Failure Mode Effect Analysis For the Energy and Natural Resources Sector

Failure Modes and Effects Analysis (FMEA) is the key reliability tool for achieving and sustaining Equipment Maintenance Plan (EMP) goals in manufacturing, minimizing unplanned disruptions to safety, the environment, and profitability. Effective FMEA implementation ensures optimal long-term ownership costs.

Failure Mode(FM)are the ways in which a process can fail.

Effects Analysis(EA) are the ways that these failures can lead to defects or harmful outcomes and analyze the risk involved in it.

Importance of FMEA:

“The sooner a failure is discovered, the less it will cost."

If a failure is discovered late in product development or launch, the impact is exponentially more devastating.

Discovering a failure early using FMEA provides the benefits of:

• Eliminating Catastrophic Failures– Reduces multi-million-dollar repair costs and liability risks.
• Minimizing Downtime – Ensures operational continuity, safeguarding revenue streams.
• Optimizes Maintenance Costs – Enables predictive strategies, reducing OPEX and extending asset life.
• Enhances Asset Integrity & ROI – Maximizes asset performance while minimizing depreciation losses.
• Achieving Compliance – Avoids fines by aligning with ISO 55001, API 580, and OSHA PSM.
• Lowering Warranty & Liability Costs– Improves reliability, cutting down warranty claims and legal exposure.
• Streamlining Operational Costs– Cuts waste, energy consumption, and unnecessary expenditures.

Late Failure Mode Discovery

Early Failure Mode Discovery

Our FMEA approach to flawless operation:

Define the Scope: The first step in an FMEA-based reliability improvement is identifying candidate equipment through critical analysis. Calculate the baseline Overall Equipment Effectiveness (OEE) and the associated financial impact for the equipment targeted for improvement.

OEE = Availability x Performance x Quality

Potential Failure Modes: Recognize all the conceivable ways in which process may fail. This can be accomplished by reviewing sop’s, analyzing records and seeking advice from experts . Evaluate severity , occurrence and detection.

Assign a Risk Priority Number: The Risk priority number is obtained by multiply of severity , likelihood and detection. Prioritize the risk based on RPN.

   RPN= Severity *Likelihood*Detection

Recommendation: Create a control measure to bring the risk rating level to the  acceptable range.

*Note: Higher the RPN , Higher the risk*

Review and Update: Regularly review and update the FMEA process to stay up-to-date. Especially any modification made to the system and operational circumstances.

“MBG – Partnering for Excellence”

MBG offers Support for Product and Process Development through FMEA Consulting, FMEA Training and FMEA Project Support. MBG provide knowledge,  guidance , direction in quality & reliability activities, tailored to your unique needs, wants and desires.

Focused Industries: