Last updated on 2024年8月15日

How do you update and revise FMEA for plant maintenance as conditions change?

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FMEA, or Failure Mode and Effect Analysis, is a tool for identifying and prioritizing potential failures and their impacts on plant maintenance. It helps you plan preventive and corrective actions, reduce downtime, and improve reliability. However, FMEA is not a one-time activity. You need to update and revise it regularly as conditions change. Here are some tips on how to do that.

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Syed Muhammad Faisal

Manager at National Refinery Limited & M.E.(ENERGY SYSTEM) From NED UE&TECH
sayid hasanul alaydrus ??

maintenance manager, reliability center maintenance, process safety, ERT fire and rescue leader

1 Review your FMEA periodically

You should review your FMEA at least once a year, or more often if there are significant changes in your plant, such as new equipment, processes, or regulations. You can use a checklist or a matrix to compare your current FMEA with the previous one and identify any gaps, inconsistencies, or errors. You should also involve relevant stakeholders, such as operators, technicians, engineers, and managers, in the review process and solicit their feedback.

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Syed Muhammad Faisal

Manager at National Refinery Limited & M.E.(ENERGY SYSTEM) From NED UE&TECH
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The first step is to identify any changes in the plant maintenance conditions that may impact the FEMA. This can be done through regular inspections, audits, and risk assessments. Once changes have been identified, the next step is to evaluate their impact on the FEMA. This involves assessing the potential consequences of the changes and determining whether any updates or revisions are necessary. Construct a concise Checksheet and checklist to enlist and enroll all the activities precisely and update accordingly for any variation / changes for any further decision as per system and procedure.

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Elaine Brito dos Santos Sepúlveda

Especialista em Gerenciamento de Manuten??o e Estratégias Operacionais | Otimizando Processos Industriais | Consultora com Experiência em Grandes Projetos
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A revis?o periódica do FMEA é crucial em ambientes industriais que sofrem mudan?as, como a introdu??o de novos equipamentos ou processos. é recomendável atualizar o FMEA pelo menos anualmente ou sempre que mudan?as significativas ocorrerem. Utilize checklists ou matrizes para comparar vers?es antigas e novas do FMEA, identificando discrepancias e erros. Incluir feedback de stakeholders como operadores, técnicos, e engenheiros é essencial para um processo de revis?o eficaz.

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2 Update your failure modes and effects

As you review your FMEA, you may discover new or modified failure modes and effects that affect your plant maintenance. For example, you may find that some components wear out faster than expected, some failures have more severe consequences than anticipated, or some failures have new causes or detection methods. You should update your FMEA accordingly, adding, deleting, or modifying the failure modes and effects as needed. You should also update the severity, occurrence, and detection ratings for each failure mode and effect, using data, experience, or expert judgment.

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Syed Muhammad Faisal

Manager at National Refinery Limited & M.E.(ENERGY SYSTEM) From NED UE&TECH
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Conduct a review of the existing FEMA to identify any potential failure modes and effects that may be impacted by changes in Plant Maintenance conditions. Identify any changes in Plant Maintenance conditions that may impact the FEMA. This can be done through regular inspections, audits, and risk assessments. Once changes have been identified, evaluate their impact on the FEMA. This involves assessing the potential consequences of the changes and determining whether any updates or revisions are necessary. To support the above process, the following aspects of all configuration items (CIs) contained in any system should be considered: Integrity Accountability Visibility Reproducibility Coordination Formal controllability Traceability

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Elaine Brito dos Santos Sepúlveda

Especialista em Gerenciamento de Manuten??o e Estratégias Operacionais | Otimizando Processos Industriais | Consultora com Experiência em Grandes Projetos
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Ao revisar o FMEA, é crucial identificar novos ou alterados modos e efeitos de falha. Mudan?as como desgaste acelerado de componentes ou falhas com consequências mais severas devem ser integradas ao documento. Atualize o FMEA adicionando, removendo ou modificando entradas conforme necessário, e revise as classifica??es de gravidade, ocorrência e detec??o com base em novos dados e julgamento de especialistas. Isso garante a precis?o e a eficácia do FMEA na preven??o de falhas e na melhoria da manuten??o.

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3 Update your preventive and corrective actions

Based on your updated failure modes and effects, you may need to revise your preventive and corrective actions for plant maintenance. For example, you may need to adjust your inspection, testing, or cleaning intervals, change your spare parts inventory or procurement, implement new maintenance procedures or techniques, or install new sensors or alarms. You should update your FMEA with the new or modified actions and their expected results. You should also update the risk priority number (RPN) for each failure mode and effect, which is the product of the severity, occurrence, and detection ratings.

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Syed Muhammad Faisal

Manager at National Refinery Limited & M.E.(ENERGY SYSTEM) From NED UE&TECH
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it is important to continuously monitor and evaluate the effectiveness of the preventive and corrective actions taken. This can be done through regular inspections, audits, and risk assessments. Any necessary updates or revisions should be made in a timely manner to ensure that the FEMA remains effective in addressing potential emergencies or disasters. Risk to be regularly monitored and updated with risk response strategy.

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Elaine Brito dos Santos Sepúlveda

Especialista em Gerenciamento de Manuten??o e Estratégias Operacionais | Otimizando Processos Industriais | Consultora com Experiência em Grandes Projetos
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Com a atualiza??o dos modos e efeitos de falha no FMEA, é essencial revisar as a??es preventivas e corretivas. Isso pode incluir ajustes em intervalos de inspe??o, atualiza??es no estoque de pe?as de reposi??o, implementa??o de novos procedimentos de manuten??o, ou a instala??o de sensores adicionais. Atualize o FMEA com essas a??es e seus resultados esperados, além de recalcular o Número de Prioridade de Risco (RPN) para cada modo e efeito de falha, considerando as novas classifica??es de gravidade, ocorrência e detec??o.

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4 Validate and verify your FMEA

After you update and revise your FMEA, you should validate and verify it to ensure its accuracy and effectiveness. Validation means checking that your FMEA reflects the actual conditions and performance of your plant, while verification means checking that your FMEA meets the requirements and expectations of your stakeholders. You can use various methods to validate and verify your FMEA, such as testing, simulation, auditing, benchmarking, or feedback.

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sayid hasanul alaydrus ??

maintenance manager, reliability center maintenance, process safety, ERT fire and rescue leader
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Information from CMMS can help to validate FMEA accuracy. the information such as a failure for certain equipment being analysis and what cause the failure can be cross check with the FMEA analysis. CMMS mostly accommodate a comment from user that can be feedback to FMEA analysis accuracy.

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Elaine Brito dos Santos Sepúlveda

Especialista em Gerenciamento de Manuten??o e Estratégias Operacionais | Otimizando Processos Industriais | Consultora com Experiência em Grandes Projetos
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Após revisar seu FMEA, valide e verifique sua precis?o e eficácia. A valida??o confirma que o FMEA reflete as condi??es reais e desempenho da planta, enquanto a verifica??o assegura que ele atenda às expectativas das partes interessadas. Utilize testes, simula??es, auditorias, benchmarking e feedback para validar e verificar o FMEA. Esses métodos ajudam a garantir que o documento esteja atualizado e alinhado com as necessidades operacionais e de seguran?a.

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5 Document and communicate your FMEA

Finally, you should document and communicate your updated and revised FMEA to your stakeholders and users. You should keep a record of the changes you made, the reasons behind them, and the sources of information you used. You should also explain how your FMEA affects your plant maintenance plan, schedule, budget, and resources. You should use clear and consistent formats, terminology, and symbols to present your FMEA, and make it accessible and understandable to your audience.

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6 Continuously improve your FMEA

Updating and revising your FMEA is not a one-off task, but a continuous improvement process. You should monitor and measure the results of your FMEA and your plant maintenance activities, and use them to identify opportunities for further improvement. You should also keep track of any changes in your plant, such as new technologies, standards, or customer needs, and incorporate them into your FMEA. You should always strive to make your FMEA more reliable, relevant, and useful for your plant maintenance.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Elaine Brito dos Santos Sepúlveda

Especialista em Gerenciamento de Manuten??o e Estratégias Operacionais | Otimizando Processos Industriais | Consultora com Experiência em Grandes Projetos
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Ao atualizar o FMEA, considere a documenta??o e comunica??o eficaz dos resultados e mudan?as. Certifique-se de que todos os stakeholders tenham acesso às vers?es atualizadas e compreendam as modifica??es. Além disso, engaje-se na melhoria contínua do FMEA, utilizando feedback e dados novos para otimizar processos e a??es preventivas. Isso n?o só aumenta a eficiência operacional, mas também fortalece a cultura de seguran?a e manuten??o proativa na planta.

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How do you update and revise FMEA for plant maintenance as conditions change?

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1 Review your FMEA periodically

2 Update your failure modes and effects

3 Update your preventive and corrective actions

4 Validate and verify your FMEA

5 Document and communicate your FMEA

6 Continuously improve your FMEA

7 Here’s what else to consider

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