Fault Tree Analysis Slides

Slide 1
May 8th, 2007 Compliance Engineering Ultratech Internal Use Only

Introduction to
FBD and FTA
Functional Block Diagrams
Fault Tree Analysis
Slide 2
Fault Tree Analysis - Review
What ?
A structured team analysis of the possible underlying
causes of a known equipment failure.
When ?
root cause analysis of a failure is needed
Why? - (outcomes)
A better understanding of the root causes of a failure
(Step 3: Root cause)
A better set of action plans to eliminate those root
causes (Step 4: Solution)
CONFIRM
RESULTS

THEME STANDARDIZE DATA ROOT CAUSE SOLUTION REFLECT
No
Yes
1 2 3 4 5 6 7
Slide 3
Fault Tree Analysis
Fault tree analysis is an effect and cause diagram that
uses standard symbols developed in the defense
industry and is used heavily in safety engineering.
FTA is a structured approach for analyzing the root
causes of a failure mode not yet fully understood.

Note: FTA is an alternative to Ishikawa (Fish Bone)
Diagrams. Many feel that FTA is better suited to
understanding layers and relationships of causes of
equipment failures. However, if you still prefer fish
bones after trying FTA, there is no reason not to use
them. The goal always remains to use the most
efficient method for solving problems.

Slide 4
FTA Example: Smoke Detector
Failure: The indicator light is on yet even with
sufficient amounts of smoke directly below the
detector vents the alarm does not signal.
Before we begin either a Fault Tree
Analysis or Failure Modes and Effects
Analysis, our first step should be to
construct a Functional Block Diagram.
CONFIRM
RESULTS

THEME STANDARDIZE ROOT CAUSE SOLUTION REFLECT
No
Yes
1 2 3 4 5 6 7
DATA
Slide 5
FBD Example: Smoke Detector
Inputs
Presence of smoke
Process
Detection of smoke
Outputs
Alarm signaling
Smoke enters
through vent
Battery powers control
box, indicator light, and
smoke detector
Smoke is ionized and
causes increase in
voltage
Signal sent from
smoke detector
triggers control box
circuit
Signal/power to
siren turns motor
Smoke enters
ionization
chamber
Control Box sends
signal/power to siren
Motor causes
siren to sound
Alarm signals
Slide 6
FAILURE
Smoke Detector does not detect smoke
Smoke not
present in chamber
Vent
is blocked
Dust
blockage
Ionization
chamber
blocked
Dust
blockage
Paint
blockage
Smoke not
detected
Defective
Control box
No power
at control box
Defective
ionization
chamber
Ionization
chamber
cracked
Broken
wire
Defective
solder
joint
Alarm not
sounding
Defective
alarm
No power
at alarm
Broken
wire
Defective
solder
joint
No power
at ionization
chamber
CONFIRM
RESULTS

THEME STANDARDIZE ROOT CAUSE SOLUTION REFLECT
No
Yes
1 2 3 4 5 6 7
DATA
Sample solution
(incomplete)
Slide 7
Typical use for an FTA:
Began by clearly identifying the failure as: The indicator light is on yet
even with sufficient amounts of smoke directly below the detector vents
the alarm does not signal.
Began brainstorming and building a functional block diagram to fully understand
how the smoke detector functions.
Continued brainstorming on possible causes for the smoke detector failure
resulting in the alarm not signaling.
Probable causes were identified:
The team constructed the FTA around the three major categories in the functional
block diagram, inputs, process, and outputs.
The team continued to build the FTA and completed it by adding lower levels of detail
under appropriate causes of failure.
The team identified the types of failure where it did not have the expertise to analyze
possible root causes. If deemed necessary, the team would seek help from suppliers
or consultants to further analyze these area.
The leading causes of failure and solutions were identified.

A design project was started to correct the problem.
Slide 8
Fault Tree
Symbols Review
Square Describes the top and lower level
failures

Or Gate Produces output (failure) if
one or more inputs exist

And Gate Produces output (failure) if
and only if all inputs exist

Circle Potential root failure which cannot be
broken down into lesser failures

Diamond Potential failure which is not
analyzed for various reasons
Slide 9
How to build a Fault Tree
1) Identify a top failure
2) Brainstorm basic contributors to failure
3) Link contributors to the top failure
Determine which combination of contributors is needed
to cause the top failure. (Ask: How many of the inputs
are needed to cause the top failure? )
Link the contributors to the top failure with the correct
gate. (And/Or)
Ask: Can we determine contributors for this
lower failure ?
Yes - repeat cycle making each contributor a top failure,
assign gates, etc...
No - we are finished - We may also end our fault tree
when we reach all indeterminable, basics, or causes
which require further research etc...
Slide 10
Understanding the symbols (Gates Review)

And gate means

For this upper failure
to occur

All of these
failures must occur

Or gate means that

For this upper failure
to occur

Only one of these
failures must occur
Failure
Failure
Slide 11
Step 1 Identify Top Level Fault
Step 2 Brainstorm first level contributors
Step 3 Link contributors to top by logic gates
Step 4 Brainstorm second level
contributors
basic event cannot be
broken down any further
event that is not
analyzed for various
reasons
Step 5 Link contributors to upper level
by logic gates
Step 6 Repeat / continue for
each lower level failure
(This page is taken from SVERDROP MANUAL - FTA and Risk Management by P.L. Clemens, 1992/1993, pg. 10 )
Slide 12
FTA Dos & Don'ts
Dos
Start at the Top
Think Categories
Brainstorm, then organize
Facilitate proper brainstorming
Know when to stop
Have action plans for all circles
Check that branches terminate with a circle or diamond
Revisit the FBD or FTA when new data is found
Use yellow stickies to capture the brainstormed causes
Don'ts
Dont get bogged down
Dont jump to solutions!

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May 8th, 2007 Compliance Engineering Ultratech Internal Use Only

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