WF10: Conduct FMECA / FMEA

Pre-requisites

• FBD Model: defined with functional flows, failure diagrams, and criticality values. This may include a valid Bond Model defined with additional bond types and control systems where necessary, to enable analysis with Bond as the Propagation Method.
• Criticality Profile: default or custom criticality profile based off one of the criticality methods/types defined in the Criticality Profile Editor.

Detailed Descriptions (numbered steps)

1. Access 'Report Wizard' from under the 'Reports' tab, of the main menu bar. Alternatively, it can be accessed with the 'Report Wizard' icon in the toolbar.
2. Select the format of the report – .pdf, .xlsx or .csv, from the drop-down menu.
3. Select the target report template with FMECA reports under the 'Criticality' folder and FMEA reports under the 'Failure Mode Effects Analysis' folder.
4. Set Level of Analysis as 'System' or 'Component/Sub-system'. Selecting a component or subsystem will limit the failures reported on to be only those within that component/subsystem.
5. To set the End Effect, select the System or Component/Subsystem from the System Model list and set with the button that has the arrow icon. To finish setting the Analysis Context, select the target System or Component/Subsystem to conduct the FMECA/FMEA on, and set with the cube icon button.
6. Select the Criticality Profile from the drop-down menu, to run the analysis with. Only criticality profiles defined in the Project Criticality Profiles of the Criticality Profile Editor, and are the same criticality method/type as the selected report template shall be available in the drop-down menu.
7. Select Propagation Method – FCM or Bond to run the analysis with, and any Output Options necessary to define additional analysis options for the FMECA/FMEA.
8. Set Criticality Threshold to either 'No Criticality Threshold' or to the target Threshold required, which shall be dependent on the criticality method/type of the analysis.
9. Review Organization Details, which should already be set, but make any changes as necessary.
10. Review Report Body Customization, which should also already be set, but make any changes as necessary.
11. Reports are automatically saved to the project, but an additional export of the report may be defined in the Report Wizard. Enable the 'Export to Directory' functionality and click 'Browse' to define a valid directory for the export.
12. Execute 'Finish' to close the Report Wizard, the report shall generate in the selected template, format and output options, and open accordingly.
13. FMECA/FMEA conducted and report generated.

Fields referenced in the diagram

• Select Export File Format: .pdf, .xlsx, .csv
• Set Level of Analysis: System, Component / Sub-system
• Set Analysis Context: End Effect, System or Component/Subsystem
• Define Additional Analysis Options: Propagation Method, Output Options

Outputs

• FMECA/FMEA Report: documentation of the analysis conducted, exported as a .pdf, .xlsx, or .csv file, and automatically saved in the MADE Report History (accessed from under the Reports tab of the main menu bar).

Screenshot walkthrough (captions/labels extracted)

Step 1: Access Report Wizard

• 'Reports' menu: Report Wizard (highlighted), Report History, Report Filtering, Report Preferences, HTML Reports, Chart Analysis...

Step 2: Select Export File Format

• "Report Wizard" — "Create a new Report": "Select a report to output from the list below, then select Next to continue." Format dropdown: PDF, Excel, Raw Data (CSV). Report tree includes many templates under folders, e.g. FMECA (HRI, Custom), FMECA (HRI, PHMT), FMECA (RPN, PHMT), FMECA – Maintainability Combined (MIL-STD-1629A), FMECA (MIL-STD-882E), FMECA (ISO26262, HARA ASIL), FMECA (AIAG, FMEA 4th Ed.), FMECA (SAE J1739, Rev. AUG2002), FMECA (SAE ARP4761, Functional), Design Potential FMECA (RPN, Custom); Data Quality Analysis > Annotation Report; Failure Mode Effects Analysis > FMEA (MIL-STD-1629A), FMEA (AIAG, FMEA 4th Ed.), FMEA (SAE J1739, Rev. AUG2002), FMEA (SAE ARP4761, Functional); General > System Information Report; Maintainability (folder, partially visible). Selected template preview: "FMECA (MIL-STD-1629A, Custom)" — "This FMECA report is a composite report based upon the MIL-STD-1629A standard with additional fields capturing qualitative failure information. The report lists Failure Modes for each item in the system model that leads to the selected End Effect with additional fields capturing failure predictability and compensating provisions."

Step 3: Select FMECA/FMEA Report Template

• Two dialogs comparing "Criticality" folder (selected: CA (MIL-STD-1629A, Quantitative Standard); FMECA variants; Data Quality Analysis; Failure Mode Effects Analysis; General; Maintainability) with description: "Failure Mode Effects and Criticality Analysis (FMECA) reports are focused on the failure modes of the model and potential effects and criticality of each failure mode. FMECA reports may use either a qualitative or quantitative analysis, and require the use of the criticality editor. All FMECA reports depend on the model functions, flows, failure diagrams (if provided) and criticality editor. If you require any additional reporting formats please email support@phmtechnology.com." — and "Failure Mode Effects Analysis" folder (selected: FMEA (MIL-STD-1629A)) with description: "Failure Mode and Effects Analysis (FMEA) reports are focused on the failure modes of the model and potential effects. FMEA reports list failure modes and effects, and generally do not contain a detailed criticality analysis (e.g. will not require the use of the criticality editor). All FMEA reports depend on the model functions, flows, and failure diagrams (if provided). If you require any additional reporting formats please email support@phmtechnology.com."

Step 4: Level of Analysis

• "Report Wizard" — "Analysis Options": Level of Analysis radio (System selected / Component/Subsystem); Propagation Method radio (FCM / Bond); Output Options checkboxes (Ignore injected failures, Include nominal paths, Root causes only [disabled], System failures only); Path Control Number checkbox "Show Path Control Number" (checked). Right panel "Analysis Context Summary": End Effect ("Vehicle System"), System ("Vehicle System"), Criticality Profile dropdown ("PHMT 1629A Criticality"). System Model tree listing Vehicle System > Coupling, Driveline (Differential, Driveshaft, Half Shaft Front/Rear, Planetary Gearbox Front/Rear, Transmission, Wheel Front/Rear, Wheel Resistance Front/Rear), Power Generation. Second screenshot shows same with Component/Subsystem selected instead of System.

Step 5: Set Analysis Context

• Same wizard page; System Model tree used to select the Component/Subsystem context. First screenshot shows System Model set to Vehicle System (whole tree); second shows Component/Subsystem set to "Power Generation" with tree scrolled to show Wheel Resistance Front/Rear, Power Generation (selected) > Control Unit, Diesel Engine (Air Filter, Coupling 1, Engine, Governor, Injector Pump, Lift Pump, Primary Fuel Filter, Secondary Fuel Filter), Fuel Tank, Vehicle.

Step 6: Select Criticality Profile

• Same wizard page with Level of Analysis = Component/Subsystem; Criticality Profile field showing a searchable dropdown list: "PHMT 1629A Criticality" (Owner "PHM Technology Pty. Ltd.", Type "MIL-STD-1629A") highlighted among available profiles. Analysis Context Summary: End Effect "Vehicle System", Component/Subsystem "Power Generation".

Step 7: Define Additional Analysis Options

• Two screenshots showing Output Options checkboxes toggled: first with "Ignore injected failures" checked (Level of Analysis = System); second with "System failures only" checked (Level of Analysis = Component/Subsystem, Component/Subsystem = "Power Generation" highlighted in tree).

Step 8: Set Criticality Threshold

• "Report Wizard" — "Criticality Threshold": "Select a Criticality Threshold to apply to the path analysis. Any paths that fall below the specified criticality will be omitted from the report." Radio options: No Criticality Threshold; Fuzzy Criticality (Threshold 9); RPN (Threshold 400); MIL-STD-1629A (selected) — Criticality Number (Cm): 1.00E+00; MIL-STD-882E — Risk: High; ARP4761 — Risk: High; ISO 26262 — ASIL Risk: ASIL D.

Step 9: Review Organization Details

• "Report Wizard" — "Cover Page - Organization Details": "Customize details about your organization such as its name, address and logo. These details will appear on the cover page of reports." Fields: Organization Name "PHM Technology Pty Ltd", Postal address "9/120 Queens Parade, North Fitzroy 3068, VIC Australia", Phone number "1300 948 505", Fax number "1300 948 505", Email address "www.phmtechnology.com", Website "www.phmtechnology.com". Organization Logo panel showing "PHM Technology / Decisions better made" logo with Browse button.

Step 10: Review Report Body Customization

• "Report Wizard" — "Report Body Customization": "Select the page format (size and orientation) for the report body as well as a message to appear in the body footer." Body Page Format: Format "Letter", Width 279.4, Height 215.9, Orientation radio Landscape/Portrait (Landscape selected). Fields: Cover Page Footer Message, Body Footer Message (note: "For best results keep the message limited to two lines.").

Step 11: Set Export Options

• "Report Wizard" — "Export Report": "Export the report to an additional directory below." Checkbox "Export to Directory" with Browse button.

Step 13: FMECA/FMEA Conducted

• Two generated report cover pages side by side: "CA (MIL-STD-1629A, Quantitative Standard)" and "FMEA (SAE ARP4761, Functional)", both branded "PHM Technology / Decisions better made", "PHM Technology Pty Ltd". Each includes description text, "PROJECT DETAILS" (Project Name "MADE Training", Date of Issue, Report Author "John Smith", Revision), "DOCUMENT SIGNOFF" (Name(s)/Signature(s)/Role(s)/Date table), "DOCUMENT CONTROL" box, "CONTACT DETAILS" (Address, Phone, Fax, Email, Website).