the kinds of failures that may occur, careful
|
||
analysis of specific risk/hazard areas, proper documentation of sources
|
||
and assumptions, and identification of interventions that manage risks
|
||
to an acceptable level. Regarding the ultimate goal of risk management,
|
||
in most applications the FMEA process requires intervention in each
|
||
identified adverse outcome until the residual level of risk is
|
||
acceptable.</p>
|
||
<p>Further, as a “bottom-up process” proceeding from the failure an
|
||
individual component of a system to the effects on the entire system,
|
||
FMEA helps organizations identify unforeseen, undesired outcomes. Its
|
||
best applications are prospective, facilitating the control or
|
||
mitigation of adverse outcomes before they occur.</p>
|
||
<p>Also, FMEA explicitly considers the detectability of failure modes,
|
||
and thus it promotes consideration of failures that can remain latent;
|
||
that is, failures that have no immediate effect and (if they remain
|
||
undetected) are capable of resulting in adverse effects when combined
|
||
with subsequent failure modes or events (however, as is discussed below,
|
||
the basic FMEA methodology may need to be modified to fully address
|
||
latent failures).</p>
|
||
<h3>Limitations of FMEA</h3>
|
||
<p>SAE ARP5580 provides the following “cautions” for the application of FMEA:</p>
|
||
<ul>
|
||
<li>First, a FMEA traditionally considers only non-simultaneous failure
|
||
modes. Each failure mode is considered individually, assuming that all
|
||
other system components are performing as designed. Hence, a typical
|
||
FMEA provides limited insight into the following anomalous behaviors:</li>
|
||
</ul>
|
||
<ol style="padding-left: 30px;">
|
||
<li> the effects of multiple component failures on system functions, and</li>
|
||
<li> latent manifestations of defects such as timing, sequencing, etc.</li>
|
||
</ol>
|
||
<ul>
|
||
<li>Second, the prioritization of the failure modes for corrective
|
||
actions is substantially subjective. Thus, care should be taken in
|
||
decision making when using any quantitative aspects of the numbers
|
||
presented in the analysis (SAE ARP5580, Section 3.3).</li>
|
||
</ul>
|
||
<p>I concur that the basic approach of FMEA is to consider single
|
||
failures and that a typical FMEA application handles multiple
|
||
(simultaneous/sequential) failures with difficulty (later in this paper,
|
||
I will suggest several extensions to FMEA that are capable of
|
||
addressing these issues).</p>
|
||
<p>Further, I suggest that the following additional general limitations exist for FMEA:</p>
|
||
<p>First, as FMEA has typically been applied in aerospace engineering,
|
||
designers are permitted to rely upon human performance (such as
|
||
interventions by pilots and mechanics) to mitigate the adverse effects
|
||
of hardware and software component or system failures. However, in doing
|
||
so, no consideration is given to given to imperfect human performance.
|
||
For example, FAA guidance for aircraft certification states, “If…a
|
||
potential failure condition can be alleviated or overcome…without
|
||
requiring exceptional pilot skill or strength, credit can be taken for
|
||
correct and appropriate action” (FAA AC25.1309-1A, pararaph 11). The
|
||
assessment of “exceptional” skill or strength is subjective, and once a
|
||
specific human response to a failure mode is determined to require
|
||
unexceptional skill or strength, FMEA typically assumes that the human
|
||
will intervene reliably every time that the failure mode occurs. I
|
||
believe that this is an unrealistic assumption for human performance,
|
||
and as a common treatment of human performance in FMEAs it constitutes a
|
||
limitation of the typical FMEA methodology.</p>
|
||
<p>Also, as FMEA typically has been applied in design/process
|
||
applications, there is no inherent feedback to the FMEA process from the
|
||
actual failure modes and outcomes experienced in field use. However,
|
||
this feedback is not excluded by the FMEA process and the continuing
|
||
refinement of an FMEA through feedback has been explicitly recognized as
|
||
an important aspect of system safety analysis in some applications.</p>
|
||
<h3>Keys to successful application of FMEA</h3>
|
||
<p>I believe that several additional issues are important for obtaining satisfactory results from an FMEA.</p>
|
||
<p>First, while FMEA is a structured technique that provides a
|
||
comprehensive analysis, it is difficult (or impossible) to prospectively
|
||
identify all possible failure modes/adverse outcomes from a complex
|
||
component or functional element of a system. Because even the best FMEA
|
||
effort may leave some failure modes and effects undiscovered, after
|
||
completing an FMEA it is essential to avoid concluding that all risks
|
||
have been compensated for or controlled. This suggests that FMEA
|
||
analysts need to maintain an open and creative attitude about
|
||
identifying failure modes and assessing their effects and consequences,
|
||
It also establishes the rationale for obtaining, analyzing, and reacting
|
||
to feedback from field use and operations, and for treating the FMEA as
|
||
a “living document” that will be revisited and revised on a continuing
|
||
basis.</p>
|
||
<p>Further while planning and performing an FMEA, it is essential to
|
||
understand the scope of the analysis and to choose a proper scope that
|
||
will allow the evaluation of all critical risks that can result from
|
||
failure modes. For example, many FMEAs are limited to design issues and
|
||
do not necessarily consider manufacturing variations or errors. An
|
||
aircraft part that includes several linkages may not consider the
|
||
effects of cumulative (stack-up) of the manufacturing tolerances that
|
||
are allowed for each individual linkage as a possible contributor to
|
||
failure modes and effects. Even if the scope of the FMEA for this part
|
||
is enlarged to include manufacturing processes and therefore considers
|
||
tolerance stack-up, the analysis still may not consider the effects of
|
||
failure modes that remain downstream from the processes that have been
|
||
included within the analytical scope, such as improper maintenance or
|
||
use. When considering all of a product’s failure modes and effects in
|
||
all environments, a still broader scope of analysis might reveal
|
||
additional factors that significantly affect safety and quality. For
|
||
example, consider a pharmaceutical product with an adverse side effect
|
||
that poses a risk to some users. One option for controlling the risks of
|
||
these side effects would be for the Food and Drug Administration (FDA)
|
||
to withdraw approval for the product. However, because the product also
|
||
has therapeutic value, withdrawal of the product may actually result in a
|
||
net reduction of patient health and safety, even considering the
|
||
adverse consequences of the side effects. The net therapeutic benefit of
|
||
the product relative to its side effects will not be identified by an
|
||
FMEA of its design, manufacturing, and use—unless the withdrawal of the
|
||
product is considered as a failure mode and the scope of analysis is
|
||
broadened to consider the net consequences of non-use.</p>
|
||
<p>In addition to considering downstream effects in scoping the
|
||
analysis, it is essential to recognize that the interventions selected
|
||
in an FMEA to mitigate an identified risk can also introduce their own
|
||
failure modes and effects having critical risks. Interventions should be
|
||
designed to “first, do no harm;” that is, they should introduce no new <em>uncorrected</em>
|
||
failure modes. This suggests that FMEA should be performed on each
|
||
intervention, as well. In some cases controlling the hazard from one
|
||
failure mode can increase the hazard from another, and this may require
|
||
consideration of multiple simultaneous or sequential failures as an
|
||
extension of FMEA.</p>
|
||
<p>Also, while interpreting the results of an FMEA, it is essential to
|
||
understand the derivation and limitations of the probability analysis
|
||
that is incorporated in the evaluation of the risks associated with
|
||
failure effects. The probability that a failure mode will occur can be
|
||
obtained from engineering, field, or registry data such as historic
|
||
component failure rates; the probability that a functional element or
|
||
complex component will fail can be estimated by combining the failure
|
||
rates of sub-assemblies or sub-systems. Failure rates may be obtained
|
||
from laboratory research if actual field data are unavailable. Lacking
|
||
in both field and laboratory data, failure mode probabilities may be
|
||
estimated. The FMEA analyst’s confidence in the results should depend on
|
||
the derivation of these probabilities. An additional probabilistic
|
||
element in some FMEA applications is the likelihood that an effect of
|
||
stated severity will follow from a failure mode. This element needs to
|
||
be estimated in a similar manner, with confidence in the results of the
|
||
analysis once again depending on the source of the probability
|
||
estimates. Another probabilistic element can enter FMEA when considering
|
||
interventions to control or mitigate an identified risk; here, the
|
||
probability that the intervention will successfully address the risk
|
||
needs to be estimated.</p>
|
||
<p>Failure and reliability rates are particularly difficult to estimate
|
||
when human performance is involved. The FAA states in its design
|
||
guidance material that “quantitative assessments of the probabilities of
|
||
crew error are not considered feasible” (FAA AC25.1309-1A, paragraph
|
||
11); as I have already discussed, the FAA then turns at times to the
|
||
unrealistic assumption that humans perform with perfect reliability. In
|
||
other domains, performance by trained professionals has been estimated
|
||
as being satisfactory in 30-60 percent of exposures to a demanding task.
|
||
Although the reliability level of human performance is highly variable
|
||
depending on the nature of the task, environment, and individual, it is
|
||
probably best to assume that human performance in systems often may be
|
||
much less reliable than what is demanded of hardware and software
|
||
systems, and accordingly to plan compensations when humans may be
|
||
responsible for detecting primary failure modes or for intervening to
|
||
mitigate failure effects.</p>
|
||
<p>Review of FMEA applications in various industries suggests that there
|
||
is no standard definition for an acceptable level of risk. Based on the
|
||
high volume of operations with consequent risk exposure and the
|
||
public’s low tolerance for mishaps, commercial aviation design and
|
||
manufacturing is held to a stringent reliability criterion:
|
||
certification guidance requires that every failure having catastrophic
|
||
consequences must be demonstrated to be extremely improbable; the FAA
|
||
defines “extremely improbable failure conditions” as “those having a
|
||
probability of on the order of 1 X 10E-9 or less” (AC251309-1A,
|
||
paragraph 10). In contrast, FMEA applications in other industrial
|
||
domains accept catastrophic outcomes with probabilities that may be
|
||
orders of magnitude more likely. An interesting criterion for aviation
|
||
design that incorporates both probability and severity factors
|
||
establishes that “in general, a failure condition resulting from a
|
||
single failure mode of a device cannot be accepted as being extremely
|
||
improbable” (FAA AC 25.1309-1A, paragraph 2-g). Thus, every failure mode
|
||
having catastrophic consequences, regardless of its estimated
|
||
likelihood, must be mitigated by a redundant system or a means of
|
||
reliably detecting the failure before it occurs (the FAA guidance does
|
||
suggest that “…in very unusual cases, however, experienced engineering
|
||
judgment may enable an assessment that such a failure mode is not a
|
||
practical possibility.”).</p>
|
||
<p>When considering the effectiveness of interventions in mitigating the
|
||
risks of failure effects, a significant implication of probability
|
||
analysis is the assumption of independent events. Normally, the
|
||
probability of two events both occurring is the probability of one event
|
||
multiplied by the probability of the other event. For example, consider
|
||
an aircraft component that FMEA determines to have an unacceptable
|
||
failure rate. To control this risk, designers require the mechanic to
|
||
check the component before each flight and also require the pilot to
|
||
recheck the component during the taxi-out checklist. If there is a 10
|
||
percent chance of the mechanic forgetting to check the component and
|
||
also a 10 percent chance of the pilot skipping the same item on the
|
||
checklist, the probability of the check being omitted by both persons is
|
||
only 1 in 100. In this manner, adequate reliability can be obtained
|
||
from two somewhat unreliable human performances by imposing multiple,
|
||
redundant interventions. However, this analysis assumes that the pilot
|
||
and mechanic events are independent, while in reality these events may
|
||
interact: a pilot who knows that the mechanic is supposed to be checking
|
||
the component may grow to rely on the mechanic and become less likely
|
||
to perform the re-check. As another example, consider a pharmaceutical
|
||
product that requires patients to receive periodic lab tests to detect
|
||
possible adverse side effects. Multiple, redundant interventions are
|
||
designed to ensure that patients receive the lab tests: doctors and
|
||
pharmacists are both instructed to track the due dates for the tests and
|
||
notify patients. However, if doctors become aware that pharmacists are
|
||
tracking the due dates, the doctors may become less likely to perform
|
||
this effort as well; therefore, multiple intervention collapses to a
|
||
single intervention and the redundancy is lost. Whenever the assumption
|
||
of independent events is violated and the likelihood of one event
|
||
becomes a function of another event, it is impossible to conclude that
|
||
the desired reliability will result from multiple interventions.
|
||
Therefore, interventions must be designed and implemented so as to
|
||
provide and preserve the independence of the events.</p>
|
||
<h3>Complementary analytical techniques</h3>
|
||
<p>In its <em>Safety Manual</em>, NASA states that “risk assessment
|
||
should use the simplest methods that adequately characterize the
|
||
probability and severity of undesired events.” The NASA manual further
|
||
states, “Qualitative methods that characterize hazards and failure modes
|
||
and effects should be used first…quantitative methods are to be used
|
||
when qualitative methods do not provide an adequate understanding of
|
||
failures, consequences, and events” (NASA NPG 8715.3).</p>
|
||
<p>A variety of analytical methods are available to apply to risk
|
||
management, in addition to FMEA. I will briefly define and discuss
|
||
several of these methods and indicate how they can be used to complement
|
||
FMEA and extend its applications into areas in which FMEA is otherwise
|
||
inherently limited.</p>
|
||
<p>I have described the FMEA method as a “bottom-up” approach that
|
||
attempts to identify failure effects (some of which may not yet have
|
||
occurred in actual use of the product) by starting with individual
|
||
component failures, imagining the ways the component can fail, and then
|
||
proceeding up the chain of the system to subsequent failures and
|
||
consequences. Further, I identified the bottom-up orientation of FMEA as
|
||
advantageous for a prospective, accident-prevention program.</p>
|
||
<p>Some alternative analytical methods are “top-down” in that they begin
|
||
with the ultimate system consequence or failure event and then proceed
|
||
down into the system to identify why the failure occurred. These methods
|
||
perform well as retrospective analyses; for example, investigations of
|
||
accidents or incidents that have already occurred. However, top-down
|
||
methods can also be useful in prospective analysis; for example, when
|
||
concerned about a severe consequence, recognizing that the primary FMEA
|
||
method may miss some failure effects, it may also be helpful to analyze
|
||
beginning with the consequence itself and to search creatively for other
|
||
sub-system functions or component failures might bring about the
|
||
undesired result.</p>
|
||
<p>The SAE’s recommended standard for the general evaluation of aircraft safety (ARP4761, <em>Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment</em>)
|
||
describes an over-arching “System Safety Assessment” (SSA) process. SSA
|
||
integrates FMEA and some of the following approaches, as required, to
|
||
thoroughly evaluate all of the failure modes, failure effects, and risks
|
||
of a system and show that the entire system (the aircraft) operates at
|
||
the required level of safety/reliability despite all anticipated failure
|
||
modes.</p>
|
||
<p><span style="text-decoration: underline;">Functional Hazard Analysis</span>
|
||
(FHA) is a top-down approach that is most often performed at the
|
||
beginning of a design effort, when the final specifications for a
|
||
product have not yet been settled yet its basic functions are already
|
||
established. Using engineering judgment and knowledge from similar
|
||
efforts, analysts review the basic functions of a product or process and
|
||
suggest system-level hazardous outcomes for further analysis. This
|
||
method allows the safety/quality improvement process to begin early in
|
||
product development, at least at a level of broad generality.</p>
|
||
<p>Methods similar to FHA also can be applied retrospectively, after a
|
||
product is fielded. One successful application is Hazard Analysis of
|
||
Critical Control Points, which is used in the food services industries
|
||
to evaluate the entire chain of food production and distribution,
|
||
identifying and controlling sources of food contamination. This
|
||
application seems amenable to the simpler FHA methodology rather than a
|
||
formal FMEA.</p>
|
||
<p><span style="text-decoration: underline;">Fault Tree Analysis</span>
|
||
(FTA) is more formal top-down approach to identifying the causal links
|
||
between functional breakdowns and their antecedents in events or
|
||
failures of lower-level components. The FTA begins with the system-level
|
||
failure or consequence that the analysts want to understand. Proceeding
|
||
down through the system from the top-end level to the underlying
|
||
processes and components, the analysis results in a graphical
|
||
representation of the combinations of subsystem and component failures
|
||
that can result in the system event. The fault tree (so-named because it
|
||
resembles the root structure of a tree) uses standard notations of
|
||
Boolean logic to denote precursor or lower-level events that must occur
|
||
individually (“or-gate”) or in combination (“and-gate”) to bring about
|
||
the higher level event. In this manner, FTA directly incorporates
|
||
multiple causation (simultaneous/sequential) events. Further, when
|
||
failure rates are added to each component of the tree diagram, the
|
||
probabilities of each of the lower-level events can be added or
|
||
multiplied to estimate the probability of the ultimate system-level
|
||
event.</p>
|
||
<p>The following is an example of FTA provided by the SAE:</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-sae-diagram.gif" alt="" height="494" width="576"></p>
|
||
<p style="padding-left: 30px;"><em>Source: SAE ARP926B, p. 46.</em></p>
|
||
<p>As a top-down approach, FTA may identify one or more underlying
|
||
causes of the top-level event but omit others that might be identified
|
||
in the bottom-up FMEA. Additional limitations of FTA are that the
|
||
methodology (unlike FMEA) does not represent the severity of
|
||
consequences; hence, it is difficult to assess the risks of failure and
|
||
evaluate them with respect to the available countermeasures, without
|
||
also undertaking an FMEA.</p>
|
||
<p>Because it handles multiple failures, various multiple causations as
|
||
expressed through Boolean logic, and the associated probabilities rather
|
||
naturally, FTA also complements FMEA where the latter is limited. I
|
||
suggest that FTA notation and techniques should be applied selectively
|
||
to explore multiple failures and associated probabilities once these
|
||
factors have been identified in the basic FMEA. Another advantage of FTA
|
||
when used in combination with FMEA is the top-down check of the
|
||
bottom-up process that I have already described. FTA might be applied
|
||
selectively, once again, to confirm that FMEA has not omitted
|
||
catastrophic outcomes. I would consider selective application of FTA as a
|
||
complementary extension to the basic FMEA methodology. This is
|
||
explicitly recognized by the SAE in ARP926B.</p>
|
||
<p><span style="text-decoration: underline;">Probabilistic Risk Assessment</span>
|
||
(PRA) has been adopted by NASA as formal methodology for analyzing “the
|
||
probability (or frequency) of occurrence of a consequence of interest,
|
||
and the magnitude of that consequence, including assessment and display
|
||
of uncertainties.” (Michael A. Greenfield, “Risk Management Tools,” NASA
|
||
Langley Research Center presentation, May 2, 2000). A key contribution
|
||
of PRA is that it considers, tracks, and documents the current state of
|
||
knowledge and certainty of the probabilities that are employed in basic
|
||
FMEA and other analyses. One significant limitation of PRA, as defined
|
||
by NASA, is that the methodology requires specific experience-based
|
||
failure rate data for the components and functions that are being
|
||
analyzed. As a result, I suggest that it may be difficult to apply
|
||
formal PRA to “softer” areas such as human performance in FMEA
|
||
interventions.</p>
|
||
<p><span style="text-decoration: underline;">Markov Analysis</span> (MA)
|
||
is a specialized probabilistic analysis especially well suited to
|
||
evaluating the failure effects and consequences of high-technology
|
||
systems that include self-monitoring, self-repairing and
|
||
self-reconfiguring functionalities. MA is capable of handling these
|
||
complex relationships between failure mode, effect, and consequence by
|
||
representing the relationship as a chain, each element in the chain in
|
||
an operational or non-operational state, and the movement between states
|
||
as a system of differential equations. I would suggest that MA is a
|
||
good methodology to employ as a complement to basic FMEA and FTA when
|
||
the nature of the components, environment, or operators require it;
|
||
otherwise, in accordance with the principle of minimizing the complexity
|
||
of risk analysis, MA does not appear warranted in most applications.</p>
|
||
<p>To summarize these alternative methodologies, it is quite possible to
|
||
extend a basic FMEA into areas in which the FMEA method is limited,
|
||
including multiply caused events, simultaneous or sequential events, and
|
||
the estimation of probabilities of failure modes, effects, and
|
||
consequences (and our confidence in the estimated probabilities), by
|
||
applying selected aspects of FTA and PRA to the FMEA. I do not suggest
|
||
that complete, formal FTA and PRA need to be undertaken in every FMEA
|
||
application; rather, these methodologies should be drawn from as
|
||
required.</p>
|
||
<h3>Complementary field reporting and data analysis systems from aviation</h3>
|
||
<p>In a previous section, I mentioned the importance of feeding
|
||
information from the post-manufacturing user communities and processes
|
||
back into the FMEA to ensure that the consequences of failure modes that
|
||
arise only in product use (perhaps because they were rare events and
|
||
did not occur during design and testing) are recognized and compensated
|
||
for once they have been discovered. There are several fairly recent
|
||
developments in aviation industry reporting and analysis systems,
|
||
potentially useful for refining and refreshing an FMEA on a continuing
|
||
basis, that may also have applications in other industries.</p>
|
||
<p><span style="text-decoration: underline;">Aviation Safety Action Programs</span>
|
||
(ASAP) are cooperative reporting systems for persons active in
|
||
commercial aviation operations, including pilots, mechanics, and
|
||
aircraft dispatchers, to report the events that happen in daily line
|
||
operations. ASAP reports are non-jeopardy; in fact, if a person reports
|
||
an event to ASAP independently of enforcement action by the regulatory
|
||
authority (FAA) then the FAA will typically waive sanctions for any
|
||
regulatory violation related to the event. This waiver of sanctions
|
||
motivates personnel to report the information. ASAP reflects the
|
||
aviation system’s recognition that for human failings, obtaining the
|
||
information is often more important than punishment the transgressions,
|
||
most of which are inadvertent in any case. A key feature of the ASAP
|
||
program is the Event Review Team, comprising representatives from the
|
||
airline, the pilot’s association, and the FAA, which meets periodically
|
||
to review all submitted ASAP reports and act on the information in the
|
||
reports. ASAP is considered to be successful in revealing,
|
||
disseminating, and promoting resolution of adverse events in daily
|
||
flight operations that would otherwise remain unknown. ASAP applications
|
||
are increasingly popular in commercial aviation. These programs are
|
||
described in official FAA guidance (Advisory Circular 120-66B, <em>Aviation Safety Action Program</em>).</p>
|
||
<p>Whereas ASAP obtains information from the personnel in the aviation
|
||
system, Flight Operations Quality Assurance (FOQA) programs tap into the
|
||
volumes of parametric data generated during regular flight operations
|
||
and recorded continuously by on-board solid state recording equipment
|
||
(similar to, but usually distinct from the crash-hardened Digital Flight
|
||
Data Recorders that are used in accident investigations). In FOQA, the
|
||
greatest challenges are handling mass data and then interpreting the
|
||
information. Initial applications of FOQA concentrated on identifying
|
||
events in which normal flight parameters (such as airspeed limitations,
|
||
g-loading, touchdown relative to target) were exceeded. The programs are
|
||
beginning to delve beyond exceedance monitoring to the consideration of
|
||
within-specification performance statistics, including both the means
|
||
and the distributions about them, which can then define the norms of the
|
||
industry. There is also a growing trend in FOQA programs to link the
|
||
information obtained from FOQA with information derived from ASAP about
|
||
the same events. This facilitates the combined analysis of “what”
|
||
happened (from FOQA) and “why” it happened (ASAP, to the extent that the
|
||
personnel involved in the event were aware of why they performed the
|
||
way that they did). A long-term NASA research program, the Automated
|
||
Performance Management System, is encouraging the establishment of FOQA
|
||
programs at various U.S. airlines and enhancing data analysis along
|
||
these lines. Most of the major U.S. air carriers are generating and
|
||
collecting FOQA data on at least their more modern fleet types (these
|
||
aircraft are equipped with the required data busses). FOQA programs are
|
||
described in the Flight Safety Foundation’s <em>Flight Safety Digest</em>,
|
||
July-September 1998, “Aviation Safety: U.S. Efforts to Implement Flight
|
||
Operational Quality Assurance Programs.” Although analogous data may
|
||
not be available in other applications, FOQA demonstrates the value of
|
||
routine monitoring of the use of products in the field, including the
|
||
identification of product misuse (exceedances in FOQA) and the
|
||
characterization of norms for product use.</p>
|
||
<p>The Continuing Airworthiness Surveillance System (CASS) is an
|
||
aviation reporting and analysis system that concentrates on tracking
|
||
product failure modes, effects, and consequences in actual line
|
||
maintenance operations. CASS is one of the oldest data-driven quality
|
||
assurance programs, beginning in 1964 and tracing its history to
|
||
industry concerns about several maintenance-related air carrier
|
||
accidents during the 1950s. Air carriers are required to implement CASS
|
||
by Federal aviation regulations (14 CFR Part 121.373); interestingly,
|
||
CASS is the only safety management/quality assurance system that has
|
||
been specifically mandated by the FAA. CASS is defined by the FAA as a
|
||
“structured process to identify factors that could lead to an accident
|
||
or incident through collection and evaluation of information that can be
|
||
used as indicators of the degree of maintenance program effectiveness
|
||
and performance…accomplished through a closed-loop, continuous cycle of
|
||
surveillance, investigations, data collection and analysis, corrective
|
||
action, corrective action monitoring, and back to surveillance.” (FAA AC
|
||
120-16D, <em>Air Carrier Maintenance Programs</em>, and AC 120-79, <em>Developing and Implementing a Continuing Airworthiness Surveillance System</em>).</p>
|
||
<p>Event reporting systems with many similarities to these aviation
|
||
systems are being developed and used in other industries, including
|
||
healthcare. I think that review of the characteristics and
|
||
implementation of ASAP, FOQA, and CASS may enhance similar systems in
|
||
alternative industries, particularly as these aviation systems are
|
||
applied in combination to obtain information that only the personnel in
|
||
the system can report, additional mass data about regular operations,
|
||
and specific product and personnel failures in the post-manufacturing
|
||
environment. Also, I suggest that information systems with these
|
||
characteristics can be effective feedback mechanisms for the ongoing
|
||
analysis of failure modes, effects, and consequences through FMEA.</p>
|
||
<h3>The Boeing 737 Flight Controls Engineering Test and Evaluation Board: a successful application of extended FMEA</h3>
|
||
<p>On September 8, 1994, USAir flight 427, a Boeing 737-300 airplane,
|
||
crashed while maneuvering to land at Pittsburgh International Airport,
|
||
Pittsburgh, Pennsylvania. All of the 132 persons aboard were killed, and
|
||
the airplane was destroyed. The accident occurred in clear weather with
|
||
light winds, during the hours of daylight. After a three-year
|
||
investigation, the National Transportation Safety Board (NTSB)
|
||
determined that the probable cause of this accident was “loss of control
|
||
of the airplane resulting from the movement of the rudder surface to
|
||
its blowdown limit…The rudder surface most likely deflected in a
|
||
direction opposite to that commanded by the pilots as a result of a jam
|
||
of the main rudder power control unit servo valve secondary slide to the
|
||
servo valve housing offset from its neutral position and overtravel of
|
||
the primary slide.” (National Transportation Safety Board, Uncontrolled
|
||
Descent and Collision With Terrain, USAir Flight 427, Boeing 737-300,
|
||
N513AU, Near Aliquippa, Pennsylvania, September 8, 1994, NTSB AAR-99/01,
|
||
adopted on 3/24/99).</p>
|
||
<p>Before this accident the rudder system of the 737 had been evaluated
|
||
by Boeing and the FAA, in full compliance with existing certification
|
||
requirements, using failure analysis (a less rigorous version of FMEA)
|
||
for the original design reviews performed during the 1960s and FMEA for
|
||
new-model reviews performed during the 1980s and 90s. Because the rudder
|
||
systems had not been completely redesigned in the new model 737s, the
|
||
FAA required only a very limited scope for the FMEAs conducted in the
|
||
80s and 90s. Despite these analyses and consistent with their limited
|
||
scope, the NTSB investigation determined that the airplane’s rudder
|
||
system was subject to several previously unidentified single-point
|
||
failures that could have catastrophic results. One or more of these
|
||
failure modes was most likely involved in the rudder system jam and
|
||
reversal, which led to the fatal accidents.</p>
|
||
<p>The NTSB issued numerous safety recommendations related to its
|
||
findings regarding the Boeing 737 rudder system and unusual attitude
|
||
recovery procedures for flight crews. In Safety Recommendation A-99-21,
|
||
the NTSB recommended to the FAA:</p>
|
||
<p style="padding-left: 30px;">Convene an engineering test and
|
||
evaluation board to conduct a failure analysis to identify potential
|
||
failure modes, a component and subsystem test to isolate particular
|
||
failure modes found during the failure analysis, and a full-scale
|
||
integrated systems test of the Boeing 737 rudder actuation and control
|
||
system to identify potential latent failures and validate operation of
|
||
the system without regard to minimum certification standards and
|
||
requirements in 14 Code of Federal Regulations Part 25. Participants in
|
||
the engineering test and evaluation board should include the Federal
|
||
Aviation Administration (FAA); National Transportation Safety Board
|
||
technical advisors; the Boeing Company; other appropriate manufacturers;
|
||
and experts from other government agencies, the aviation industry, and
|
||
academia. A test plan should be prepared that includes installation of
|
||
original and redesigned Boeing 737 main rudder power control units and
|
||
related equipment and exercises all potential factors that could
|
||
initiate anomalous behavior (such as thermal effects, fluid
|
||
contamination, maintenance errors, mechanical failure, system
|
||
compliance, and structural flexure). The engineering board’s work should
|
||
be completed by March 31, 2000 and published by the FAA.</p>
|
||
<p>In response to this recommendation, the Engineering Test and
|
||
Evaluation Board (ETEB) was convened in May 1999 and completed its work
|
||
in July 2000 with the issuance of a final report. (Federal Aviation
|
||
Administration, <em>737 Flight Controls Engineering Test and Evaluation Board Final Report</em>,
|
||
July 20, 2000.) The staff of the ETEB was detailed from the FAA, Boeing
|
||
(Commercial, Space, and Military Airplane divisions), Air Line Pilots
|
||
Association, Ford Motor Company, Air Transport Association, Interstate
|
||
Aviation Commission (Russia), NASA, and U.S. Navy.</p>
|
||
<p>According to the ETEB’s report, the group conducted:</p>
|
||
<ul>
|
||
<li>A failure analysis of the flight control system to identify potential failure modes;</li>
|
||
<li>Component and subsystem tests to isolate particular failure modes found during the failure analysis; and</li>
|
||
<li>Full-scale integrated systems tests, including ground and flight
|
||
testing, of the … 737 rudder actuation and control system to identify
|
||
potential latent failures and to validate the operation of the system
|
||
(ETEB Final Report, p. 2-3).</li>
|
||
</ul>
|
||
<p>The ETEB noted that normal certification procedures for aircraft and
|
||
components require consideration of the probabilities of a failure mode
|
||
or adverse effect. However, the ETEB chose to evaluate the severity of
|
||
failure mode consequences without regard to their probability of
|
||
occurrence. The ETEB’s rationale for this approach was that the Boeing
|
||
737 had experienced approximately four serous failures of its rudder
|
||
system in 100 million flight hours, two of which had resulted in fatal
|
||
accidents. Therefore, the failures under investigation were extremely
|
||
rare but of extremely adverse outcome. Consequently, it was considered
|
||
appropriate to treat any failure mode with the potential for
|
||
catastrophic consequences as of the highest risk level, regardless of
|
||
how unlikely the failure mode or effect. A related goal of this new
|
||
analysis was to “focus…on rare failures that may not have been
|
||
considered in the original certification requirements” (because the
|
||
failures were considered extremely improbable, ETEB Final Report, p.
|
||
2-8). The ETEB described its analytical approach as follows:</p>
|
||
<p style="padding-left: 30px;">The ETEB conducted a comprehensive and
|
||
detailed failure modes and effects analysis (FMEA) for the complete
|
||
rudder control system…Preliminary hazard classifications were assigned
|
||
to each failure, based on the predicted severity and the ability of the
|
||
flight crew to maintain control of the airplane and conduct a safe
|
||
landing. For all failures classified as “catastrophic (Class I)” or
|
||
“hazardous (Class II),” the ETEB conducted failure simulations using a
|
||
detailed high-fidelity simulation of the rudder control system. In
|
||
addition, the ETEB conducted pilot-in-the-loop failure simulations using
|
||
a motion-base flight simulator. The purpose was to identify the impact
|
||
of the failures on the operation of the airplane following flight crew
|
||
actions. The hazard classifications of the failures were updated, based
|
||
on the combined results from these two simulation activities (ETEB Final
|
||
Report, p. 2-7).</p>
|
||
<p>These tests and simulations were used to verify and validate the
|
||
hazard levels that had preliminarily been assigned to the failure modes.
|
||
Because some failures and interventions had unexpected consequences in
|
||
the testing, the feedback from these verifications was extremely
|
||
important and influential in the final conclusions and recommendations
|
||
of the ETEB. This demonstrates how an FMEA that is open to feedback and
|
||
change, either from testing or field experience, can provide much better
|
||
results than a one-time evaluation.</p>
|
||
<p>The ETEB illustrated the verification and feedback built into the FMEA in the following figure from its final report:</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-eteb-diagram.gif" alt="" height="416" width="575"></p>
|
||
<p style="padding-left: 30px;"><em>Source: ETEB Final Report, p. 2-6</em></p>
|
||
<p>The full range of hazard classifications followed standard FAA practice and was defined as follows by the ETEB:</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-eteb-hazards-table.gif" alt=""></p>
|
||
<p style="padding-left: 30px;"><em>Source: ETEB Final Report p. 3-3</em></p>
|
||
<p>The ETEB used a standard adaptation of the FMEA analysis form (see
|
||
table). It is interesting to note how the form explicitly recognized the
|
||
mitigating effects of flight crew actions in response to equipment
|
||
malfunctions (columns 5, 7, and 8).</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-eteb-analysis-form.gif" alt="" height="584" width="576"></p>
|
||
<p style="padding-left: 30px;"><em>Source: ETEB Final Report, p.3-2</em></p>
|
||
<p>Although the possibility of imperfect flight crew performance (a
|
||
realistic expectation for human intervention in a complex or stressful
|
||
situation) was not explicitly modeled on the FMEA worksheet, the ETEB
|
||
accomplished this important extension to the basic FMEA by validating
|
||
and revising assumptions about the reliability of flight crew
|
||
performance through its testing process. The ETEB found that flight
|
||
crews were not able to reliably intervene and mitigate the consequences
|
||
of rudder component failures in some operational circumstances, and
|
||
these revised expectations were entered into the final versions of the
|
||
FMEA worksheets.</p>
|
||
<p>The following figure provides an excerpt of an actual FMEA worksheet.
|
||
This worksheet includes a finding of catastrophic severity for a
|
||
failure effect that could not be mitigated:</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-eteb-appendix.gif" alt="" height="559" width="689"></p>
|
||
<p style="padding-left: 30px;"><em>Source: ETEB Final Report, appendix A, p. 95</em></p>
|
||
<p>Another useful extension that the ETEB added to the basic FMEA was
|
||
the explicit consideration of latent (preexisting, undetected) failures
|
||
combined with active failures. Although FMEA is not considered to be
|
||
well-suited to the analysis of multiple failure modes, the ETEB was able
|
||
to readily analyze these sequential failure combinations by treating
|
||
the latent and active failures as a single combined failure mode for
|
||
subsequent evaluation of the failure effects and consequences. This
|
||
manual extension of the FMEA method was effective for linked pairs of
|
||
errors; I think that it may have been very complicated to use this
|
||
method to track and display triple or even more complicated failure
|
||
combinations, but these failure combinations were not required.</p>
|
||
<p>The table that follows (from ETEB Final Report, p. 3-40) provides a
|
||
sample of the new latent/active failure combinations that the ETEB was
|
||
able to identify and analyze using FMEA:</p>
|
||
<p><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/burman-1-eteb-failures-table.gif" alt="" height="510" width="571"></p>
|
||
<p>The FMEA undertaken by the ETEB was successful in identifying a large
|
||
number of previously unknown or unevaluated failure modes, several of
|
||
which had the potential to result in catastrophic consequences. The
|
||
following are excerpted from the results presented by the ETEB in its
|
||
final report:</p>
|
||
<p style="padding-left: 30px;">The [Boeing] 737 rudder control system is susceptible to a number of:</p>
|
||
<ul>
|
||
<li>Failures and jams that can cause uncommanded rudder motion;</li>
|
||
<li> Failures and jams that affect the operation of both the rudder main
|
||
and standby power control units (PCU), thereby defeating the
|
||
independence of the two systems; and</li>
|
||
<li> Latent failures.</li>
|
||
</ul>
|
||
<p>These failure modes are single failures, single jams, or latent failures in combination with a detectable failure or jam.</p>
|
||
<p>The rudder control system of the Initial and Classic Model 737s with
|
||
the modifications required by the applicable FAA [Airworthiness
|
||
Directives]…have:</p>
|
||
<ul>
|
||
<li>14 single failures and jams, and 12 latent failure combinations,
|
||
that have Class I failure effects in the takeoff and landing regimes.
|
||
These same failure modes have 4 Class I effects and 22 Class III (major)
|
||
effects in the rest of the flight envelope.</li>
|
||
<li>8 single failures and jams, and 11 latent failure combinations, that have Class II failure effects. (ETEB Final Report p.. 1-3)</li>
|
||
</ul>
|
||
<p>The ETEB drew strong conclusions about factors influencing the
|
||
efficacy of human interventions to mitigate rudder system failures:</p>
|
||
<p>The ETEB conducted 40 hours of pilot-in-the-loop rudder failure
|
||
simulations with10 pilot and co-pilot flight crews from four airlines.</p>
|
||
<ul>
|
||
<li>In general, the flight crews found the existing Jammed or Restricted Rudder Emergency Procedure difficult to use.</li>
|
||
<li>The flight crews appeared to have received little training in the
|
||
use of the Jammed or Restricted Rudder Emergency Procedure or the
|
||
Uncommanded Yaw or Roll Emergency Procedure.</li>
|
||
<li>The lack of a clear and unambiguous display of rudder position made
|
||
it difficult for the crews to diagnose uncommanded rudder deflections
|
||
and take prompt corrective actions.</li>
|
||
<li>Uncommanded rudder hardover deflections during takeoff and landing
|
||
resulted in Class I failure effects [i.e., human intervention was not
|
||
reliably effective] (ETEB Final Report, p. 1-4).</li>
|
||
</ul>
|
||
<p>The ETEB’s investigation of latent failure effects using extended
|
||
FMEA methods resulted in a conclusion that “there are several latent
|
||
failures that, when combined with one additional single failure or jam,
|
||
result in Class I or Class II failure effects. There are insufficient
|
||
inspections for these latent failures” (ETEB Final Report, p. 1-5).</p>
|
||
<p>As I have indicated throughout, no FMEA is can be considered complete
|
||
unless it leads to the mitigation of the unacceptable risks that the
|
||
analysis identifies. The ETEB’s application of FMEA resulted in the
|
||
following recommendations for redesign of the rudder system:</p>
|
||
<p style="padding-left: 30px;">Modify the Boeing Model 737 rudder control system to ensure that:</p>
|
||
<ul>
|
||
<li>No single failure or single jam of the rudder control system will
|
||
cause uncommanded motion of the rudder surface that results in a Class I
|
||
failure effect;</li>
|
||
<li>No combination of failures or jams will result in a Class I failure
|
||
effect, except for those combinations that are shown to be extremely
|
||
improbable; and</li>
|
||
<li>No probable single failure or jam will have an effect worse than Class IV.<br>In
|
||
addition, The Boeing Company should consider providing a fail-safe
|
||
rudder control system design that provides protection from latent
|
||
failures that contribute to a Class I failure effect (ETEB Final Report,
|
||
p. 1-6).</li>
|
||
</ul>
|
||
<p>As a result of these recommendations (and the preceding accident
|
||
investigation causal findings and recommendations of the NTSB), the
|
||
Boeing 737 rudder system has been redesigned to provide reliable
|
||
redundancy, and a major hardware retrofit program is underway for the
|
||
entire fleet.</p>
|
||
<p>To mitigate risks pending completion of this fleet retrofit, the ETEB
|
||
also provided the following recommendations to improve the risk
|
||
mitigation value of human (pilot and mechanic) interventions following a
|
||
rudder system failure:</p>
|
||
<ul>
|
||
<li>Revise and simplify the current “Jammed or Restricted Rudder” emergency procedure.</li>
|
||
<li>Provide additional training to flight crews in the use of the
|
||
“Jammed or Restricted Rudder” emergency procedure and the related
|
||
“Uncommanded Yaw or Roll” emergency procedure.</li>
|
||
<li>Display rudder position to the flight crew.</li>
|
||
<li>Alert flight crews and maintenance crews to the signs of rudder
|
||
malfunctions, such as uncommanded pedal motion (ETEB Final Report, p.
|
||
1-6).</li>
|
||
</ul>
|
||
<p>These recommendations targeted at improving human performance have
|
||
been partially implemented by the aircraft manufacturer and FAA, from
|
||
2000 to present. Despite the limitations that remain in human
|
||
interventions, it is most significant, I believe, that the result of the
|
||
FMEA performed by the ETEB was to render the designers’ expectations
|
||
for human performance, and the design’s reliance on human intervention,
|
||
much more consistent with realistic human capabilities and limitations.
|
||
This was a strong contributor to the accuracy and applicability of the
|
||
FMEA’s results and its ability to improve system safety.</p>
|
||
<p>In all, I believe that the ETEB process was a very successful example
|
||
of the application of FMEA extended with (1) top-down analysis (the
|
||
program began with foreknowledge that the end-level adverse event to
|
||
eliminate or mitigate was flight control malfunction leading to loss of
|
||
aircraft control), (2) consideration of multiple (latent) failures, and
|
||
(3) realistic consideration of human performance during interventions,
|
||
and (4) feedback from external data sources to FMEA revision. In the
|
||
ETEB application, FMEA was not supplemented by data-driven analysis of
|
||
conditional probabilities, this was an appropriate, conservative
|
||
response to the extremely rare/extremely hazardous nature of the
|
||
environment and threats.</p>
|
||
<p>The ETEB’s work shows how the basic FMEA combined with complementary
|
||
extensions can form a comprehensive safety analysis that results in real
|
||
safety improvement. The excellent results of the ETEB program are
|
||
equally a testament, I think, to a strong effort to creatively re-think
|
||
the failure modes and effects for a system that had been thought to be
|
||
completely well-understood and thoroughly time-tested by 100 million
|
||
hours of field use. This creativity and openness are necessary
|
||
ingredients for any successful analysis.</p>
|
||
<h3>Conclusions about FMEA</h3>
|
||
<p>Based on the foregoing review, I conclude the following about the Failure Modes and Effects Analysis methodology:</p>
|
||
<ul>
|
||
<li>FMEA is a sound methodology for basic, structured risk management and quality improvement analysis.</li>
|
||
<li>The ideal approach can be to use FMEA as the backbone for analysis
|
||
that also includes the integration of complementary methods, as
|
||
required; for example, it may be appropriate to apply elements of FTA or
|
||
PRA to understand and explore the proper scope of analysis, the
|
||
significance of failure effects, and the effectiveness of risk
|
||
management interventions.</li>
|
||
<li>Thoughtful application of FMEA can identify when these extensions
|
||
are required and to integrate and document results of an extended
|
||
analysis.</li>
|
||
<li>The limited reliability of humans in complex systems argues for
|
||
multiple, redundant, independent interventions when relying on humans to
|
||
detect failure modes or actively intervene to mitigate failure effects.</li>
|
||
<li>FMEA, as extended with appropriate top-down, probabilistic, and
|
||
feedback methods, is an excellent framework for risk management and
|
||
quality improvement in the post-design/post-manufacture (field
|
||
distribution, application, or user) environment, including the human
|
||
performance aspects of this environment.</li>
|
||
</ul>
|
||
<p> </p>
|
||
<p><a name="1"></a><span style="vertical-align: super; font-size: 70%;">[1]</span>
|
||
I acknowledge and thank ParagonRx, LCC for its support of my review of
|
||
risk-management methodologies and the writing of this paper. All
|
||
opinions expressed herein are my own and do not necessarily represent
|
||
the opinions, policies, and products of ParagonRx, LLC.</p>
|
||
<p> </p>
|
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<p><a href="http://www.paragonrx.com/downloads/white_papers/Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques.pdf" target="_blank"><img src="Effective%20Risk%20Management%20and%20Quality%20Improvement%20by%20Application%20of%20FMEA%20and%20Complementary%20Techniques%20%7C%20ParagonRx_files/adobe_pdfdoc.gif" alt="" height="14" width="14"><em> Download</em></a></p>
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