Analyzing Transformer Manufacturing Failure By Using FMEA Approach

Zharif Anwar, Sulaiman (2011) Analyzing Transformer Manufacturing Failure By Using FMEA Approach. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This report is focused on the failure analysis of the Tangent Delta failure in transformer manufacturing process. Failure Mode and Effect Analysis or FMEA is a one of the quality tools that able to guide the engineer or designer to overcome the failure which has occurred in the product or in the manufacturing process. FMEA helps managements to figure out the failures by determining potential of the failure mode, effect of each failure, occurrences of each failure and the current control process through Severity (S), Occurrences (O), and Detection (D) rankings. From the combination of those rankings by using Risk Priority Number (RPN) technique, the priority to reduce or eliminate (if possible) the failure can be executed by identifying the highest RPN. For the FMEA effectiveness, other tools such as fish bone diagram, Pareto chart and Why-Why Analysis will be used along with the FMEA experiment which serves as communication tool and documentation for the FMEA Team. Literature review provides the theories and facts which obtained from the journal and books. That information will become an important reference in order to guide the project achieves its main objective. Before executing this project, the methodology need to be constructed regarding to the objectives and the problem stated. The project flowchart indicates the process flow and serves as a guideline for the entire project course. As well for the preparation for the next PSM II, the technique, equipment and the required information also been defined to ensure the project is on course and achieves its main objective. The case study is been concluded with the study of the each process involved in the production line and also to strengthen the information in order to provide better understanding. The experiment of the FMEA analysis has reveals the possibilities from several factors which lead towards the Tangent Delta failure. With proposed countermeasure based on the FMEA analysis, the possibility to reducing the failure effect could be achieved if the correct actions have been taken seriously.

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