Failure analysis of machinery component by considering external factors and multiple failure modes – A case study in the processing industry

This paper proposes a failure analysis method by integrating the Failure Mode Effect and Criticality Analysis (FMECA) and Failure Time Modelling (FTM) based on Proportional Hazard Model (PHM). The objectives of FMECA application are twofold: to classify the censored and uncensored data based on the criticality measure of FMECA, and to identify possible external factors (covariate effects) based on cause and effect assessments of FMECA. FTM based on PHM is applied to analyze statistically the censored and uncensored failure time data by considering the effects of external factors. The applicability of proposed methodology is illustrated in a case study in the processing industry. The analysis results of FTM based on PHM by considering external factors present a more reliable hazard rate and lifetime or mean-time-to-failure of the targeted component, hence enabling engineers to plan a more effective maintenance strategy.

► The paper deals with FTM by considering the external factors, and censored and uncensored data.
► Proposed failure analysis method by integrating the FMECA and FTM based on PHM.
► The applicability of the method is illustrated using a real industry case.
► The method presents more reliable info/inputs for engineers to plan a more effective maintenance strategy.