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FMEA (FAILURE MODE AND EFFECT ANALYSIS), AND EXPERT SYSTEM IN

LUBRICANT MACHINE OIL PRODUCTION PROCESS

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Proceeding, International Seminar on Industrial Engineering and Management
Aston Hotel, Manado, Indonesia, February 14th – 16th, 2012 ISSN : 1978-774X

FMEA (FAILURE MODE AND EFFECT ANALYSIS), AND EXPERT SYSTEM

IN LUBRICANT MACHINE OIL PRODUCTION PROCESS

Rina Fitriana1, Andhika Mandala Utama2, Johnson Saragih3

Quality Engineering Laboratory

Industrial Engineering Department, Industrial Technology Faculty, Trisakti University
rinauda@yahoo.com1, mr.andhikamandalautama@gmail.com 2

ABSTRACT
PT.X wanted to know what is the consequences of repeat blending from the product that
has been produced. The purpose is for analyzing problems/failures arise on the production
process thus it needs problem identification through interviewing production operator on the
company so as to continue a research about Failure Mode and Effect Analysis (FMEA)
method. The process that has higher RPN will earn priority class A, which means begin
checking process: Checking Base Oil material condition with RPN 280 and additive from
VIM with RPN value of 280. The effort of tackling each process will reflect to the Expert
System
Keywords: FMEA, RPN, expert system

1. INTRODUCTION limit set by the company, which is 100%.

Today the business world in the era of
globalization, especially developments in
the industry becomes increasingly rapid
and modern as it is supported by the
development of increasingly sophisticated
technology. With the advancement in the
industry as well as the more established
company, thus has increasing competition
among these companies. Industrial
companies are also mutually competent to
seize the market interest in their product
that their produced. Manufacturers are
required to be able translates the
expectations and consumers needs.
PT. X, found some parts of the
production that has potential to produce
products that fails during the production
process which one of them applied on
blending machine that is also utilize for
blending lubricants. In this section,
operators are expected to have a high level
of accuracy for setting up machinery and
supply the raw material aiming the output
blending of lubricant that is able to be
produced and meet the specifications.
Based on research and direct
interviews with the production department
manager, the percentage of disability
products at PT.X in August 2010 and
November 2010 reached 175%. The
percentage of disability has been over the
PT. X has not been able to identify and
analyze the factors that caused failure of
the process. Therefore, a conventional
technique that has already widely known to
analyze the occurrence of failures in the
process or product that is FMEA (Failure
Mode and Effect Analysis) with the Expert
System utilized. So with the
implementation of this method is expected
to identify, analyze problems or failures
that occur in the production process and
can propose suggestions to improve the
quality of the company as well as with
Expert System can be generated by a
system that can be used to facilitate the
operator in solving problems encountered
in process lubricants and able to make the
best decisions and like an expert.
2. THEORETICAL BACKGROUND
2.1. Failure Modes and Effect
Analysis (FMEA)
FMEA is a technique that identifies,
first, forms a potential error of a product
during its life cycle, secondly, the influence
this error and third, the critical influence of
errors in the functionality of this product.
FMEA (Failure Mode and Effect Analysis)
provides information for the prediction of

FMEA & Expert System

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Proceeding, International Seminar on Industrial Engineering and Management
ISSN : 1978-774X

reliability, and design products and tests used to determine the accuracy of the
processes. (Sheng, 1996). model. Typically, a given data set is divided
FMEA (Failure Mode and Effect Analysis) into training and test sets, with training set
is a tool of systematic and analytical quality used to build models and test sets used to
planning to identify the product design validate it.
stage and the use of the process, the
possibility of errors can occur either by the
product during production and final use by 3. RESEARCH METHOD
consumers. by (Dale, 1994), FMEA
(Failure Mode and Effect Analysis) is This is the flowchart Research Method
technical analysis (a written test) that of making FMEA and Expert System.
combines the technology and experience in
identifying the forms of error that can be Primer Data
predicted from a product or process and
planning for their elimination.
(Besterfield,1995)
Collect information
2.2. Risk Priority Number: about production
Prioritization of issues important part in process.
the troubleshooting process because of
two reasons. First, because of the limited
resources available, and therefore may not Identify kind of failure
solve all problems. Second, because of the in production process
relationship between one problem with
another problem, and therefore do not
need all the problems solved (Anwar, Identify Occurrence
1996). from failure production
process.
2.3. Expert system
Expert system expert system is a
system that employs human knowledge as
outlined in the computer to solve a Identify Detectability
problem, where the problem requires from failure production
knowledge and expertise of the human process
(human expertise). The system is designed
to mimic the thought processes of experts
in solving specific problems, and can be Identify Severity from
used by those who are not experts to failure production
upgrade their ability to solve problems process.
(Turban, 1992). Peter Jackson defines
expert systems as a computer program to
describe and consider the knowledge of Calculation RPN.
some specialized experts with a view to
resolve the problem or give enter the
above problems (Jackson, 1998).
Scoring Rangking
2.4. Decision Tree Priority
Decision Tree according to (Tan, 2004) Figure 1. Flowchart FMEA
for a given collection of records (training
set). Each record contains a set of
attributes, one attribute is the class. Find a
model for class attribute as a function of
the value of other attributes. Goal:
previously unseen records should be given
a grade as accurately as possible. A set of

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 Proceeding, International Seminar on Industrial Engineering and Management
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Start Table 1. The range of priority class

Class Range
A 248-280
Identify knowledge from expert B 216-248
C 184-216
D 152-184
Knowledge Acquisition E 120-152
After determining the range of classes,
then the determination of priority of each
Knowledge Representation
process based on a class that has been
created which can be seen in the following
table.
Develop Inference Mechanism
System Decision tree
E1

Implementation

F1

Yes No
Is it part of Human No
Expert? C1 F2

Yes Yes No
Yes No

End

Figure 2. Flowchart expert system x S1

C2 X

Yes No
4. RESULT AND DISCUSSION

The making of FMEA table is based on

every process that has been done by
product starting from the time raw materials
come until completion of the process of
cleaning products. We specify the value of
severity, occurrence and detection so that
we can know which issues have priority to
be completed first. Here is an example of
the FMEA table creation for production
process in PT. X with two of the highest
RPN values This high RPN values indicate
that the problems of the stretcher gets top
priority to be resolved, or in other words,
prevention efforts must be done to
overcome the failure of the process.
(RPN Max - RPN Min)
Span class 
(Number of Class)
Span class = (280-120) / 5
Span class = 160 / 5
Span class = 32
Range derived class is 116 so it can be
divided into classes as follows:
X S2
Figure 2. decision tree
• F1 - F7 is the code for the type of
failure in the process.
• E1 - E5 is the code for the effects of
failure on the process.
• C1 - C8 is the code for the cause of
failure in the process.
• S1 - S8 is a code for prevention efforts
that can be done to overcome the
failure of the process.
E1 (The first effect failure) is repeat
blending viscosity. After know the effect,
then will be ask about the type of failure
(F1) Are you using SN-XXX and AP-
XXXX? There are 2 choice of the question
from question F1. If the answer is Yes, and
then the question will be go to source of
failure (C1) with the question: Is that
blending process is suitable to SOP, Is it 2
hours blending process? Solution will be
found after answer the question from C1.

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Proceeding, International Seminar on Industrial Engineering and Management
ISSN : 1978-774X

Table 2. FMEA (Failure Mode and effect Analysis)

Effect
that has
Type been Cause from Control that
Process
No Failure of done S process O has been D RPN Efforts Rank
Function
Process from failure done
process
failure
First
Process base oil has
Using raw There is no SOP process
Checking been
materials control blending be
: repeat included in
base oil between applied again,
1 Checking blending 5 specification 7 8 280 A
SN-XXX Laboratory 2 hours
condition viscosity limit but
and AP- and operator blending
raw quality is
XXXX blending process
materials not good
base oil
there is no
recalibrate
The filling gauges are controlling
4 6 120 measuring E
process Charging not reliable the blending
repeat devices
of base process is operator
2 blending 5
oil from not exactly there is no
Metal Ca Miss To do
the tank the size controlling
Hide calculation 6 8 240 controlling to B
the blending
operator the operator
operator
Pressure inspect every
at the maintenance
Blending wind dirty air part
time of 6 6 180 performed C
Process: under two filter maintenance
inspection periodically.
blend bar periodically
3 the color 5
base oil inspect every
Temperatu less maintenance
and steam not part
re under rapidly 5 6 150 performed E
additive running maintenance
60 C soluble periodically.
periodically
there is no
The recalibrate
gauges are controlling
process 4 6 120 measuring E
Charging not reliable the blending
of filling repeat devices
process is operator
4 of the Color, 5
not exactly there is no
tank TBN Conducted
the size miscalculati controlling
additive 6 8 240 surveillance of B
hide on operator the blending
the operator
operator

length of after the VIM

Charging pipe line transferred to
Charging there is no
process repeat and the rest a holding tank
process is controlling
5 of the blending 5 of the 7 8 280 due to having A
not exactly the blending
additive viscosity additive the proper
the size operator
VIM contained in measuring
the pipeline tools

The
Additive process of
charging filling the repeat operator There is no
To supervise
6 process remaining blending 5 rush to 4 controlling to 8 160 D
the operator
of the oil mixed CCS cleaning the operator
drum with the
previous
process
filling to
repeat
lithos tank operator is There is no
pumping blending To supervise
7 is blending 5 hurry to do 4 control to the 8 160 D
oil viscosity operator
to the cleaning operator
in nozzle
previous
oil before

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 Proceeding, International Seminar on Industrial Engineering and Management
ISSN : 1978-774X

Expert System

Figure 3. Form Effect/Problem

Figure 4. Form Kind failure process question

Figure 5. Form Action Problem

5. CONCLUSION experiencing repeat blending due to

Based on the results of processing the data
and discussion that has been done, it can
be concluded that:
1. There are two processes which have
priority class A based on the highest
Risk Priority Number value that needs
to be addressed first, namely:
 Initial Inspection Process: Check
the condition of Base Oil raw
materials and additives
- This year the use of raw materials
SN-XXX and AP-XXXX, oftenly
insufficient quality of raw materials
but are included in the specification
limits provision LAB, by the time of
blending is less than 2 hours
resulted in less rapid mixed of raw
materials, the operator will be doing
the blending process only 30
minutes because based on their
experience of those who do not use
raw materials, repeat blending SN-
XXX and AP-XXXX did not happen.
In order to set back to standard
operating procedures that have set

FMEA & Expert System

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 Proceeding, International Seminar on Industrial Engineering and Management
the blending process for 2 hours for
these raw materials.
 Filling additive process of VIM
- At the time of the additive from the
VIM, the operator does not use a
holding tank for a few months ago
performed the inventory taking, so
many repeat blending are caused a
pipeline from VIM to the blending
tank far enough, and the possibility
of a remaining oil before, though
when filling is often over the size, in
order to set back and accommodate
the oil holding tank just before
inserted into the blending tank,
because inaccurate measuring
devices and distance are too far
away from the holding tank to tank
blending.
2. Knowledge Representation of Expert
System is applying it with a tree
diagram. Here is one example of a tree
diagram and analysis : E1 (Securities
First Failure) is a viscosity blending
repeat After knowing the effect, then
will be asked about the type of failure
(F1): Will using SN-XXX-XXXX and
AP? There are two possible answers to
the question earlier F1. If answered
yes, then the question will be traced to
the cause of failure (C1) with the
question: whether the blending process
in accordance with the SOP, which is 2
hours blending process? The solution
will be found after answering a question
from C1.
3. Expert system developed using Visual
Basic 6.0 software which contains
questions about what problems were
found during the production process of
Mesran Super 20W-50, the type of
failure process, and the cause of
failure. After that the expert system will
give the response that can be done by
the user (the operator) to overcome the
FMEA & Expert System
(Rina Fitriana)
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ISSN : 1978-774X
failure of the process. In this expert
system inference using backward
reasoning (backward chaining) that
begins with the interpretation of the
effect was discovered to be found types
of failures and causes of failures that
resulted in failure effects can occur so
we are get the response of the
problem. In addition to backward
reasoning mechanism, this expert
system uses data searching techniques
on the nodes are defined vertically and
from left to right or commonly referred
to as Depth First Search.
6. REFERENCES
(a) Azwar, A, (1996). Pengantar Ilmu
Kesehatan Lingkungan, Penerbit
Mutiara. Sumber Widya, Jakarta.
(b) Bersterfield, Dale.H. (1995). Total
Quality Management 3rd ed. Pearson
Prentice Hall. New Jersey
(c) Dale, Barrie G. (1994). Management
Quality 2nd ed. Prentice Hall UK
(d) Jakson, Peter. (1998). “Introduction to
expert system”. Edinburgh Gate :
Addison Wesley Longman Limited.
(e) Sheng-Hsien Teng, Shin-Yann Ho.
(1996). An Integrated Approach for
Product Design and Process Control.
International Journal of Quality &
Reliability Management, Vol. 13, No. 5.
(f) Tan, steinbach, kumar, (2006)
“Introduction to Data Mining”. Pearson
Education, inc. Addison Wesley.
(g) Turban, Erfaim. (1992). “Decision
Support System and Expert System”.
4th Prentice Hall International. Inc
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