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STANDARD RAW MATERIAL PROCEDURE 25/03/2024 Page 1 of 8

Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

Failure Mode and Effects Analysis (FMEA) Report for Shutter Door with Risk Priority Numbers (RPN) and
Corrective/Preventive Actions

1. . Introduction: Shutter doors are critical components in various industrial, commercial, and residential settings, serving functions such as security,
weather protection, and access control. This FMEA report aims to systematically analyze potential failure modes associated with shutter doors and their
effects on performance, safety, and reliability, while also outlining preventive actions to mitigate identified risks.

2. Scope:

This FMEA report focuses on identifying potential failure modes of a typical shutter door system, including mechanical, electrical, and
structural components. It covers failure modes that could occur during operation, maintenance, or in response to external factors.

3. Methodology:

The FMEA process involves identifying failure modes, determining their effects, assigning severity, occurrence, and detection ratings,
calculating RPNs, and proposing corrective/preventive actions.

The RPN is calculated using the formula: RPN = Severity × Occurrence × Detection. Each failure mode is assigned a severity rating (1-10),
occurrence rating (1-10), and detection rating (1-10). The higher the RPN value, the higher the priority for mitigation actions.

4. Analysis:
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STANDARD RAW MATERIAL PROCEDURE 25/03/2024 Page 2 of 8
Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

The calculated RPN values range from 245 to 336.

The failure mode with the highest RPN is "Jamming of door tracks" with an RPN of 336.

Failure modes with RPN values above 250 are considered high priority and require immediate attention.

"Broken springs or cables" and "Corrosion of hinges/rollers" also have significant RPN values, indicating considerable risk.

"Misalignment of panels" and "Motor malfunction" have relatively lower RPN values but still pose significant risks to the system.

5. Failure Modes and RPN Calculation:

 Mechanical Failure Modes:

 Jamming of door tracks
 Broken springs or cables
 Misalignment of panels
 Corrosion of hinges or rollers
 Electrical Failure Modes:
 Malfunctioning motor or control unit

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Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

 Short circuits in wiring

 Sensor failures leading to improper operation
 Power supply failure
 Structural Failure Modes:
 Excessive wind load causing deformation or detachment
 Impact damage from vehicles or objects
 Degradation of materials due to environmental factors
6. Risk Assessment:
Risk priority numbers (RPNs) are calculated based on severity, occurrence, and detection ratings assigned to each failure mode. RPN = Severity ×
Occurrence × Detection

Severity Occurrence Detection RPN (S ×

Failure Mode Description (S) (O) (D) O × D)
Jamming of door Tracks of the door become
tracks jammed 8 6 7 336
Broken springs or Springs or cables supporting
cables the door break 9 5 6 270
Misalignment of Panels of the door become
panels misaligned 7 7 5 245

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Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

Severity Occurrence Detection RPN (S ×

Failure Mode Description (S) (O) (D) O × D)
Corrosion of Hinges or rollers corrode over
hinges/rollers time 6 8 6 288
Motor failure leading to door
Motor malfunction malfunction 9 4 7 252
Short circuits in Electrical wiring suffers from
wiring short circuits 8 5 8 320
Failure of sensors controlling
Sensor failures the door 7 6 7 294
Failure of power supply for the
Power supply failure door system 9 4 8 288
Wind load Deformation of door due to
deformation excessive wind load 8 6 6 288
Damage to the door due to
Impact damage external impact 9 5 7 315
Degradation of door materials
Material degradation over time 7 7 6 294

7. Corrective and Preventive Actions:

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Document title:
FMEA FOR SHUTTER
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Failure Mode Corrective Actions Preventive Actions

Jamming of door Repair or replace damaged tracks. Lubricate tracks Implement regular maintenance schedule for tracks. Train personnel on
tracks regularly to prevent jamming. proper lubrication.

Broken springs or Replace broken springs or cables promptly. Ensure proper Conduct regular inspection of springs/cables. Replace before reaching
cables installation and tensioning. end of life.

Misalignment of Realign panels and ensure proper installation during Implement quality control measures during installation. Ensure proper
panels maintenance. alignment during maintenance.

Corrosion of Replace corroded hinges/rollers with corrosion-resistant Apply protective coatings to hinges/rollers during installation. Regularly
hinges/rollers materials. inspect and maintain.

Repair or replace malfunctioning motor. Implement Perform routine maintenance on motors. Monitor motor performance for
Motor malfunction redundancy for critical operations. signs of wear.

Short circuits in Routinely inspect wiring for wear or damage. Implement proper cable
wiring Repair wiring faults. Install circuit protection devices. management practices.
Replace faulty sensors promptly. Implement redundancy Conduct regular calibration checks on sensors. Train personnel on
Sensor failures for critical sensors. sensor maintenance.
Power supply Install backup power supply (e.g., UPS). Implement power Conduct regular testing of power supply systems. Implement preventive
failure surge protection. maintenance schedule.

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Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

Failure Mode Corrective Actions Preventive Actions

Wind load Reinforce door structure to withstand higher wind loads. Perform wind load analysis during installation. Implement wind load
deformation Ensure proper installation. rating for door design.
Install protective barriers or bollards. Use impact-resistant Conduct risk assessment for potential impact areas. Regularly inspect
Impact damage materials for door construction. for signs of damage.
Material Select durable materials resistant to environmental factors. Conduct material degradation assessment. Implement preventive
degradation Apply protective coatings. maintenance for materials.

8.After preventive action RPN NUMBER

Severity
Failure Mode Description (S) Occurrence (O) Detection (D) RPN (S × O × D)
Jamming of door
tracks Tracks of the door become jammed 6 4 5 120
Broken springs or
cables Springs or cables supporting the door break 8 4 5 160
Misalignment of
panels Panels of the door become misaligned 5 5 6 150
Corrosion of
hinges/rollers Hinges or rollers corrode over time 6 4 5 120
Motor malfunction Motor failure leading to door malfunction 5 4 6 192

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Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

Severity
Failure Mode Description (S) Occurrence (O) Detection (D) RPN (S × O × D)
Short circuits in wiring Electrical wiring suffers from short circuits 7 4 7 196

Sensor failures Failure of sensors controlling the door 7 6 7 196

Power supply failure Failure of power supply for the door system 7 4 6 168
Wind load Deformation of door due to excessive wind
deformation load 7 5 4 140

Impact damage Damage to the door due to external impact 8 5 6 240

Material degradation Degradation of door materials over time 6 6 5 180

9. Effects Analysis: Each failure mode is analyzed for its potential effects on:

 Personnel safety
 Property damage
 Operational downtime
 Security vulnerabilities
 Customer satisfaction

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 Document type: Date prepared: Number of pages:
STANDARD RAW MATERIAL PROCEDURE 25/03/2024 Page 8 of 8
Document title:
FMEA FOR SHUTTER
Prepared by: Reviewed by: Approved by: Date approved:
Md Tarique Anwar Er. sultan Er. 25/03/2024

 5. Conclusion: The RPN analysis highlights critical failure modes of the shutter door system, guiding prioritization of mitigation efforts.
Effective preventive actions should target failure modes with high RPN values to minimize risks and ensure the reliability and safety of shutter
doors in various applications. Regular monitoring, maintenance, and implementation of corrective measures are essential to mitigate potential
failures and enhance system performance

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