Designing Safe and Reliable Machines and Processes

1.Safety Analysis, Risk Assessments

A safety analysis project is typically completed in the following steps:

Determine analysis scope and organization
Perform a) Preliminary risk analysis and b) detailed risk analyses (Hazop, FMEA etc)
Perform risk classification using SIL number (Safety Integrity Levels) or RPN (Risk Priority Number)
Reporting: improvement actions for identified risks
Contact authorities or certification bodies for approval

We have developed effective analysis tools and procedures. This allows designers to apply the analysis results in time. For Functional Safety and SIL (EN 61508, EN 62061, EN 13849), see our 'Conformance Engineering' page.

2.RAM Models and Reliability Analysis

RAM model of a system predicts potential production losses and pinpoints the 'bottleneck' equipment ('Top 10 lists'). It can be used further in RCM and LCC analyses of systems. (RCM= Reliability Centered Maintenance, LCC= Life Cycle Costs).

We have developed effective methods and tools for

RAM data collection
RAM, RCM and LCC analysis
Planning of Maintenance tasks based on RAM model
RAM reporting

The RAM analysis results are readily available supporting the design of safe, reliable and optimized process systems. We can use generic RAM data from different sources or arrange tailored RAM data collection campaigns on existing plants.

We have modeled power plants, chemical processes, wind power, fuel cells, biopower, oil refineries, paper machines, heavy machinery, transportation systems, control systems etc.

3.Manufacturing and Assembly Process Analysis

Unfortunately the manufacturing errors are the main cause of product failures during warranty period. This means increased warranty costs and customer dissatisfaction. The P-FMEA method (Process Failure Modes and Effects Analysis) is very effective in analyzing Manufacturing and Assembly processes. It was first introduced in the QS-9000 standard by automotive industry. The P-FMEA analysis can be complemented with the D-FMEA method (Design FMEA), in which the product failure modes and potential effects are studied in detail.