Risk Analysis of Equipment Failure through Failure Mode and Effect Analysis and Fault Tree Analysis

Competitive environment in manufacturing sector cannot afford frequent breakdown of aged critical equipment. In this paper, an attempt is made to develop a method to determine critical equipment with the help of failure mode and effect analysis (FMEA) and occurrence of failure. In this research, the impact of machine breakdown on production, safety, availability of standby, and equipment or asset value is considered with weights of 30, 30, 25, and 15%, respectively. With these factors and corresponding weights, a critical equipment of shop floor is identified. Further, this identified critical equipment is analyzed in detail to determine the highest risk priority number (RPN) of subassembly or component. This high RPN of component or subassembly is reduced with the appropriate maintenance action by determining reliability of each subassembly or component. This approach is useful for the maintenance personnel to plan the maintenance activities and reduce the probability of failures, thereby reducing the machine breakdown.