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Enhanced FMECA: Integrating Health Management Design and Traditional Failure Analysis

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Conference paper

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DOD acquisition programs have recognized that operating and support costs dominate the total life cycle costs of complex military systems, and therefore should be considered up front in the design process. In order to estimate operating costs, which are predominately related to maintenance costs, a view of the conceptual design must exist that can be used to evaluate the effects of system design variables upon maintenance requirements. This view is currently best embodied in the Failure Modes, Effects, and Criticality Analyses FMECA. Additionally, many DOD acquisition programs are interested in designing health management systems through the optimal application of system diagnostic and prognostic techniques to produce substantial safety and life cycle cost benefits. To achieve these benefits, a more systematic and accurate method to evaluate candidate health monitoring approaches during the design process must be incorporated. While the FMECA is a keystone of the maintenance planning process, it has limitations in estimating the impact of Condition-Based Maintenance CBM implementation on life cycle costs. CBM technology deals not just with failures, but also with monitoring the progression towards failure through detection, diagnosis, and prognosis. If we are to evaluate maintenance efforts and diagnosticprognostic technology design choices, then the failure modes must be defined in a way that deals with incipient and evolving failures. Hence, the current paper discusses the development of a tool called FMECA for use by designers and end users that addresses these issues and helps to collaboratively design the optimal health management solutions for complex machinery from a cost benefit andor availability standpoint We discuss the processing concept of the FMECA and introduce methods to optimize the expanded failure mode analysis, health management metrics, and maintainabilityavailability considerations.

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  • Computer Programming and Software
  • Machinery and Tools

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