TQM IEM Lecture Reliability FMEA TPM

Reliability, FMEA and
TPM
© Tapan Bagchi TQM IEM Reliability 1

Reliability
• Generally defined as the ability of a
product to perform as expected over
time
• Formally defined as the probability that
a product, piece of equipment, or
system performs its intended function
for a stated period of time under
specified operating conditions
Tapan Bagchi TQM IEM Reliability 2
Maintainability
• The probability that a system or product
can be retained in, or one that has
failed can be restored to, operating
condition in a specified amount of time.

Types of Failures
• Functional failure – failure that occurs
at the start of product life due to
manufacturing or material detects
• Reliability failure – failure after some
period of use
These relate to the ―bathtub curve‖.

Types of Reliability
• Inherent reliability – predicted by
product design
• Achieved reliability – observed during
use; based on observed failure data

How do you measure Reliability?
• Failure rate (l) – number of failures

per unit time
• Alternative measures
– Mean time to failure
– Mean time between failures (MTBF)

Failure Rate Curve
“Infant
mortality
period”

Cumulative Failure Rate
Curve

Average Failure Rate = 0.02

Typical Forms of Failure
 Early failure
due to design faults,
poor quality components,
manufacturing faults,
Failure Rate
installation errors,
operator & maintenance errors
 Useful life
Early Wear-out has a low, constant failure rate
Failure Useful Failure
Life
 Wear-out failure
Time parts approach the end of life

Measuring Reliability
 Reliability R(t):
The probability of operating to an
agreed level of performance
 Unreliability F(t):
The probability of failing to operate
to an agreed level of performance
Rt   F t   1

Reliability Function for Service Life
• Probability density function of failure time

is exponential: f(t) = le-lt for t > 0
• Probability of failure from (0, T)
F(t) = 1 – e-lT
• Failure rate = l
• Reliability function
R(T) = 1 – F(T) = e-lT
In general, Failure Times fit
Weibull Distribution
In probability theory and statistics, the Weibull distribution is a
continuous probability distribution with the probability density function
for and f(x; k, λ) = 0 for x < 0, where k > 0 is the shape

parameter and λ > 0 is the scale parameter of the distribution.
The Weibull distribution is often used in the field of life data analysis due
to its flexibility—it can mimic the behavior of other statistical distributions
such as the normal and the exponential. If the failure rate decreases over
time, then k < 1. If the failure rate is constant over time, then k = 1. If the
failure rate increases over time, then k > 1.

The Weibull Distribution
expressions

Life Testing Data
r(t) =
Observed Reliability
No. of Cumulative No. f(t)= n(t)/
R(t)=
Failure of n(t)/ avg S(t)/20
Time t s n(t) Failures Surviving S(t) 2000 S 00 F(t) = 1 - R(t)
0 0 2000 1.000 0.000

650 0.325 0.388
1 650 1350 0.675 0.325
350 0.175 0.298
2 1000 1000 0.500 0.500
210 0.105 0.235
3 1210 790 0.395 0.605
166 0.083 0.235
4 1376 624 0.312 0.688
131 0.066 0.235
5 1507 493 0.247 0.754
103 0.052 0.233
6 1610 390 0.195 0.805
82 0.041 0.235
7 1692 308 0.154 0.846
65 0.033 0.236
8 1757 243 0.122 0.879
120 0.060 0.656
9 1877 123 0.062 0.939
123 Tapan Bagchi TQM IEM Reliability
0.062 2.000 16
10 2000 0 0.000 1.000
r(t) and R(t) Calculations displayed
Failure Rate vs. Time

2.500
2.000
1.500 r(t) Faiure Rate

1.000 Reliability R(t)
0.500
0.000
0 1 2 3 4 5 6 7 8 9 10
Time

Reliability of Non-Repairable Items
T1 T2 T3
Td1 Td2 Td3
 Mean Time To Fail (MTTF)

ratio of total up time to number
of failures.
 Mean Failure Rate (l)

inverse to MTTF.
 Mean Down Time (MDT)

ratio of total down time to
number of failures.
Reliability of Repairable Items
Tup1 Tup2 Tup3
Td1 Td2 Td3
T
 Total Up Time (Tup)

total time minus total down time
 Mean Time Between Failures

(MTBF)
ratio of total up time to number
of failures.
 Mean Failure Rate (l)

inverse to MTBF.
Availability
• Operational availability
MTBF MTBM = mean time between
AO 
MTBM  MDT maintenance
MDT = mean down time
• Inherent availability
MTBF = mean time between
MTBF failures
A
MTBF  MTTR MTTR = mean time to repair

Design for Reliability
 Element selection
elements with well-established failure rate data
 Environment
elements can withstand normal working environment
 Minimum complexity
fewer elements (series systems)
 Redundancy
several identical elements in parallel
 Diversity
a give function is carried out by two parallel systems

Series Systems
1 2 n
RS = R1 R2 ... Rn

Reliability of Series System
Reliability of a series
I O system is the product of
R1 R2 Rn individual element
reliabilities.
Rsystem  R1  R2    Rn System reliability is

 l1t  l2 t  ln t
lower than the lowest
e e  e element reliability
 ( l1  l2  ln ) t
e
Parallel Systems
RS = 1 - (1 - R1) (1 - R2)... (1 - Rn)

Reliability of Parallel System
R1 Reliability of a parallel
system is determined by
I R2 O
the product of individual
element unreliabilities.
Rn
System reliability is
Rsystem  1  F1  F2    Fn
greater than the
 1  (1  e l1t )  (1  e l2t )    (1  e lnt )
greatest element
reliability

Series-Parallel Systems
C
RA RB RC RD
A B D
C
RC
• Convert to equivalent series system

RA RB RD
A B C’ D
RC’ = 1 – (1-RC)(1-RC)
Reliability Management
• Define customer performance requirements
• Determine important economic factors and
relationship with reliability requirements
• Define the environment and conditions of
product use
• Select components, designs, and vendors
that meet reliability and cost criteria
• Determine reliability requirements for
machines and equipment
• Analyze field reliability for improvement
Configuration Management
1. Establish approved baseline
configurations (designs)
2. Maintain control over all changes in the
baseline programs (change control)
3. Provide traceability of baselines and
changes (configuration accounting)

Design Issues
• Access of parts for repair
• Modular construction and
standardization
• Diagnostic repair procedures and
expert systems

Maintainability
• Maintainability is the totality of design

factors that allows maintenance to be
accomplished easily
• Preventive maintenance reduces the
risk of failure
• Corrective maintenance is the
response to failures
Reliability Engineering
• Standardization
• Redundancy
• Physics of failure
• Reliability testing
• Burn-in
• Failure mode and effects analysis
(FMEA)
• Fault tree analysis (FTA)
FTA
Tapan Bagchi TQM IEM Reliability

http://www.weibull.com/basics/fault-tree/index.htm 32
Fault Tree Analysis (FTA)
Bulb
Fails
Example:
No Glass Filament Vacuum

electricity Broken Broken Leak
Power Plant Power Line Connector

Impurities Vibrations
Fails Fails Corroded
Wind Breaks Tree Breaks

Line Line
Bicycle fails when I rush to class
Draw the FTA:
Hint: Draw an FTA diagram

for the total system first.

Faults/Pathways Magnified N-fold for a
Simple Manufacturing Process!

FMEA

http://www.npd-solutions.com/fmea.html
FMEA
Failure Mode and Effect Analysis
37
Failure, Likelihood,
Impact…
• Most real systems are designed to serve a purpose or deliver
some function
• But few systems are perfect—most are liable to failure. Then
they fail to deliver their designed functionality
• A car may not start, or its braking system may fail
• The consequence of such failure may be drastic and its
occurrence is generally uncertain
• It is possible to plan contingent actions, or modify the design—to
reduce (a) the likelihood of a failure, or (b) its impact, or (c) both
• FMEA—an analytical procedure that helps one mitigate the risks
by proactively reducing (a) the severity of the adverse situation,
or (b) the likelihood (probability) of its occurrence
38
Steps for doing FMEA
• Identify possible causes (modes) of failure
• Estimate the likelihood of the cause being active
• Determine the potential impact (severity) of the consequent
failure
• Calculate RPN—the Risk Priority Number—for this failure mode
• Order the modes in descending order of RPN
• Plan actions to reduce RPN, starting with the mode with the
highest RPN—by reducing the likelihood (probability) of this
failure mode becoming active, and/or by reducing its potential
impact
• Implement the preventive actions
39
A Simple Example of performing
FMEA
• Mission: A family vacation at Goa
• Modes that may cause the mission to fail:
Sickness Wallet lost Strike
Vacation is
spoiled
Travel Can’t
Accident
mix up find hotel
40
Severity × Likelihood = RPN
Mode Severity Likeli- RPN Possible Causes
(Impact) hood of failure
Sickness 1 0.1 0.1 Exposure
Infection
Wallet lost 9 0.25 2.2 Unsafe acts

One wallet
Strike 3 0.1 0.3 Did not see news
Accident 8 0.2 1.6 Hazards
Unsafe actions
Travel Mix 5 0.1 0.5 No reservation
up Unreliable agent
Can’t find 5 0.25 0.63 No reservation
41
hotel No map; no car
The ―Risk Map‖—before
10 FMEA
Impact
Wallet
8 lost
Accident
Strike
6
4 Travel No hotel
mix up
Sickness
42
0 0.2 0.4 0.6 0.8 1.0 Probability 
Mitigation actions facilitated by FMEA
Causes Mitigation & Severity Likeli- RPN
(things that may proactive (Impact) hood
go wrong or fail) actions
Exposure Avoid 1 0.1 0.1
Infection
Unsafe acts Safe keeping 3 0.1 0.3

One wallet Split $; use Visa
Did not see news Check news 1 0.1 0.1
Hazards Identify and 2 0.1 0.2

Unsafe actions Resolve
No reservation Reserve seats 1 0.1 0.1
Unreliable agent through
licensed agent
No reservation Book ahead 2 0.05 0.1
43
No map; no car Carry map
The Risk Map—After FMEA
10
Wallet
Impact lost
Accident
8
Strike
6
Travel No Hotel
Sickness
44
0.0 0.2 0.4 0.6 0.8 1.0  Probability
Benefits of doing FMEA
• It enhances system performance by helping one to identify
adverse factors that may impact performance
• It makes most of the risks visible, and helps one to quantify their
impact and probability of occurrence
• It helps one take proactive steps to prevent problems ahead of
the system’s being put into service, e.g. in new product design
and launch
• It helps in reduction of waste and costs due to nonperformance
caused by failures
• Today FMEA is an indispensable tool in the hands of engineers,
product and process designers, and trouble-shooters
45
High-Level Combinations of
Severity and Probability
Increasing Probability of
High Risk
Occurrence
Medium
Risk
Low
Risk
Increasing Severity of Harm/Consequence

FMEA – Why?
• Why FMEA’s?
• Definition, Purpose,
Types, Benefits
• Team Approach
Introduction

FMEA – Definition
FMEA is a Structured group of activities

which...
• Identify potential failure modes

• Prioritize actions
• Document the process.

FMEA – Purpose
Failures
FMEA
Crisis Time
(Production start)

FMEA – Purpose
FMEA’s are intended to ...
• Rate severity of failure modes

• Identify actions to reduce occurence
• Test adequacy of controls

Potential failure Modes
Failure Mode Type Example

No function Not operational
Partial function Not all of function operating

Severity (Weightfactor)
What is the severity of

each effect identified?

Rating criteria for Severity
(Weightfactor)
Effect Criteria: Severity of effect Class
Non-conforming
Safety failure
with safety
S
Unacceptable Correction is nescessary

risk A
Correction is recommended
Relative big
risk
B
risico Correctie isisnuttig

Correction usefull
Minimum risk C
C
None AcceptedTapan
failure
Bagchi TQM IEM Reliability D 53
Potential Cause of Failure
It is a weakness in the design with a failure mode

as effect.
(see next slide)

Manufacturing misbuilds
Due to design Deficiencies
+ +
- -

Manufacturing misbuilds
Robust Design done after FMEA
+ +
- -

Searching for Causes of failure
Use Fishbone Diagram:
Text in wrong location
“Text
unreadable”
Ink of poor quality

Cause of failure – ―Why‖-ladder
“Text unreadable”
Ink doesn’t stick

Surface roughness
level 1
not ok.
WHY?
level 2
Design requirement
WHY?
level 3
Tapan Bagchi TQM IEM Reliability WHY? 58
Sentencing Technique: Is it an
effect or a cause?
Could result in Effect
Failure
Mode Due to
Cause

Sentencing Technique -
Example
Dissatisfied
Could result in customer
“Text
Unreadable”
Due to Surface
roughness
(designreq.)

Product-FMEA – Occurrence
What is the probability that

the failure will occur?

Rating criteria
of occurrence
Probability of failure Possible Failure Rates Ranking
Very high 1 of 3 5

> 1 of 20 4
Moderate > 1 of 400 3
> 1 of 15000 2
Low < 1 of 15000 1

Product-FMEA – Actions/Solutions
What are the possible actions to:

- eliminate the failure
- reduce effect
- reduce occurrence

Do the Bicycle exercise again—by
FMEA

Total Productivity Maintenance
The Stars of TPM are the Japanese!

What is TPM?
What does maintenance mean anyway…
Maintenance = The act of maintaining

Maintain = To keep in a state of order. To keep in
due (rightful, proper, fitting) condition, operation,
or force; keep unimpaired.
Definition cont…
Fix and Repair = Maintenance
HOZEN (Maintenance in Japanese)

= Maintaining and preserving perfection through
Asset Management.
A common sight: Equipment
breakdown, waiting for repair
The goal of TPM is to change “Button-
pusher Operators” to Process Owners
or
change Firefighters to Maintainers.
It cuts downtime and losses and saves $.

The Five Pillars of TPM
• Autonomous Maintenance
• Maintenance Process Improvement
• Systematic Equipment Improvement
• Training and Skill Development
• Early Equipment Management
These are actualized through cross-functional Team-based

improvement activities
TPM Goals
T1 T2 T3
Td1 Td2 Td3
Characteristics of TPM
With TPM, Maintenance no more
remains the job of only the
―Maintenance Staff!!!‖
Like Six Sigma, TPM is best executed
by Cross-Functional Project Teams
Typical Cross-Functional TPM
Team at work
Results delivered by TPM
TPM programs deliver Real $
Note carefully that these bring direct savings to the plant

But moving to TPM requires a
Paradigm Shift
SEI—Systematic Equipment
Improvement
Autonomous
Maintenance
©2008 Productivity Inc. All Rights Reserved

What is
Autonomous Maintenance?
Seven Steps of Autonomous
Maintenance
—Operators not only run the machines,
they also maintain them
1. Conduct initial 5. Conduct general
cleaning/inspection inspections
2. Eliminate sources of 6. Improve workplace
contamination management and control
3. Establish provisional 7. Participate in advanced
standards improvement activities
4. Develop general
inspection training
Poor or neglected maintenance—no
TPM thinking by users
What losses could it lead to?

Still not that rare in a factory!
Dr Bagchi saw a similar sight at a Jute Mill

6 months ago
TPM changes the scene:
Cross-Functional Teams take
over maintenance activities
Maintenance Process
Improvement (MPI)
(Planned, Scheduled Maintenance System)
The Different Maintenance
Techniques
Maintenance Process
Improvement (MPI) Activities
The Case of a TPM Culture at
work
Old Chain guard After TPM MPI action

by operators
Six Major Losses due to Equipment
maintenance being not up to mark
Motivation for doing TPM:
How the 6 Losses reduce Effectiveness
Overall
Equipment = Availability x Perf.
Efficiency x Quality
Effectiveness
Equipment Reduced Rejects and

Failures Speed Defects
Adjustments Minor Stops Startup

6 Major
and Set-Ups and Idling Losses
Losses
Systematic Equipment
Improvement
(Improve Equipment Effectiveness)
SEI
A systematic approach to eliminate waste
through analysis of the ―6‖ major losses utilizing
cross-functional teams to continuously
investigate, test, and implement improvements
with a goal of maximizing equipment
effectiveness.
SEI is a DATA DRIVEN PROCESS. The goal is

to reduce equipment failures, adjustments and
setups, correct speed, and eliminate stops and
idling— systematically. This engages reliability
engineering and knowledge of the machines.
Training and Skill
Development
Why does TPM require Training
and Skills Development?
TPM Training needs are often obvious…
Just looking…taking a walk-around the workplace

A walk through the offices
―The part must be somewhere in here…‖
Well the drip seems fixed… must be busy time.
Clogged motor casing intake—that isn’t
good. I know that, but the manager should
get it cleaned!
I guess there is enough light …ya I pasted the
sheet bit low ☺
―They should know what they are looking at…‖
Enter TPM
I like that!
And that too!
God! Don’t they have anything else to do other than shining dials
all day? What did you say, ―TPM?!‖
Zero Breakdown Strategies
Restore equipment
Maintain basic equipment conditions
Adhere to standard operating procedures
Improve operator maintenance skills
Don’t stop at emergency fixes
Correct design weaknesses
Study breakdowns relentlessly
… if you care to survive in business.

TPM pushes down the floor and
pushes out the wear-out end

TPM Implementation—as the
Japanese do it
• Announce top management’s decision to introduce TPM
• Launch educational campaign
• Create organizations to promote TPM
• Establish basic TPM policies and goals
• Formulate master plan for TPM development
• Hold TPM ―kickoff‖
• Improve equipment effectiveness
• Establish an Autonomous maintenance program for operators
• Set up a scheduled maintenance program for the maintenance
department
• Conduct training to improve operator and maintenance skills
• Develop initial equipment management program
• Implement TPM fully and aim for higher goals

TQM IEM Lecture Reliability FMEA TPM

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Reliability, FMEA and

© Tapan Bagchi TQM IEM Reliability 1

Tapan Bagchi TQM IEM Reliability 3

These relate to the ―bathtub curve‖.

Tapan Bagchi TQM IEM Reliability 5

• Failure rate (l) – number of failures

Tapan Bagchi TQM IEM Reliability 6

Tapan Bagchi TQM IEM Reliability 7

Tapan Bagchi TQM IEM Reliability 8

Tapan Bagchi TQM IEM Reliability 9

Tapan Bagchi TQM IEM Reliability 10

Tapan Bagchi TQM IEM Reliability 11

• Probability density function of failure time

for and f(x; k, λ) = 0 for x < 0, where k > 0 is the shape

Tapan Bagchi TQM IEM Reliability 13

Tapan Bagchi TQM IEM Reliability 15

0 0 2000 1.000 0.000

Failure Rate vs. Time

1.500 r(t) Faiure Rate

Tapan Bagchi TQM IEM Reliability 17

 Mean Time To Fail (MTTF)

 Mean Failure Rate (l)

 Mean Down Time (MDT)

 Total Up Time (Tup)

 Mean Time Between Failures

 Mean Failure Rate (l)

Tapan Bagchi TQM IEM Reliability 20

Tapan Bagchi TQM IEM Reliability 21

Tapan Bagchi TQM IEM Reliability 22

Rsystem  R1  R2    Rn System reliability is

RS = 1 - (1 - R1) (1 - R2)... (1 - Rn)

Tapan Bagchi TQM IEM Reliability 25

• Convert to equivalent series system

Tapan Bagchi TQM IEM Reliability 28

Tapan Bagchi TQM IEM Reliability 29

• Maintainability is the totality of design

Tapan Bagchi TQM IEM Reliability

No Glass Filament Vacuum

Power Plant Power Line Connector

Wind Breaks Tree Breaks

Hint: Draw an FTA diagram

Tapan Bagchi TQM IEM Reliability 34

Tapan Bagchi TQM IEM Reliability 35

Tapan Bagchi TQM IEM Reliability 36

Failure Mode and Effect Analysis

Sickness Wallet lost Strike

Wallet lost 9 0.25 2.2 Unsafe acts

Accident 8 0.2 1.6 Hazards

Unsafe acts Safe keeping 3 0.1 0.3

Hazards Identify and 2 0.1 0.2

Increasing Severity of Harm/Consequence

Tapan Bagchi TQM IEM Reliability 47

FMEA is a Structured group of activities

• Identify potential failure modes

Tapan Bagchi TQM IEM Reliability 48

Tapan Bagchi TQM IEM Reliability 49

FMEA’s are intended to ...

• Rate severity of failure modes

Tapan Bagchi TQM IEM Reliability 50

Failure Mode Type Example

Tapan Bagchi TQM IEM Reliability 51

What is the severity of

Tapan Bagchi TQM IEM Reliability 52