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FMECA - Failure Mode, Effects & Criticality Analysis
Failure Mode, Effects (& Criticality) Analysis (FME(C)A).  FME(C)A is a procedure that analyzes failures (failure modes) and determines their impact (effect) at both the local and system levels.  The analysis can be carried out from the lowest to the highest level of the system (bottom up), which is commonly referred to as a hardware analysis.  Alternatively, the analysis can be carried out from the highest level to the lowest level (top down) of the system, which is commonly referred to as a functional FMEA.  The functional FMEA considers the functional failure of components within a system. FMEA is applied in maintenance tasks, such as reliability-centered maintenance (RCM) and risk-based maintenance (RBM).  The effects are generally classified as operational (production), environmental, and safety effects.  This procedure is used to plan tasks to find minimum ratio between maintenance cost and cost due to failure effects.  FME(C)A is a structured method to determine equipment functions, functional failures, and assess failure causes and effects.

Item / FunctionPotential Failure modePotential Effects of FailureS (severity rating)Potential Cause(s)O (occurrence rating)Current controlsD (detection rating)CRIT (critical characteristicRPN (risk priority number)Recommended actionsResponsibility and target completion dateAction takenNew SNew ONew DNew RPN
Fill tubHigh level sensor never tripsLiquid spills on customer floor8level sensor failed
level sensor disconnected
2Fill timeout based on time to fill to low level sensor5N80Perform cost analysis of adding additional sensor halfway between low and high level sensors




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