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by Doug Lehr Leave a Comment

FMEA Improves the Bottom Line

FMEA Improves the Bottom Line

Refer to Article 7 for the expansion joint project. This project had progressed – perhaps beyond lab testing – before it was realized that the design could not meet ASME LRFD criteria. LRFD was considered necessary for reliability. The engineering manager had to consider a redesign. 

Missing the LRFD may be the result of not conducting a design failure modes and effects analysis (dFMEA). FMEA is a risk discovery process. Discovering design risks early in the project improves reliability and increases profitability by avoiding redesign and schedule delays.

A “check the box” dFMEA (CTB) may also explain the miss. A CTB FMEA is usually completed only to achieve the appearance of due diligence. A CTB FMEA delivers little value because typically:

  • One project member completes the entire FMEA template.
  • Controls reflect tribal knowledge, not documented practices.
  • Initial and final RPNs are all low risk (it’s a perfect product!).
  • There are few recommended actions.
  • The recommended actions are vague and un-auditable.
  • The template is submitted at the end of the project.

To realize value, FMEA must be conducted correctly. Here are some key elements of a value generating FMEA program:

  • FMEA program documents exist to promote consistency. 
  • A senior design SME provides FMEA program oversight.
  • A group of SMEs are trained to facilitate FMEAs.
  • FMEA requirements are modified for high TRLs.
  • FMEA is conducted with small teams of SMEs (4 to 8) who can anticipate design risks.
  • dFMEA is conducted by the end of design; pFMEA is conducted by the end of lab test. 
  • A document workflow exists for approval and implementation of recommended actions.
  • Metrics exist for measuring the effectiveness of the FMEA program.

Reduce design risk as much as possible using an FMEA program. And remember that a sustained focus on FMEA is a trait of an organizational culture that values high reliability. 

TRUTH: When conducted correctly, an FMEA delivers savings to the bottom line.

This is the 9th in a series of 10 articles on critical equipment design for offshore completions.

  1. Critical Equipment Fundamentals
  2. Technology Readiness Level (TRL)
  3. Materials and Design Risk
  4. Temperature Deration
  5. Design for Reliability (DfR)
  6. Using Industry Standards in Design
  7. Factors of Safety and Load Factors
  8. Modelling and Simulation
  9. FMEA Improves the Bottom Line
  10. Lab Testing Programs

Filed Under: Articles, Equipment Risk and Reliability in Downhole Applications, on Risk & Safety

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Articles by Doug Lehr, P.E., Founder and Principal, Integris Technology
in the Equipment Risk and Reliability in Downhole Applications series

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