FMEA Presentation Agenda

Transcription

1 Using Failure Mode and Effects Analysis (FMEA) to Address EHS Concerns Chris Heaton Director of EHS Services Keramida, Inc. FMEA Presentation Agenda Background on FMEA s Essential System Steps Example Worksheet Team Participants Environmental FMEA Example Safety FMEA Example 1

2 What is an FMEA? A Failure Mode and Effects Analysis is a tool to conduct a systematic evaluation of a process to identify key failure possibilities and then develop actions to eliminate or reduce the severity/likelihood of the failure effects Team knowledge and experience is crucial Background on FMEAs Started in 1950 s by Dept. of Defense Primarily used as a design tool for early identification of all catastrophic and critical failure possibilities Controls identified to eliminate or minimize the effects of the failure Included by OSHA as a methodology to be used in Process Safety Management programs 2

3 What is in for me? Tool to evaluate new installations as well as modified equipment Identify and control critical risks before installation and/or modification In the design phase, can prevent costly modifications after initial installation Can result in increased reliability, minimize potential for injuries/environmental impact, and increase productivity and efficiency Essential FMEA Steps Subsystem Component Failure Mode Severity Likelihood Detection Risk Priority Number Recommended Action Severity Likelihood Detection Risk Priority Number 3

4 Subsystem Components Use drawings or prints to break up the whole system into smaller subsystems Group similar functions Able to keep the team focused upon one area of equipment/process Where to start? Walk the process! Failure Mode Team brainstorming to determine all of the ways in which this sub-system can fail You can prompt discussion by using questions, such as: What happens if the safety device is by-passed? What if too much of this chemical is added? What happens if the wrong control button is activated? 4

5 Risk Ranking The risk ranking criteria for severity, likelihood, and detection should be defined for the team Number selection is subjective Example: 1 Remote 2 Low 3 Medium 4 High 5 Very Likely Risk Priority Number Used to address failure modes by priority Team can set key milestone numbers that require a specific action Agree on RPN set points for required action Immediate Action Required Review Required Recommendations suggested, not required 1-24 No further action required 5

6 Recommended Actions Recommended actions should be developed to address severity, likelihood, and/or detection ability After implementation of a recommended action, the team can then complete another risk ranking (RPN) to measure the improvement Team Approach Desktop exercise to determine all of the ways in which an operation can fail Accuracy and thoroughness is dependent upon team members included in the study Atmosphere to allow each team member to contribute 6

7 FMEA Team Leader Specific knowledge about the process/modification is not required Selection of FMEA team members Trainer for FMEA tool use Selection of risk ranking Able to keep team focused and on track Tie-breaker if consensus cannot be reached Drive to capture all necessary details FMEA Team Members Team knowledge and experience is crucial Select team members with a diverse background Environmental, Health & Safety Production/Operational Leaders Engineering Equipment Operator Maintenance 7

8 Example Worksheet Environmental Microsoft Excel Workshee Environmental FMEA Wastewater treatment system potential exceedance reduction Characteristics of a typical wastewater treatment system Evaluation of system efficiency (contaminant removal) is usually after routine sampling and results are reportable 8

9 Environmental FMEA Create a water balance sheet Measure contaminant loading from each contributor to the treatment system Gather up all relevant documentation Walk the system to verify that the prints represent as built conditions Undocumented changes that may seem minor can result in a significant impact to the system s performance Environmental FMEA Typical Team Structure Wastewater Treatment Operators EHS Engineering Maintenance Supervisor(s) from the equipment areas that contribute waters to the treatment system Primary benefits of this team structure 9

10 Safety FMEA Step by Step Safety FMEA Equipment is purchased as-is from a supplier under the assumption of normal or anticipated use (i.e. saw, press, etc.) The equipment may be used for a specialty part or function that may not constitute normal use and will require modification to the point of operation guarding 10

11 Safety FMEA Perform a complete EHS review of the equipment prior to purchase Discuss Severity and likelihood of injury Use of machinery as-is Solutions Assess and develop proper clearance at the point of operation FMEA Team Leader Specific knowledge about the process/modification is not required Selection of FMEA team members Trainer for FMEA tool use Selection of risk ranking Able to keep team focused and on track Tie-breaker if consensus cannot be reached Drive to capture all necessary details 11

12 FMEA Team Members Team knowledge and experience is crucial Select team members with a diverse background Environmental, Health & Safety Production/Operational Leaders Engineering Equipment Operator Maintenance Supervisor(s) from the department receiving the new equipment Team Approach Desktop exercise to determine safe operations for running the new machine Depth of knowledge will dependent upon team members included in the study Location and raw materials will be needed to simulate actual operations 12

13 Example Worksheet Safety Microsoft Excel Workshee Safety FMEA Activities performed by the EHS review team Complete a Job Safety Analysis (JSA) for the machine as it will be used Determine safety of existing point of operation guarding Assure safe and unobstructed clearance for all parts to be run on new machinery Develop training for new machinery 13

14 Safety FMEA Assure provisions are made in the machinery quote for necessary changes Provide timeline for machinery changes prior to operation Train all affected employees on the safe operations of the new machine Critique operational safety during initial run of new machinery Problem Summary Evaluate and determine exactly what needs to be accomplished Project Identify challenges Rank risk Rank priority 14

15 Process Summary Teamwork to identify what, how, when Discuss options Results Develop an action plan Develop an implementation plan Benefits Summary Safe Compliant Increased reliability Increase productivity Cost reduction Quality improvements 15