Kaizen
Running Head: FAILURE MODE AND EFFECT ANALYSIS 1
FAILURE MODE AND EFFECT ANALYSIS 3
Failure Mode and Effect Analysis
AbdulHameed Alalwani
IE 590
HW2
Part2
Failure Mode and Effect Analysis
Maintaining a suitable humidity in all parts of a building can be difficult to achieve. However, due to air conditioners, it is possible to regulate the heat inside a room, helping bridge the gap left by ventilations. Without such implements, the stagnant air in buildings has the potential to cause discomfort and other significant health problems. Being a widely used tool especially in hot areas, gaining insight in its manufacture is key to achieve maximum utility. In this light, examining the step-wise procedure of the engineering approach can aid shed light on the possible faults and take actions before severe consequences are realized. Focusing on the manufacturing process, an FMEA would be conducted to provide the severity, probability of occurrence, detectability of failure modes and consequently, evaluate the risk priority number (RPN) (Vanyi, 2016).
Most air conditioners are made from either a sheet of steel or plastic. The process begins by forming the metal or plastic parts. In most cases, the metal parts are sheet stamped to fashion them into the desired shapes and sizes. When the sheets are large, they are vacuum formed while the smaller pieces are formed using other techniques (ZHU & WANG, 2004). Steel is then galvanized through adding a layer of zinc to minimize on rusting and other deterioration. Afterwards, painting is done on the galvanized steel. These form the exterior parts making them ready for assembly. Other vital parts needed are the condensers which perform the function of heat transfers and compressors which are responsible for compressing the gas that go through them. Assembling of the air conditioner entails installation of the outside condenser which transmits heat from inside the building to the outside air, the inside condenser which cools the air being brought into the indoor area and the compressor (ZHU & WANG, 2004). Most of these implements are pre-built and just require assembling. The condensers are usually connected to the compressor via copper pipes while the electronic controls are connected to an electric motor that causes the compressor to spin (ZHU & WANG, 2004). After assembling, a coolant gas is pumped into the condensers, pipes and compressors to a pre-determined pressure level. The air conditioner is then operated using either a control knob or a remote control.
Since remanufacturing is often not a viable option in the event of a mechanical problem, conducting an FMEA can help to avert such considerations. The compressor is such a crucial component in the functionality of the air conditioner. In case it fails to work, the causes may be either a low gas pressure or low lubricant level. This could lead to production of cold air. As a result, the severity rating for such a scenario would be S= 8 and the possibility of occurrence, O = 7. Similarly, the possibility of detection, D is moderately high. Through multiplication of these values, the RPN = 224. To increase the detection of failure and decrease the severity, the lubricant level meter and a gas pressure sensor have to be applied which can provide a hint concerning the possibility of the compressor breaking down. Upon such a re-evaluation, the severity of failure, S=8, the possibility of occurrence, O = 7 but the possibility of detection, D = 1. Consequently, the new RPN = 56.
References
Vanyi, G. (2016). Improving the effectiveness of FMEA analysis in automotive–a case study. Informatica, 8(1), 82-95.
ZHU, S. Q., & WANG, H. (2004). Development of Air-conditioners CAD System [J]. Construction Machinery For Hydraulic Engineering & Power Station, 5.