FMEA Example of an Investment Cast Rifle Bolt
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FMEA Homework Due per the course syllabus
Fill in the FMEA analysis Chart below using a subsystem or part of your Senior Design Project. Use a part or subsystem with at least three functions, determine at least two failure modes and follow those failure modes through the rest of the chart. Turn the assignment in to your Senior Design instructor and include the FMEA analysis in your end of semester proposal. Special Note: The lecture will walk the class through a similar FMEA process. The following homework assignment is intended as a simplified version to be done for your project.
Part & Function Potential Failure Mode Potential Effect(s) Of Failure S E V Potential Cause(s)/ Mechanism(s) Of Failure O C C Detection Method & Quality Controls D E T RPN Recommended Actions
1. Three key questions to be answered by the FMEA process: What could fail in each component of my product or design? To what extent might it fail and what are the potential hazards produced by the failure?
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FMEA Example of an Investment Cast Rifle Bolt
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What steps should be implemented to prevent failures? 2. Design FMEA Analysis Delta = Critical characteristic which may effect safety, compliance with Gov. regulations, or require special controls. SEV = Severity rating (1 to 10) OCC = Occurrence frequency (1 to 10) DET = Detection Rating (1 to 10) RPN = Risk Priority Number (1 to 1000)
Item and Potential Function Failure Mode
List Part Name, Number and Function List the possible modes of failure
Potential Effects of Failure
List the consequences of failure on part function and on the next higher assembly
S Potential O Detection E Cause(s) C Method & V of Failure C Quality Controls
List those such as: inadequate design, improper materials, etc. List these measures available to detect failures before they reach the customer
D R Recommended Actions E P T N
List them for each of the failure modes identified as being significant by the RPN
3. Let's go through a simple column-by-column example using a rifle bolt.
Item and Function Rifle Bolt Chambers bullet Locks into receiver Fires a round Sustains firing pressure on lugs Provides extraction of spent case Potential Failure Modes Fracture Jamming
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FMEA Example of an Investment Cast Rifle Bolt
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FMEA Example of an Investment Cast Rifle Bolt
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6 7 8 9 10
Significant Major Extreme Serious Hazardous
The product requires repair. Product performance is degraded. Comfort or convenience functions may not operate. Product performance is severely affected but functions. The system may not be operable. Product is inoperable with loss of primary function. The system is inoperable. Failure involves hazardous outcomes and / or noncompliance with govt. regulations or standards. Failure is hazardous, and occurs without warning. It suspends operation of the system an/or involves noncompliance with govt. regulations
Potential Effects of Failure Catastrophic failure with destruction of weapon and injury to personnel------> Failure of weapon to function-------------------------->
Delta yes no
SEV 10 1
Likelihood of Occurrence (OCC) - Estimate the potential occurrence of failure
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FMEA Example of an Investment Cast Rifle Bolt
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7 8 9 10
4 x 10-2 0.2 0.33 0.55
High Repeated Failures Very High Extremely High: Failure Almost Inevitable
Detection Method & Quality Controls Incoming Part Inspection Dye penetrate testing Measure patterns Confirm finished casting dimensions
Ranking
1 2 3 4 5 6 7 8 9 10
Almost Certain Detection Very High Chance of Detection High Probability of Detection Moderately High Chance of Detection Moderate Chance of Detection Low Probability of Detection Very Low Probability of Detection Remote Chance of Detection Very Remote Chance of Detection Absolute Uncertainty No Control
Detection Probability
Calculate the RPN number RPN = (SEV) x (OCC) x (DET) A 1000 rating implies a certain failure that is hazardous and harmful A 1 rating is a failure that is highly unlikely and unimportant
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FMEA Example of an Investment Cast Rifle Bolt
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Ratings above 100 will occur Rating below 30 are reasonable for typical applications Final Column - Based on your RPN number, develop recommended actions to solve failure modes Assign responsibilities Outline corrective actions Revise test plans, material specifications These actions should be specific, not general action items
Part and Function Potential
Failure Mode
Potential Effects of Failure
D E L T A
yes
S E V
Potential Cause (s) of Failure
O C C
Detection Method & Quality Controls
D E T
Rifle Bolt Chambers bullet Locks into receiver Fires Round Sustains firing pressure on lugs Provides extraction of spent case
Fracture
Catastrophic failure with destruction of weapon and injury to personnel Failure of weapon to function
10
Shrinkage Porosity caused by improper feed
Incoming Part Inspection Dye penetrate testing
Jamming
Out of spec. Dimension Change in shell refractory
Measure patterns Confirm finished casting dimensions
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FMEA Example of an Investment Cast Rifle Bolt
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