Machine failure defects due to no/poor maintenance for FMEA - Looking for examples

B

Bartosz Murawski

#1
Im preparing training for maintenance staff . I want to show them that prevention is better than repairs. I want to use FMEA as a good tool to predict failure.
Therefore Im looking for example of machine failure where lack of maintenance activites was a reason of demage:
- description of failure, what was demage,
- root causes,
- what preventive action You done.

regards
barth
 
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B

bgwiehle

#2
Which type of equipment are you looking for help with? Production equipment (making product for a customer) or support equipment (compressors, boilers, etc.)? Your effects could include manufacturing delays and downtime, quality defects, safety, etc.

Here's a quick list of the kinds of things to consider:
hydraulics or pneumatics
power and electrical connections & wiring
programming (logic)
sensor adjustments or failure
ergonomics for operator or maintenance (equipment design)
wrong or missing replacement components
accidently or deliberately disabled functions
wrong processing chemical or lubricants, or loss/contamination
dirt, wear, damage

When listing preventative measures such as inspection and repair before effects unacceptable, consider also the required frequency. We not only add new PM items if necessary, but change the frequency or the trigger event. Example: a PM can be triggered by a calendar date or by run-hours.

Others may provide specific examples.

B.G. Wiehle
 
B

Bartosz Murawski

#3
Its good point-type of equimpment is important.
We are producing components for automotive and machine industry. We are using CNC machine-turning and milling and many of auxilary equimpment for preparing tools.
Therefore Im looking for example especial for hydraulics, pneumatics and mechanicals failure caused by lack or not properly make maintenance.
 
Last edited by a moderator:
Q

Qaware

#4
Maybe this could help you?

Hi there

Here are some errors which I can think of:

Machines stopping because oil levels are to low.
Oil leakage.
Chips blocking pumps for coolant, can cause leakage etc.
Wear on leadscrews causing accuracy problems.
Debris and coolant reaching areas it shouldn't because of broken seals.
Collisions causing geometrical errors between axes and accuracy problems.
Wear on tool measuring device leads to incorrect measurements of tool geometry.
Screws not tightened causing vibrations.
Faulty components such as bearings, valves creating excessive heat and thereby affecting accuracy etc.
Damaged wiring causing misc. errors.

I'm sure there are a lot more but this was all I could come up with right now.
Good luck! :bigwave:
 
R

RAHarpster

#6
Maintenance Issues In PFMEA

I very simple example of a maintenance issue and its prevention covered in a PFMEA is as follows:

Process Action: Transport assembly to next operation.
Failure Mode: Exposed surface of part is scratched.
Effect: Customer is dissatisfied with appearance. Item is rejected.
Failure Cause: Worn or damaged table rolls.
Prevention Control: There are two possiblities. If it is possible to detect unacceptable levels of table roll wear or damage before the scratch occurs, the prevention control would be "Table Roll Condition Check (PM)". If you cannot see unacceptable levels of wear before the scratch occurs, the appropriate prevention control would be "Table Roll Scheduled Changeout (PM). In both of these cases you will be preventing the defect.

I hope this helps.
Rich Harpster
 
B

Bill Ryan - 2007

#7
RAHarpster said:
I very simple example of a maintenance issue and its prevention covered in a PFMEA is as follows:

Process Action: Transport assembly to next operation.
Failure Mode: Exposed surface of part is scratched.
Effect: Customer is dissatisfied with appearance. Item is rejected.
Failure Cause: Worn or damaged table rolls.
Prevention Control: There are two possiblities. If it is possible to detect unacceptable levels of table roll wear or damage before the scratch occurs, the prevention control would be "Table Roll Condition Check (PM)". If you cannot see unacceptable levels of wear before the scratch occurs, the appropriate prevention control would be "Table Roll Scheduled Changeout (PM). In both of these cases you will be preventing the defect.
:topic:
Rich - Welcome to the Cove :bigwave:

I hope you stop by as often as you can. Your insight with the FMEA and Control Plan methodologies, as well as your experience in the industry will be most welcome!

Bill
 
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