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Root Cause Failure Analysis Overview

The document discusses Root Cause Failure Analysis (RCFA), defining failure as the inability of a component to perform its intended function and outlining various types of failures. It emphasizes the importance of analyzing failures to improve product and process reliability, prevent malfunctions, and ensure safety. Common techniques for performing failure analysis include Failure Modes & Effects Analysis (FMEA) and Fault Tree Analysis (FTA).

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25 views11 pages

Root Cause Failure Analysis Overview

The document discusses Root Cause Failure Analysis (RCFA), defining failure as the inability of a component to perform its intended function and outlining various types of failures. It emphasizes the importance of analyzing failures to improve product and process reliability, prevent malfunctions, and ensure safety. Common techniques for performing failure analysis include Failure Modes & Effects Analysis (FMEA) and Fault Tree Analysis (FTA).

Uploaded by

mostafamohamedsaeid
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

ROOT CAUSE FAILURE ANALYSIS

Mahmoud Heshmat
PhD in IEsM
Failure

❑ Failure is inability of a component to perform according to its


intended function.
❑ Failure is any loss that interrupts the continuity of production.
❑ Failure is a loss of asset availability.
❑ Failure is the unavailability of equipment.
❑ Failure is a deviation from the status quo‫الوضع الراهن‬.
❑ Failure is not meeting target expectations.
❑ Failure is any secondary defect.
Failure

Failures can be:


❑ Pump not working
❑ Seized valve
❑ Broken wire
❑ Software crash
❑ System down
❑ Reactor melt down
❑ No money in a checking account
What, Why and How?

What Why How


What?

❑ Every product or process has modes of failure.


❖Some types of mechanical failure mechanisms are: excessive
deflection, buckling, ductile fracture, brittle fracture, impact, creep,
relaxation, thermal shock, wear, corrosion, fatigue.
❑ An analysis of potential failures helps designers focus on and
understand the impact of potential process or product risks and
failures.
❑ Several systematic methodologies have been developed to quantify
the effects and impacts of failures.
❑ Failure Analysis: The examination of a failed component and of the
failure situation in order to determine the causes of failure.
Why perform failure analysis?

❑ Product Development:
• Prevent product malfunctions ‫عطل‬-‫خلل‬
• Insure product life
• Prevent safety hazards while using the product
❑ Process Development:
–Insure product quality
–Achieve process reliability
–Prevent customer dissatisfaction
–Prevent safety or environmental hazards
❑ Reliability engineering and predictive maintenance
▪ Preventing catastrophic failures of critical plant production systems
▪ Avoiding deviations from acceptable performance levels that result in personal
injury, environmental impact, capacity loss, or poor product quality
How to Perform Failure Analysis?

Common Failure Analysis Techniques:


❑ Failure Modes & Effects Analysis (FMEA)
❑ Cause and Effect Diagram
❑ Fault Tree Analysis (FTA)
❑ What-If Analysis
❑ Checklist
The purpose of RCFA is to;
resolve problems that
affect plant performance
NOT
an attempt to fix blame
Root Cause Failure
for the failure Analysis
RCFA
What are “Root Causes”?

▪ Physical
▪ Physical component or material that failed
▪ Human
▪ Human actions or decisions leading to failure
event
▪ Latent)‫(كامن‬
▪ Reasons why actions or decisions were made
RCFA Process
See You Next Lecture
FMEA

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