Merging FMEA and FTA for safety analysis of sensors for ...

1 Attracting TomorrowTDK-EPCA TDK Group CompanySEN Business Group Product DevelopmentBerlin, GermanySeptember, 15, 2016 Merging FMEA and fta for safety analysis of sensors for automotive applicationS. Mergen, Schreiber-Prillwitz, P. Schmidt-WeberMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 2 Attracting Tomorrow Motivation to write this paper Background on FMEA Background on FTA Integrative Methods in the Literature Forward Integration Backward Integration Simple sensor Model Merging FTA and FMEA in 5 Steps ConclusionsOutlineMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 3 Attracting TomorrowMotivation for this paper / ISO 26262 on safetyanalysesIn sensordevelopment: traditionallyDesign-FMEAI ncreasingASIL level limitationsoftheFMEA analysisQuestions: Can wecombineFTA andFMEA? Can weimprovethequalityofanalysis? Isitlesseffort?Can itwork? Hasitbeenanyonedonebefore?

2 Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 4 Attracting Tomorrow Traditional analysisin componentdevelopmentDFMEAA nalyse design faultsAssumption: processingisfailure-freePFMEAA nalyse failurein processAssumption: design isfailurefreeOutcome:-Single failures/ riskrating-Design optimisation-Bottom-upapproach: detailedanalysisofsinglepartsandtheirint eractionsBottomupapproach: detailedanalysisofsingleprocessingstepsa ndtheireffectson theassembledcomponentNot ofmuchConcerntoISO26262 Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 5 Attracting TomorrowAutomotive Design-FMEA (VDA)ProductanditspartsWhatarethefunctio nsoftheproduct, parts, andtheirinteractionsWhataretheFailuresin oftheProduct, partsTheirinteractionsHowtopreventfailur esearlier,howtoreducetherisk?Failureeffe ctFailuremodeFailurecauseHowtopreventfai lures, howtodectectthem?VDA Qualit tsmanagement in der Automobilindustrie Sicherung der Qualit t w hrend der Produktrealisierung Methoden und Verfahren, Band 4 Kapitel: Produkt-und Prozess-FMEA, 2.

3 Auflage, 2006 Step1:StructureanalysisStep2:Functionsan alysisStep3:FailureanalysisStep4:Detecti onandPreventionactionsStep5:Optimisation Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 6 Attracting TomorrowFTA on a logiccircuitexampleABCDS ignal inSignal outNooutputsignalACADBCBD&&&& 1-Focus on onefailure(TOP EVENT) -Single pointandmultiple pointfailures-Can Includefailuresfromprocessing, handlingorexperienceMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 7 Attracting TomorrowISO 26262-10 on combiningFTA andFMEA-Use FTA to analysethe hazards down to the component level-The failure modes of the components are analysedusing an FMEA to determine their failure modes and safety mechanisms to close out the bottom level of the fault FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 8 Attracting TomorrowIntegrative FMEA / FTA analysis Forward Integration: FMEA FTA Backward Integration.

4 FTA FMEA Bi-directional / Bouncing Integration the strength of forward integration: identification of latent failure modes the strength of backward integration: coincident circumstances that allow failure mode to occur / more efficient in security analysisMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 9 Attracting TomorrowForward Integrated analysis : FMEA FTA Hong, & Liu, B. 2009, Integrated analysis of Software FMEA and fta , Information Technology and Computer Science, ITCS Conference on , , no., development: Forward Integrated analysis in Requirement Phase comprehensive and meticulous analysisMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 10 Attracting TomorrowBackwardIntegrated analysis : FTA FMEAHong, & Liu, B. 2009, Integrated analysis of Software FMEA and fta , Information Technology and Computer Science, ITCS Conference on , , no., Integrated analysis in Design Phase: more efficient and more suitable than forward integrated analysisMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 11 Attracting TomorrowMergingFMEA withtheFTAM erging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 12 Attracting TomorrowMergingFMEA FTA Case Study: Simple sensor ModelMechanical/ electricalinterfacetosystemPackage / housing/ PCB / stimulusinletaccelerometer, gyroscope, current,pressure, Not partofthesensor systemin whichthesensorisintegratedMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 13 Attracting TomorrowSimple sensor Model: FunctionsandfailuresSafetygoal1: provide correct signal to the systemFailures: nosignalsignalnot withinspecificationssignalisnot correct(undectectedwrongsignal)signalnot on timesignaldriftssignaloffsetSafety goal 2.

5 Provide signal failure to the systemFailures:failurenot detectedWrongfailureassignedDiagnosticsf ailedSelftestnot availableSelftestfailstemporarlyMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 14 Attracting TomorrowStep 1: Do Design FMEA Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 15 Attracting TomorrowStep 1: Do Design FMEA Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 16 Attracting TomorrowStep2: Create the FTA top-levelWhencanthingsgowrong?Howcanthin gsgowrong?DFMEA: Whatcangowrong? Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 17 Attracting TomorrowStep3: Deduce dual-point faults from the FMEA and include them in the FTAB luvband, Z, Polak, R & Grabov, P 2005 Bouncing Failure analysis (BFA): The Unified FTA-FMEA Methodology ,Proceeding of Annual Reliability and Maintainability Symposium, 467 analysis ofall failuresthatdo not contributedirectlytothefailureeffects(no signal, wrongsignal), andtheircombinationsMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 18 Attracting TomorrowStep 4: Transfer dual-point faults back into the FMEAM erging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 19 Attracting Tomorrow AND -gate in FMEA torepresentMultiple-point failuresMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 20 Attracting TomorrowStep5.

6 RPN calculationformultiple-point failuresPickard, K, M ller, P & Bertsche, B 2005, Multiple Failure Mode and Effects analysis An Approach to Risk Assessment of Multiple Failures with FMEA , Proceedings of the Annual Reliability and Maintainability Symposium, (2005), RiskPriorityNumber(RPN) = Severity(S) X Occurence(O) X Detection(D) Merging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 21 Attracting TomorrowStep5: RPN calculationformultiple-point failuresMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 22 Attracting TomorrowStep 5: FMEA optimization // Double-point failureMerging FMEA with FTA [Chapter title] TDK-EPC 2016A TDK Group CompanyProduct Development 09/16 23 Attracting TomorrowConclusions-The analysisisthoroughwithnewfailuremodesfou ndandincludedwhereapplicable-Improvedpro ductdesign withfocuson safety -Inclusionofmultiple pointfailures(latent faults) in theFMEA-Systematicapproachthrough5-Steps -Working in