9 ssgb amity bsi faul tree
TRANSCRIPT
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Module-9
Fault Tree Analysis (FTA)
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At the end of this section delegates will be able to:
• Understand the role of Fault Tree Analysis within
the DMAIC Improvement Process
• Construct a Fault Tree from “Top Event” down to
actionable “Basic Events”
• Identify appropriate actions to “close” a branch of
the tree
• Recognise that Fault Tree can be used both as a
prevention tool and a diagnostic tool
Fault Tree Analysis Learning Objectives
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1. Fault Tree Analysis Within DMAIC
2. Fault Tree Analysis Roadmap:
• Define Top Event
• Define scope of system
• Understand system
• Construct Fault Tree
• Analyse the Tree
• Closing Actions
3. Workshop
4. Summary
Fault Tree Analysis – Agenda
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15 20 25 30 35
LSL USL
� Define Measures (y’s)
� Check Data Integrity
� Determine Process Stability
� Determine Process Capability
� Set Targets for Measures
Phase Review
� Control Critical x’s
� Monitor y’s
� Validate Control Plan
� Identify further opportunities
� Close Project
1 5 10 15 20
10.2
10.0
9.8
9.6
Upper Control Limit
Lower Control Limit
y
Phase Review
� Develop Detailed Process Maps
� Identify Critical Process Steps (x’s) by looking for:
– Process Bottlenecks
– Rework / Repetition
– Non-value Added Steps
– Sources of Error / Mistake
� Map the Ideal Process
� Identify gaps between current and ideal
START
PROCESSSTEPS
DECISION
STOP
Phase Review
� Brainstorm Potential Improvement Strategies
� Select Improvement Strategy
� Plan and Implement Pilot
� Verify Improvement
� Implement Countermeasures
Criteria A B C D
Time + s - +
Cost + - + s
Service - + - +
Etc s s - +
15 20 25 30 35
LSL USL
Phase Review
Analyse Improve ControlMeasureDefine� Select Project
� Define Project
Objective
� Form the Team
� Map the Process
� Identify Customer Requirements
� Identify Priorities
� Update Project File
Phase Review
Define
Six Sigma Transactional Improvement Process
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• Fault Tree Analysis (FTA) is a graphical tool for analysing
possible causes of a failure.
• Can be used as a Prevention Tool - Prevent the failure
mode from occurring.
• Or can be used as a Diagnostic Tool - Identify what caused
the failure
• Focuses on a single failure mode (as opposed to FMEA
that looks at all failures)
• In Six Sigma it can be used to help identify the Critical
Inputs or Process Steps (x’s) (Analyse), and develop
improvements and controls for the Critical Inputs or
Process Steps (x’s) (Improve/Control)
Introduction to Fault Tree Analysis
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Step 2:
Define Scope of System
Step 3:
Understand System.
Step 1:
Define Top Event.
Step 4:
Construct Fault Tree
Step 5:
Analyse the Tree
Step 6:
Closing Action.
Fault Tree Analysis Roadmap
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• The ‘Top Event’ is the major failure to be analysed in
the fault tree.
• Within Six Sigma DMAIC this typically will be the
issue(s) identified in the Measure Phase e.g. Delay in
invoice payment, Incomplete order shipment etc.
• When identifying, consider main functions of
processes, major “customer” effects, historical
failures…
• A separate fault tree should be generated for each Top
Event that is a fundamental concern.
Step 1 – Define Top Event
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Step 2 – Define Scope of System
What comprises the ‘system’ (transactional
process) to be analysed:
• Which parts/process steps will be considered ?
• Which parts/process steps will be outside the
scope (responsibility of supplier or third party)?
• What level of detail ?
(macro/micro process steps)
• ‘System’ can consist of manual steps and / or
automated steps (e.g. IT system).
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Step 3 – Understand the System
• The relevant experts (IT, Process “Operators” etc.) explain the function of each part/process step to the team.
• Supported by:
• Process Maps
• Specification Documents
• “Walking the process”
• Customer Feedback data
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Dark
Room
Bulb Blown
Switch Failed
To Close
No PowerFuse Blown
Power Cut
AND OR
AND Gate OR Gate
OR OR
ANDBattery failureLoss of
Power
Step 4 – Construct Fault Tree
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Top Event Intermediate Events
Basic
EventClosing
Action
Specification
Supplier
Quality
Process
OR OR OR
AND
Step 4 – Construct Fault Tree
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Step 4 – Construct Fault Tree
Basic Events
Events leading to (causing) top event. Sequenced from high level to lower level (“Macro” process step to “micro” step).
Lowest level events within scope of FTA. Actionable level of detail. Three types of basic events should be considered (although not all may be present).
Main failure to be investigated Top Event
Intermediate
Events
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Basic Event Types
Event relates to inadequate or
incorrect processing, e.g.
information entered incorrectly.
Specification
Related
Supplier Quality
Related
Process Related
Event relates to incorrect
specification e.g. information
not specified as required
Event relates to supplier not
meeting specification, e.g.
incorrect information provided.
Step 4 – Construct Fault Tree
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Top Event
Incorrect
labeling of
product
Wrong label
fixed to
product
No label
Wrong label
printed
Basic Events Closing
Actions
Intermediate
Events
Incorrect part
number entered
Error in
database
Information on
label incorrect
OROR OR
Labels mixed
up on line
Stock of Labels
held
on line
Multiple Product
Types on
Production Line
AND
FTA Example: Labelling Example
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Pricing
information
incorrect
Top Event
Delay in
Invoice
payment
Missing/
Incorrect
Information
Bankruptcy
Missing order
number
Basic Events Closing
Actions
Intermediate
Events
Lack of
authorisation
Not supplied
by Sales
Sent to wrong
person/place
OROR OR
FTA Example: Invoicing Example
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Method 1
• Brainstorm all possible events (causes) that might lead to Top Event.
• Transfer to Post-Its or cards.
• Sort into groups of events for related parts.
• Organise into a tree structure with Top Event on left side, branching
to the Basic Events on the right.
Method 2
• Starting from the top event and ask the question “how could this
happen ?”
• Work on each branch in turn, repeating the question “how could
this happen?”
In practice a combination of both methods can be used.
Step 4 – Construct Fault Tree
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Step 5 – Analyse Tree
Check:
• All known (historical) failures shown.
• Sequence of events from left to right.
• All branches have been developed to an
actionable level.
• Optional step :
• Prioritize the basic events in terms of their
probability of occurrence. (ref. FMEA
Occurrence Rating).
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• ALL Basic Events should have a closing action.
• ‘Level / depth’ of action dependent upon the level of concern (occurrence).
• Three areas of focus:
• Specification Validation– to ensure that the transactional process has been correctly specified
• Supplier Quality- to ensure that any process inputs are correct
• Process Control – to ensure that the transactional process is operated correctly
• Action not closed (signed off) until completed.
Step 6 – Closing Action
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Typical closing actions include:
• Standard Operating Procedures, SOP’s
• Operator Training
• Mistake Proofing
• Statistical Process Control, SPC
• Control Plan
Step 6 – Closing Action
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Step 2:
Define Scope of System
Step 3:
Understand System.
Step 1:
Define Top Event.
Step 4:
Construct Fault Tree
Step 5:
Analyse the Tree
Step 6:
Closing Action.
Fault Tree Analysis Roadmap
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15 20 25 30 35
LSL USL
� Define Measures (y’s)
� Check Data Integrity
� Determine Process Stability
� Determine Process Capability
� Set Targets for Measures
Phase Review
� Control Critical x’s
� Monitor y’s
� Validate Control Plan
� Identify further opportunities
� Close Project
1 5 10 15 20
10.2
10.0
9.8
9.6
Upper Control Limit
Lower Control Limit
y
Phase Review
� Develop Detailed Process Maps
� Identify Critical Process Steps (x’s) by looking for:
– Process Bottlenecks
– Rework / Repetition
– Non-value Added Steps
– Sources of Error / Mistake
� Map the Ideal Process
� Identify gaps between current and ideal
START
PROCESSSTEPS
DECISION
STOP
Phase Review
� Brainstorm Potential Improvement Strategies
� Select Improvement Strategy
� Plan and Implement Pilot
� Verify Improvement
� Implement Countermeasures
Criteria A B C D
Time + s - +
Cost + - + s
Service - + - +
Etc s s - +
15 20 25 30 35
LSL USL
Phase Review
Analyse Improve ControlMeasureDefine� Select Project
� Define Project
Objective
� Form the Team
� Map the Process
� Identify Customer Requirements
� Identify Priorities
� Update Project File
Phase Review
Define
Six Sigma Transactional Improvement Process
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• Analyse - Fault Tree can be used to identify possible Critical
Inputs or Process Steps (x’s) that are causing the poor
performance in Process Outputs (y’s)
• Improve - Fault Tree can be used to help identify how the Critical
Inputs or Process Steps (x’s) might be changed / eliminated /
controlled to improve the Process Output (y)
• Control - Fault Tree can be used to identify appropriate controls
for the Critical Inputs or Process Steps (x’s)
• Control - Fault Tree can be used as a diagnostic tool to identify
corrective action when a failure occurs
Summary Fault Tree Analysis
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Workshop Time:
Develop a Fault Tree Analysis for the given “Top Event” and Transactional Process scope:
1. Understand the “System” (for a transactional process application, develop/review the process flow).
2. Brainstorm “How could top event happen?”. Put each idea onto a post-it as it is generated.
3. Organise the post-its into the tree structure, starting with the top event on the left, working towards the root causes (basic events) on the right.
4. Analyse the tree to check that the branches are logical and identify any missing causes.
5. Identify closing actions for the five most likely causes (use the FMEA Occurrence rating if required).
6. Prepare a short presentation on your team's findings.
Workshop – Construct a Fault Tree Analysis