ISSN XXXX XXXX © 2017 IJESC

Research Article Volume 7 Issue No.4

Failure Mode Effect Analysis with Pareto Chart for Various Critical
Equipment used in Ceramic Industry
Appil Ora1 , Dharan i Ku mar2 , Nupur Darade 3
Student1, 3 , Professor2
University of Petroleu m and Energy Studies , India1, 2
Vidhyasagar Institute of Science and Technology, India3

Abstract:
As Industrialization growing in today’s world, lots of innovation leads to development of critical equip ment which are defin itely
enhancing the production but also associated with the numerous of hazards which may lead to mishap. In order to prevent accidents,
several measures need to be taken in order to prevent such kind of incidents. So, the first step starts with the hazard identification
which requires lots of practice and expert experience to apply best hazard identification technique. Particularly, if we take equip ment
safety into consideration then, failure mode effect analysis is one of the best ways to make it possible. To resolve any of the issue first
of all it is very necessary to identify the root cause of the particular problem and hence to make the equipment functioning safer,
failure mode of the equipment is to be identified and it is also necessary to know about its severity, occurrence and several other
factors. This paper discuss about the failure mode effect analysis of various equipment used in ceramic industry and identify the
hazards associated with all those critical equip ment which may lead to life loss, property damage or may cause harm to enviro nment
also. There are total seven different equipment are considered so that on the basis of risk priority number, Pareto chart can be draft so
that on the basis of finding action plan can be suggested. RPN can be obtained fro m consulting the experienced person who is looking
forward to such equipment and past record can also be referred so that exact problem can be identified and necessary measures can be
suggested. Management can look to the issues on the basis of RPN and if it is significant then refer action p lan to resolve it as per
there need. For all the failure modes identified necessary recommendations are made so that prior action can be taken before that
failure mode can result in mishap.

Keywords: Failure mode, Functional failure, Risk prio rity nu mber, Occurrence, Detection

I. INTRODUCTION
Failure mode effect analysis is conducted in order to find out all
the possible ways in which equipment can fail, so that all the
necessary measures can be taken in order to prevent its failure or
in case if it fails then determine the way in wh ich it can attain the
condition to resume its primary function. Report also shows the
ways of failure modes for different equipment. It is basically a
pro-active action that is to be taken by every organization with
respect to safety so that all preventive measures can be placed in
advance so that no adverse failure effect can be seemed
throughout an organization and a good safety environ ment can
be developed. It not only includes preventive action but it also
includes various corrective actions that are necessary to be taken
as a reactive action after failure o f any equipment. Since it is an
analysis based on experience or past records of an organization
so some scale is to be assumed so that Risk priority number can
be find out and can be understand that whether risk can be
acceptable or not. If it is not then some strict action needs to be
taken in order to resolve such barrier. Before conducting failure
mode effect analysis, detail study of all the equipment is
required so that hazard associated with them can be analyzed.
Now prioritize the equip ment and select the equipment having
more chances/modes of failure. Then Select equip ment and
apply the technique (FM EA) on it. In order to find out the Risk
priority number calculate likelihood, severity and detection
system as per the table given below and take the help of skilled
and experienced people to evaluate that. Finalize the calcu lation
and recheck all the parameters. Apply same process to the next
equipment.
II. MATERIALS AND METHODS
Risk priority number can be calculated as multiplication of
Likelihood of occurrence, severity and detection rank. Here on a
scale of 1 to 5 all the parameters are defined below.
Table.1. Likelihood of occurrence rank list
Rank of likelihood of Description
occurrence
1 Never
2 Once in 10 year
3 Once in year
4 Once in month
5 Once in week
It discusses about the likelihood of occurrence of any failure
mode and that needs to be considering while calculat ing RPN,
below given table shows the scale as per the probability of
occurring of any particular event.

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Table.2. Severity rank list Table.3. Detection rank list

Rank o f severity Description Rank o f detection Description

1 No Loss
2 Minor performance losses only
3 Partial breakdown of system and can
be repaired
4 Co mplete breakdown of
system/minor injury
5 Major Losses or Fatal/multip le
injury
This table discusses about the severity of the event that will
occurred after failure mode, because sometimes failure mode
may leads to very hazardous event. Hence severity is also needs
to be consider in calcu lation of the RPN.
1 Online detection and automatic
response
2 Online detection and manual
response
3 Manual detection and manual
response
4 Random Manual detection and
manual response
5 No detection system installed
This particular table d iscusses about the method of detection so
that it can be known that how immediate that failure can be
seemed and action can be taken because if it exceeds a time, it
may lead to some undesired event too.

Equi pment-1 A ir operated diaphrag m pu mp (Tab le-4)

Function: To transfer slip, glaze and water via air mediu m
Failure Mode Effect CA/PA S O D RPN
Hard glaze o r pin Pump will stop working Mesh should be installed 2 3 3 18
chock the blade of at inlet in order to prevent
pump such conditions
Ball/sheet wear & Pump will stop working Shield is to be changed on 2 3 3 18
tear regular interval basis
Water comes along Air seal/O-ring got Air filter or hair dryer 2 1 3 6
with the air damaged element is to be used

Equi pment-2 Heat Treat ment Dryer (Table-5)

Function: To dry the finished product (ceramics)
Failure Mode Effect CA/PA S O D RPN
Motor of the dryer Bearing damage/Motor Damper arrangement is to 3 3 3 27
got damaged due to burn be made in order to prevent
overheat overheating
Panel or automation Dryer will stop working Proper observation is 3 2 2 12
system got failed due required
to software problem
Cone/bearing failure Proper drying of the Regular g reasing of the 2 2 3 12
due to striking with product cannot be bearing is required
the product/vehicle achieved

Equi pment-3 Kiln Blower (Tab le-6)

Function: Suck and discharge the air to maintain temperature of the kiln
Failure Mode Effect CA/PA S O D RPN
Bearing got failed Blower will stop to 1. Regular 4 2 3 24
due to heat or wear & perform its function. maintenance and
tear greasing is to be
done in order to
avoid overheating.
2. Stand by blower is
to be arrange

Belt got failed due to Blower will stop to Belt needs to be changed in 3 2 2 12
overheat or wear & perform its function. case of damage
tear
Misbalance of the Blower will stop to Re-balancing is to be done 4 2 3 24
blower due to belt perform its function. by vendor
failure after getting
jerk

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Equi pment-4 A ir Co mpressor (Table-7)
Function: To co mpress the air as per the requirement/function
Failure Mode Effect CA/PA S O D RPN
Fails to perform Proper maintenance of the 4 2 3 24
function due to equipment is required
overheating or
continuous running
Belt of air Co mplete breakdown of Require to replace the belt 4 2 3 24
compressor got failed equipment in case of belt damage
due to overheating
Dust accumulation in Ensure cleaning of air 4 1 3 12
filter of equip ment filters on regular interval
basis

Equi pment-5 ROTO Pu mp (Table -8)

Function: To transfer slip and water as per usage
Failure Mode Effect CA/PA S O D RPN
Shaft and bearing Proper maintenance of 4 2 3 24
damage equipment is require as per
schedule
Belt damage due to Pump will stop working Manual supervision is 4 3 3 36
overload required and load is to be
maintain according to the
prescribed limit only
Overheating may lead Load is to be limit within 4 3 3 36
to the belt damage safe working load
Running empty Rotor starter may damage Strict supervision is 3 4 3 36
without product input required so that pumps runs
only when product input is
given

Equi pment-6 Carousel (Table-9)

Function: To rotate product at particular speed in order to perform glazing
Failure Mode Effect CA/PA S O D RPN
Derailing of chain Carousel will stop working Chain cleaning is to be 4 4 3 48
due to bearing jam perform on regular basis
Trolley get jammed Carousel will stop working Inspection of trolley on 4 4 3 48
resulting in derailing weekly basis
Dust suction blower Improper functioning of Proper cleaning of blower 3 2 3 18
failure due to carousel fan on regular basis
accumulat ion of glaze
in motor
Motor may got burnt Improper functioning of Remove glaze on regular 4 3 3 36
due to accumulation carousel basis and supervision is to
of glaze leads to be considered
overheating

Equi pment-7 Blanzer (Table-10)

Function: Proper mixing of clay in order to make slip for mou ld
Failure Mode Effect CA/PA S O D RPN
Impeller got damage 1. Maintain impeller 4 3 4 48
due to heavy on regular basis
accumulat ion of clay 2. Repair impeller if
found damage
Bearing failure due to Manual supervision is 4 3 3 36
overload of clay require to allow load as per
Co mplete breakdown of capacity
Belt damage due to equipment Increase the load gradually 4 3 3 36
mis matching of RPM as per the safe working load
of motor and blanzer

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III.RES ULTS AND DISCUSS ION RPN as well as cu mulative % is been calculated, find below
attached table for calculation of pareto analysis and the graph
In order to draft a pareto analysis, RPN no. has been categories chart for the same.
into 7 different category as per their RPN and finally cumulat ive

Table.11. Pareto Analysis

Category RPN Cu mulat ive RPN Cu mulat ive %
Category-1 48 48 28%
Category-2 36 84 49%
Category-3 27 111 65%
Category-4 24 135 79%
Category-5 18 153 89%
Category-6 12 165 96%
Category-7 6 171 100%

60 120%

50 100%

40 80%
RPN
30 60%
Cumulative %
20 40% 80% marker

10 20%

0 0%
Category-1 Category-2 Category-3 Category-4 Category-5 Category-6 Category-7
Figure.1.Pareto chart wi th 80% marker

As we find out the maximu m RPN would be 5*5*5=125, and on
the basis of finding we got seven different category of RPN
ranging fro m 6 to 48 and for the same pareto analysis is done
can with 80% marker it can be seen that which category require
immed iate action and rest of the category require regular
observation so that they cannot exceed the safe RPN. Detail
discussion of all the equip ment is given below:-
Equi pment-1 : In air operated diaphragm pump, maximu m RPN
is 18 stands for two failure modes and for the same few CAPA is
suggested which needs to be followed in order to prevent such
failure mode specially mesh to be provided and shield to be
changed.
Equi pment-2: Heat treat ment dryer is one of the typical
equipment that is using in ceramic industry; damper system is to
be provided in order to prevent overheating.
Equi pment-5: ROTO pump is the most critical equip ment
which got failed maximu m no. of time and got highest RPN no.
for 3 failure modes i.e; 36 several CAPA actions are available
not only to prevent such failure but also to correct the equipment
to regain its function if it got failed.
Equi pment-6: Again one of the critical equip ment that is using
by glazing department and mult iple people are simultaneously
exposed to this equipment and got various failure modes and
even few are having RPN of 48 which is significant and strict
observation is required and some plan is to be schedule so that
proper functioning of the equipment can be ensured.
Equi pment-7: Effect of blan zer failure mode directly leads to
complete breakdown of the system which stops the further
processes and again RPN for failure mode of this equipment is
36 & 48 which are significant and strict actions is required.

Equi pment-3: It has been observed maximu m time belt and
bearing got failed wh ich requires regular maintenance and
monitoring is to be imp lemented.
Equi pment-4: Dust accumulation and overheating are the
issues, due to which air compressor got failed various times, and
CAPA has been recommended in order to prevent such failure
mode to occur.
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