Competitive environment in manufacturing sector cannot afford frequent breakdown of aged critical equipment. In this paper, an attempt is made to develop a method to determine critical equipment with the help of failure mode and effect analysis (FMEA) and occurrence of failure. In this research, the impact of machine breakdown on production, safety, availability of standby, and equipment or asset value is considered with weights of 30, 30, 25, and 15%, respectively. With these factors and corresponding weights, a critical equipment of shop floor is identified. Further, this identified critical equipment is analyzed in detail to determine the highest risk priority number (RPN) of subassembly or component. This high RPN of component or subassembly is reduced with the appropriate maintenance action by determining reliability of each subassembly or component. This approach is useful for the maintenance personnel to plan the maintenance activities and reduce the probability of failures, thereby reducing the machine breakdown.
This is a preview of subscription content, access via your institution.
Buy single article
Instant access to the full article PDF.
Tax calculation will be finalised during checkout.
Subscribe to journal
Immediate online access to all issues from 2019. Subscription will auto renew annually.
Tax calculation will be finalised during checkout.
C.-C. Chen, A developed autonomous preventive maintenance program using RCA and FMEA. Int. J. Prod. Res. (2013). https://doi.org/10.1080/00207543.2013.775521
D. Jung, Z. Zhang, M. Winslett, Vibration analysis for IoT enabled predictive maintenance, in 2017 IEEE 33rd International Conference on Data Engineering (2017)
R. Ahmad, S. Kamaruddin, I. Azid, I. Almanar, Maintenance management decision model for preventive maintenance strategy on production equipment, J. Ind. Eng. Int. 7(13), ISSN: 1735-5702, 22–34 (2011)
E.R. Weishaupt, M.E. Stevenson, J.K. Sprague, Overload fracture of cast aluminum wheel. ASM J. Fail. Anal. Prev. 14(6), 702–706 (2014)
M.C. Eti, S.O.T. Ogaji, S.D. Probert, Integrating reliability, availability, maintainability and supportability with risk analysis for improved operation of the Afam thermal power-station. Appl. Energy. 84, 202–221 (2007)
T.-M. Yeh et al., Preventive maintenance model with FMEA and Monte Carlo simulation for the key equipment in semiconductor foundries. Acad. J. Sci. Res. Essays. 6(26), 5534–5547 (2011)
N.E. Myeda, S.N. Kamaruzzaman, Measuring the performance of office buildings maintenance management in Malaysia. J. Facil. Manag. 9(3), 181–199 (2011)
F. Saleem et al., Overall equipment effectiveness of tyre curing: a case study. J. Qual. Maint. Eng. 23(1), 39–56 (2017). https://doi.org/10.1108/jqme-06-2015-0021
G. Xu, G.Q. Huang, J. Fang, J. Chen, Cloud based smart asset management for urban flood control. Enterp. Inf. Syst. 11, 719–737 (2017). https://doi.org/10.1080/17517575.2015.1086493
F.I. Khan, S.A. Abbasi, Techniques and methodologies for risk analysis in chemical process industries. J. Loss Prev. Ind. 11, 261–277 (1998)
X.-S. Si, W. Wang, C.-H. Hu, D.-H. Zhou, Remaining useful life estimation—a review on the statistical data driven approaches. Eur. J. Oper. Res. 213, 1–14 (2011)
F. Rath, Tools for developing a quality management program: proactive tools (Process Mapping, Value Stream Mapping, Fault tree analysis and Failure mode and effect analysis). Int. J. Radiat. Oncol. Biol. Phys. 71(1), S187–S190 (2008)
M. Shafiee, E. Enjema, A. Kolios, An integrated FTA-FMEA model for risk analysis of engineering systems: a case study of subsea blowout preventers. Appl. Sci. 9, 1192 (2019). https://doi.org/10.3390/app9061192
I.H. Afety, Reliability centered maintenance methodology and application: a case study. Sci. Res. Eng. 2, 863–873 (2010)
D.H. Besterfield, Total Quality Management. (Pearson Education Publication, Delhi, 2003)
L.S. Shrinath, Reliability Engineering. (East West Press, New Delhi, 2013)
M.E. Stevenson, M.D. Hayes, J.L. McDougall, S.A. Sanders, Failure analysis of hydraulic fitting brazed connections. ASM J. Fail. Anal. Prev. 12(2), 118–122 (2012)
M.E. Stevenson, M.D. Hayes, D.A. Turnquist, Failure analysis of a glass filled phenolic resin power steering pump pulley. ASM J. Fail. Anal. Prev. (2014)
K. Fraser, Maintenance management models—a study of the published literature to identify empirical evidence [A greater practical focus is needed]. Int. J. Qual. Reliab. Manag. 32(6), 635–664 (2015)
F.L. Cook, Plant maintenance strategy: evidence from four British manufacturing firms. J. Qual. Maint. Eng. 9(3), 239–249 (2011)
M.E. Stevenson, D.G. Klepacki, J.L. McDougall, D.E. Alexander, Failure investigation of an aircraft crankshaft gear connection. ASM J. Fail. Anal. Prev. 12(6), 617–622 (2012)
K. Khazraei, J. Deuse, A strategic standpoint on maintenance taxonomy. J. Facil. Manag. 9(2), 96–113 (2011)
I am Anand S. Relkar, greatfully thanks to Dr. Dipen Kumar Rajak, Assistant Professor, Department of Mechanical Engineering, at Sandip Institute of Technology and Research Centre, Nashik for going through the manuscript and provides valuable comments and suggestions for improving the quality of this work.
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
About this article
Cite this article
Relkar, A.S. Risk Analysis of Equipment Failure through Failure Mode and Effect Analysis and Fault Tree Analysis. J Fail. Anal. and Preven. (2021). https://doi.org/10.1007/s11668-021-01117-7
- Failure mode and effect analysis
- Fault tree analysis
- Equipment performance
- Risk priority number
- Criticality analysis