Introduction to FBD and FTA

Functional Block Diagrams Fault Tree Analysis

Compliance Engineering

Ultratech Internal Use Only

Slide 1 May 8th, 2007

Fault Tree Analysis - Review

What ?

A structured team analysis of the possible underlying causes of a known equipment failure. root cause analysis of a failure is needed

When ?

Why? - (outcomes)

A better understanding of the root causes of a failure

A better set of action plans to eliminate those root causes (Step 4: Solution)
2 DATA 3 ROOT CAUSE 4 SOLUTION 5 CONFIRM RESULTS
No

1 THEME

6 STANDARDIZE

7 REFLECT

Yes

Compliance Engineering

Ultratech Internal Use Only

Slide 2 May 8th, 2007

Fault Tree Analysis

Fault tree analysis is an effect and cause diagram that uses standard symbols developed in the defense industry and is used heavily in safety engineering. FTA is a structured approach for analyzing the root causes of a failure mode not yet fully understood.

Note: FTA is an alternative to Ishikawa (Fish Bone) Diagrams. Many feel that FTA is better suited to understanding layers and relationships of causes of equipment failures. However, if you still prefer fish bones after trying FTA, there is no reason not to use them. The goal always remains to use the most efficient method for solving problems.

Compliance Engineering

Ultratech Internal Use Only

Slide 3 May 8th, 2007

FTA Example: Smoke Detector

Failure: The indicator light is on yet even with sufficient amounts of smoke directly below the detector vents the alarm does not signal. Before we begin either a Fault Tree Analysis or Failure Modes and Effects Analysis, our first step should be to construct a Functional Block Diagram.

THEME

DATA

ROOT CAUSE

SOLUTION

CONFIRM RESULTS
No

Yes

STANDARDIZE

REFLECT

Compliance Engineering

Ultratech Internal Use Only

Slide 4 May 8th, 2007

FBD Example: Smoke Detector

Process
Detection of smoke

Outputs
Alarm signaling Signal/power to siren turns motor Motor causes siren to sound

Smoke enters through vent Smoke enters ionization chamber

Battery powers control box, indicator light, and smoke detector

Smoke is ionized and causes increase in voltage Signal sent from smoke detector triggers control box circuit Control Box sends signal/power to siren

Alarm signals

Compliance Engineering

Ultratech Internal Use Only

Slide 5 May 8th, 2007

Sample solution (incomplete)

FAILURE Smoke Detector does not detect smoke

Smoke not present in chamber

Smoke not detected

Alarm not sounding

Vent is blocked Dust blockage Paint blockage

Ionization chamber blocked Dust blockage

Defective Control box

No power at control box

No power at ionization chamber

Defective ionization chamber

Defective alarm

No power at alarm

Broken wire

Defective solder joint

Ionization chamber cracked

Broken wire

Defective solder joint

1 THEME

2 DATA

3 ROOT CAUSE

CONFIRM RESULTS
No

STANDARDIZE

Compliance Engineering

Ultratech Internal Use Only

Slide 6 May 8th, 2007

Typical use for an FTA:

Began by clearly identifying the failure as: The indicator light is on yet even with sufficient amounts of smoke directly below the detector vents the alarm does not signal. Began brainstorming and building a functional block diagram to fully understand how the smoke detector functions. Continued brainstorming on possible causes for the smoke detector failure resulting in the alarm not signaling. Probable causes were identified:

The team constructed the FTA around the three major categories in the functional block diagram, inputs, process, and outputs. The team continued to build the FTA and completed it by adding lower levels of detail under appropriate causes of failure. The team identified the types of failure where it did not have the expertise to analyze possible root causes. If deemed necessary, the team would seek help from suppliers or consultants to further analyze these area. The leading causes of failure and solutions were identified.

A design project was started to correct the problem.

Compliance Engineering

Ultratech Internal Use Only

Slide 7 May 8th, 2007

Fault Tree

Symbols Review

Square

Describes the top and lower level failures Produces output (failure) if one or more inputs exist Produces output (failure) if and only if all inputs exist

Or Gate

And Gate

Circle

Potential root failure which cannot be broken down into lesser failures
Potential failure which is not analyzed for various reasons
Ultratech Internal Use Only Slide 8 May 8th, 2007

Diamond

Compliance Engineering

How to build a Fault Tree

Determine which combination of contributors is needed to cause the top failure. (Ask: How many of the inputs are needed to cause the top failure? ) Link the contributors to the top failure with the correct gate. (And/Or)

Ask: Can we determine contributors for this lower failure ?

Yes - repeat cycle making each contributor a top failure, assign gates, etc... No - we are finished - We may also end our fault tree when we reach all indeterminable, basics, or causes which require further research etc...
Ultratech Internal Use Only

Compliance Engineering

Slide 9 May 8th, 2007

Understanding the symbols (Gates Review)

Failure

All of these failures must occur

Or gate means that

Failure

Only one of these failures must occur

Compliance Engineering

Ultratech Internal Use Only

Slide 10 May 8th, 2007

Step 1 Identify Top Level Fault Step 3 Link contributors to top by logic gates Step 2 Brainstorm first level contributors Step 5 Link contributors to upper level by logic gates Step 4 Brainstorm second level contributors

basic event cannot be broken down any further

Step 6 Repeat / continue for each lower level failure

event that is not analyzed for various reasons

(This page is taken from SVERDROP MANUAL - FTA and Risk Management by P.L. Clemens, 1992/1993, pg. 10 )
Compliance Engineering Ultratech Internal Use Only Slide 11 May 8th, 2007

FTA Dos & Don'ts

Dos

Start at the Top Think Categories Brainstorm, then organize Facilitate proper brainstorming Know when to stop Have action plans for all circles Check that branches terminate with a circle or diamond Revisit the FBD or FTA when new data is found Use yellow stickies to capture the brainstormed causes Dont get bogged down Dont jump to solutions!
Ultratech Internal Use Only Slide 12 May 8th, 2007

Don'ts

Compliance Engineering