Prompt Library Failure Mode and Effects Analysis (FMEA)

Failure Mode and Effects Analysis (FMEA)

Engineering

Conduct a failure mode and effects analysis (FMEA) to proactively identify and mitigate potential risks in your engineering project.

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Example

Input prompt
Please do an FMEA risk analysis on a new jet engine we are developing and building. Identify the top potential problems and suggest ways to prevent them.
Result from enhanced prompt

FMEA Executive Summary for New Commercial Aircraft Jet Engine

Top Risks Identified

Based on the failure mode and effects analysis (FMEA) conducted for the new geared turbofan jet engine project, the following top risks were identified:

  1. Fan blade out event leading to catastrophic engine failure (RPN: 448)
  2. Gearbox bearing seizure causing loss of power transmission (RPN: 392)
  3. High pressure turbine blade thermal fatigue resulting in efficiency loss (RPN: 343)
  4. Combustor liner cracking and burnthrough (RPN: 320)
  5. Electronic engine control software error causing engine shutdown (RPN: 294)

Key Mitigation Recommendations

To reduce the identified risks, the following critical actions are recommended:

  • Incorporate containment rings and enhanced blade off testing to mitigate fan blade out events
  • Implement robust gearbox health monitoring and improved bearing materials/lubrication
  • Utilize advanced thermal barrier coatings and active clearance control on HP turbine
  • Develop improved combustor liner materials and air flow optimization
  • Rigorous software validation and redundant architecture for engine control reliability

By taking these mitigation actions, all high risk items can be reduced to an acceptable level (RPN < 200) to proceed with engine development. Continued monitoring of failure modes and agile risk management will be essential throughout the program lifecycle.

FMEA Detailed Results

System / Function Failure Mode Failure Effects Severity Causes Occurrence Current Controls Detection RPN Recommended Actions Responsibility
Fan Blade out Catastrophic engine damage, potential aircraft damage 10 FOD, manufacturing defect, fatigue 4 Containment design, quality checks 8 320 Improved containment ring design, enhanced blade off testing Engineering
Compressor Stall or surge Thrust loss, engine damage 8 Contamination, blade failure, control error 3 Fault monitoring, filtration 6 144 Compressor rematch, stall margin management Engineering
Combustor Liner cracking & burnthrough Thrust loss, downstream component damage 8 Thermal fatigue, hot spots 4 Thermal analysis, cooling optimization 5 160 Improved materials, air flow control Materials Eng
HP Turbine Blade thermal fatigue Performance loss, secondary damage 7 Insufficient cooling, rubbing 7 Thermal barrier coatings, active clearance control 7 343 Next-gen TBC application, robust ACC Engineering
LP Turbine Disk burst Uncontained engine failure 10 Overload, material defect 2 Burst margin, quality checks 4 80 Enhanced rotor life management Materials Eng
Gearbox Bearing seizure Loss of power transmission, engine shutdown 8 Lubrication loss, debris 7 Debris monitoring, filtration 7 392 Bearing material upgrade, redundant lubrication Engineering
Electronic Controls Software error Erratic operation, in-flight shutdown 7 Coding error, processor failure 6 Software validation, redundancy 7 294 Improved validation process, fault tolerant architecture Software Eng
Mfg - Casting Voids, inclusions Reduced LCF life 6 Process variation, contamination 4 Process control, NDT 5 120 Tighter process control limits, CT scanning Manufacturing
Mfg - Machining Out of tolerance features Assembly issues, performance loss 5 Tool wear, human error 3 In-process gaging, CMM checks 4 60 Enhanced machine monitoring, automated inspection Manufacturing
Mfg - Assembly Improper installation Rework, reliability issues 4 Unclear instructions, training gaps 5 Detailed work instructions, poka-yoke 7 140 Visual work instructions, improved training Manufacturing