Scenario-Based FMEA: A Life Cycle Cost Perspective

Kmenta, Steven; Ishii, Kosuke

doi:10.1115/detc2000/rsafp-14478

Cited by 55 publications

(14 citation statements)

References 9 publications

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“…FMEA is a method to identify and prioritize potential failure of a product or a process (Sutrisno et al , 2018). The traditional FMEA uses three factors, occurrence, severity and detection, to determine the risk priority number (Kmenta and Ishii, 2000). Prasad et al (2012) defined the Ishikawa/fishbone diagram as a tool used to identify and systematically list the different root causes that can be attributed to a problem.…”

Section: Resultsmentioning

confidence: 99%

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

Mishra

Sharma

Sachdeo

et al. 2019

IJLSS

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Purpose The main purpose of this paper is to analyze the current state of a bonnet-manufacturing industry and to optimize the process by designing a future state map using simulation approach. Design/methodology/approach The case study approach has been proposed to highlight the applicability of value stream mapping (VSM) in an Indian bonnet manufacturing organization. The methodology used relies on formulation of VSM being the main tool used to identify the opportunities for classifying and eliminating bottlenecks with the help of various lean techniques. A contrast of present and past scenarios is highlighted to underscore the importance of using VSM with ARENA simulation. Findings Application of the proposed simulation approach has helped the organization reduce the cycle time significantly by 30 per cent over the entire production time. The average number of work-in-progress pieces has also decreased by about ten. In addition, enhancements have been seen with respect to ecological parameters, e.g. carbon footprint has been reduced to 83.7 percent across the process. Research limitations/implications The proposed approach of using a simulation-based VSM helps in reducing the time involved in traditional VSM method. This approach is also easy to implement at any organizational level. Practical implications It is believed that this paper will aid not just industrialists but also academic professionals to appreciate the role of simulation using ARENA in helping them understand how to attack the various problems faced by industries. The results of the study indicate that by applying this methodology, there will be a reduction not only in cost but also in environmental impacts. Originality/value The paper incorporates a real case study, which shows application of VSM for implementing lean principles in a bonnet-manufacturing industry. Break-even analysis presented fills the gap which previous literatures have been missing.

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Section: Resultsmentioning

confidence: 99%

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

Mishra

Sharma

Sachdeo

et al. 2019

IJLSS

View full text Add to dashboard Cite

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“…Life cost-based FMEA Steven Kmenta & Kosuke Ishii, [2]. Stated that risk contains two basic elements: chance and consequences.…”

Section: Literature Reviewmentioning

confidence: 99%

Cost Implications of Equipment Failures Using Life Cost Based Failure Modes and Effects Analysis (FMEA) on 365KVA Caterpillar Generator

Emughedi

2021

JERR

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Equipment failures have implication on financial sustainability of the organization. This showcase the fact that equipment failures have cost implications and there is need to convert failures using Failure Modes and Effect Analysis, FMEA numerical analysis of 3parameters of severity, occurrence and detection that resulted to Risk Priority Number (RPN). The formula used in analyzing the results includes labour cost, material cost and opportunity cost. The labour cost is equals to the occurrence {[Delay Time.Labor rate.no of Operators]} plus [Fixing Time. Labor rate.no of Maintenance of personnel. Quantity] + [Detection Time. Labor rate no of Operators]}. Material Cost is equals to the occurrence x Quantity of parts to replace x Cost of Part. Opportunity Cost is equals to the Loss Time x Hourly Opportunity Cost. Loss Time is equals to the {Detection Time + Fixing Time + Delay Time}. This researched have proven that since installation of 365kva caterpillar generator in NNPC Lokoja that every time the generator failed to run, we can easily calculate the cost of labour, material to replace failed parts and opportunity cost of those idle times of failed production. Using the concept of FMEA, Failure Modes, Effects Analysis which produces Risk Priority Number (RPN) that is being computed by multiplying severity, occurrence and detection in which occurrence was gotten from equipment history card and logbooks since year 2005 when the installation of 365kva caterpillar generator was made till date. Likert questionnaires from industry experts were collated and Delphi method used to arrive accepted severity and detection to aid in the analysis. Millions of naira are being lost whenever equipment failures occurs and engineers from all fields, should always carry out root cause analysis whenever equipment failure occurs in order to prevent further occurrence.

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“…The degree of risk of each failure is represented by the product of these 3 ranked indices, called the Risk Priority Number (RPN). But inconsistent definitions result in questionable risk priorities, and the use of failure modes rather than cause and effect fault chains inhibits ones understanding of the true causes of failures [3]. Furthermore traditional FMEA ends with the calculation of RPNs, the team does not consider the consequences of the failures in terms of costs.…”

Section: Problems With Traditional Fmeamentioning

confidence: 99%

“…Risk contains 2 basic elements (1) chance, measured by probability, and (2) consequence, measured by cost. A new methodology has been developed to overcome these shortcomings, it is called "Life Cost-based FMEA" [3,4] It measures risk of failure in terms of cost. Cost is a universal language understood by engineers without ambiguity.…”

Section: Lifetime Cost: a Measure Of Riskmentioning

confidence: 99%

Cost Based Failure Modes and Effects Analysis (FMEA) for Systems of Accelerator Magnets.

Spencer¹

2003

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The proposed Next Linear Collider (NLC) has a proposed 85% overall availability goal, the availability specifications for all its 7200 magnets and their 6167 power supplies are 97.5% each. Thus all of the electromagnets and their power supplies must be highly reliable or quickly repairable. Improved reliability or repairability comes at a higher cost. We have developed a set of analysis procedures for magnet designers to use as they decide how much effort to exert, i.e. how much money to spend, to improve the reliability of a particular style of magnet. We show these procedures being applied to a standard SLAC electromagnet design in order to make it reliable enough to meet the NLC availability specs. First, empirical data from SLAC's accelerator failure database plus design experience are used to calculate MTBF for failure modes identified through a FMEA. Availability for one particular magnet can be calculated. Next, labor and material costs to repair magnet failures are used in a Monte Carlo simulation to calculate the total cost of all failures over a 30-year lifetime. Opportunity costs are included. Engineers choose from amongst various designs by comparing lifecycle costs.

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Scenario-Based FMEA: A Life Cycle Cost Perspective

Cited by 55 publications

References 9 publications

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

Cost Implications of Equipment Failures Using Life Cost Based Failure Modes and Effects Analysis (FMEA) on 365KVA Caterpillar Generator

Cost Based Failure Modes and Effects Analysis (FMEA) for Systems of Accelerator Magnets.

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