FMEA

Articles, guides, and products tagged "FMEA" — a combined view of every catalogue resource on this topic.

User guide

E-scooter functional safety engineering: safety integrity as the sixth cross-cutting infrastructure axis — IEC 61508:2010 (E/E/PE safety-related systems, SIL 1-4) + ISO 26262:2018 (automotive FuSa, ASIL A-D) + ISO 13849-1:2023 (safety-related parts of machinery, PLr a-e, Cat B/1/2/3/4) + IEC 62061:2021 (SIL CL for machinery E/E/PES) + EN 17128:2020 Annex G (PLEV functional safety requirements) + IEC 60812:2018 FMEA + IEC 61025:2006 FTA + IEC 61709:2017 reliability data + MISRA C:2023 software safety subset + ISO/PAS 21448:2022 SOTIF + IEC 61511 process industry + IEC 60730-1:2024 controls + UL 991 + UL 1998 + DO-178C analogy

Engineering deep-dive into e-scooter functional safety as the sixth cross-cutting infrastructure axis — parallel to [fastener/joining](@/guide/fastener-and-bolted-joint-engineering.md), [thermal management/heat-dissipation](@/guide/thermal-management-engineering.md), [EMC/EMI/interference-mitigation](@/guide/emc-emi-engineering.md), [cybersecurity/interconnect-trust](@/guide/cybersecurity-engineering.md), and [NVH/acoustic-vibration-emission](@/guide/nvh-engineering.md). Covers: 10-row standards matrix (IEC 61508, ISO 26262, ISO 13849-1, IEC 62061, EN 17128 Annex G, IEC 60812 FMEA, IEC 61025 FTA, IEC 61709, MISRA C, ISO/PAS 21448 SOTIF); SIL/ASIL/PL/SIL CL cross-mapping; 6-row hazard-by-subsystem matrix (motor controller throttle-stuck, brake actuator loss, throttle position drift, BMS thermal runaway, display HMI critical info, lighting fail-dark); FMEA worked example for BLE throttle injection scenario; FTA worked example for wheel lock at speed; FMEDA with PFD/PFH calculation, Safe Failure Fraction, Hardware Fault Tolerance; risk reduction equation R_residual = R_unmitigated × (1 - RRF); 6-row mitigation matrix; ALARP principle; software safety V-model + MISRA C:2023 + formal methods; SOTIF (ISO/PAS 21448) as extension to IEC 61508; HIL testing + fault injection; 8-row real-incidents timeline (Lime brake recall 2019, Ninebot ES2 throttle creep 2020, Apollo Pro firmware bug, Boosted board fire, Bird scooter rear-wheel hub crack, Tier scooter motor-stuck); 8-step DIY safety check; 6-step DIY remediation; industry shift 2020→2026; 16 numbered sections.

17 min read

User guide

Manufacturing Quality Engineering of an E-Scooter as the 31st Engineering Axis: Manufacturing-Process Axis — ISO 9001:2015 + IATF 16949:2016 + AIAG APQP + PPAP + SPC + MSA + AIAG-VDA FMEA + 8D + Lean Manufacturing TPS + Six Sigma DMAIC + Poka-yoke

Engineering deep-dive into manufacturing quality engineering as the 31st engineering axis and the fourteenth cross-cutting infrastructure axis — describes how engineering specifications are systematically translated into production-floor reality: ISO 9001:2015 QMS foundation (10-clause Annex SL + 7 quality principles + risk-based thinking), IATF 16949:2016 automotive QMS layered on ISO 9001 with ~140 additional automotive requirements + customer-specific requirements (CSRs), AIAG Advanced Product Quality Planning (APQP, 2nd ed. 2008) with 5-phase development methodology, Production Part Approval Process (PPAP, 4th ed. 2006) with 18-element submission package + 5 submission levels, Statistical Process Control (SPC, 2nd ed. 2005) with 7 control charts + Western Electric / Nelson rules + 3-sigma control limits, Measurement System Analysis (MSA, 4th ed. 2010) with Gage R&R + NDC + Type-1 Cg/Cgk, AIAG-VDA FMEA Handbook (1st ed. June 2019) with 7-step approach + Action Priority (AP) replacing RPN, 8D (Eight Disciplines) problem-solving (Ford TOPS 1987) with root-cause vs escape-point distinction, Lean Manufacturing + Toyota Production System (Ohno + Toyoda 1948-1975) with Jidoka + JIT + Andon + Kanban + Heijunka + 7+1 wastes (muda), Six Sigma DMAIC + DMADV (Motorola Bill Smith 1986; GE Jack Welch 1995) with 3.4 DPMO at 6σ + 1.5σ shift, Poka-yoke mistake-proofing (Shigeo Shingo 1960s). Process capability indices Cp/Cpk/Pp/Ppk formulas + threshold values (1.33 capable / 1.67 preferred / 2.0 Six Sigma). 30-row cross-axis matrix maps the manufacturing-quality concept onto each of the 30 prior engineering axes (battery cell capacity Cpk + brake-pad μ batch variation SPC + motor stator winding torque control plan + tire compound durometer Gage R&R + ...); 8-step DIY owner manufacturing-quality 'tells' checklist (batch serial cross-check, weld bead consistency, fastener torque marks, label-to-spec match, paint defect AOI proxy).

15 min read

User guide

Reliability engineering of an electric scooter as the 28th engineering axis: meta-axis of all engineering axes — MIL-HDBK-217F Notice 2 + IEC 61709:2017 + FIDES Guide 2009 Edition A + Telcordia SR-332 Issue 4 + IEEE 1413-2010 + JEDEC JEP122H + IEC 62308:2006 + ISO/IEC 25023:2016 + IEC 60300 + IEC 60812:2018 FMEA + IEC 61025 FTA + MIL-STD-1629A FMECA + Hobbs HALT/HASS + Weibull/Arrhenius/Eyring/Coffin-Manson/Norris-Landzberg

Engineering deep-dive into the reliability of an electric scooter as the 28th engineering axis and meta-axis of all other engineering axes — defines how system-level MTBF is computed from component-level FIT rates, how it is validated through ALT/HALT, how Weibull analysis of field returns is interpreted. Covers: 9-row standards matrix (MIL-HDBK-217F Notice 2 + IEC 61709:2017 + FIDES Guide 2009A + Telcordia SR-332 Issue 4 + IEEE 1413-2010 + JEDEC JEP122H + IEC 62308:2006 + ISO/IEC 25023:2016 + IEC 60300 dependability); three-phase bathtub curve (infant mortality + constant failure rate + wear-out); probability distributions (Exponential / Weibull β/η/γ / Lognormal); MTBF/MTTF/MTTR/FIT definitions; 5-row acceleration model matrix (Arrhenius temperature + Eyring temperature-voltage + Inverse Power Law + Norris-Landzberg solder TC + Coffin-Manson low-cycle fatigue); parts-count vs parts-stress prediction workflow; reliability block diagrams (series + parallel + k-out-of-n + bridge); FMEA (MIL-STD-1629A → IEC 60812:2018) RPN; FTA (IEC 61025) cut sets; FRACAS closed-loop + DRBFM; ALT/HALT/HASS (Hobbs method) + step-stress; 27-row cross-axis matrix with the existing engineering articles; 8-step DIY owner reliability practices; 16 numbered sections.

15 min read

User guide

E-scooter risk management engineering as the 32nd engineering axis: risk-anticipation meta-axis — ISO 31000:2018 + ISO/IEC 31010:2019 + ISO Guide 73:2009 + Bowtie + ALARP + SFAIRP + LOPA + HAZOP IEC 61882 + FTA IEC 61025 + ETA IEC 62502 + FMEA IEC 60812 + ISO 14971:2019 + ERM COSO 2017 + Kaplan & Garrick 1981 triplet

Engineering deep-dive into risk-management engineering as the 32nd engineering axis and the 15th cross-cutting infrastructure axis — describes the systematic methodology for identification + analysis + evaluation + treatment + monitoring of risks layered over all the other axes: ISO 31000:2018 *Risk management — Guidelines* (8 principles + framework with 6 components + risk-management process with 7 stages), ISO Guide 73:2009 *Risk management — Vocabulary* (61 terms with risk / hazard / consequence / likelihood definitions), ISO/IEC 31010:2019 *Risk assessment techniques* with 41 assessment techniques, Kaplan & Garrick 1981 triplet definition «What scenario? How likely? What consequences?», ALARP (As Low As Reasonably Practicable) + SFAIRP (So Far As Is Reasonably Practicable) UK HSE principles + reverse burden of proof, risk appetite vs risk tolerance ISO 31000 vocabulary distinction, IEC 31010 risk matrix + heat map + risk register tools, HAZOP IEC 61882:2016 deviation/guide-word inductive process-hazard methodology, FMEA IEC 60812:2018 inductive component-level failure-mode analysis, FTA IEC 61025:2006 deductive top-down boolean-logic event-tree, ETA IEC 62502:2010 inductive consequence-tree with branching on mitigation success/failure, Bowtie methodology (CGE Risk Management Solutions formalized 1990s) — combines threats + barriers (preventive + recovery) + consequences around a central top event, LOPA (Layer of Protection Analysis) CCPS 2001 semi-quantitative methodology with IPL (Independent Protection Layer) credit, ISO 14971:2019 *Application of risk management to medical devices* (cross-industry inspiration), ERM (Enterprise Risk Management) COSO 2017 framework with 5 components + 20 principles, 3 Lines of Defense model IIA Position Paper 2013 (updated 2020), risk-based thinking ISO 9001:2015 clause 6.1 + IATF 16949 cross-link, ISO 26262 HARA + ISO 21434 TARA cybersecurity cross-link, ISO 31000:2009 → 2018 simplification (from 11 principles to 8). 31-row cross-axis matrix maps the risk-management concept to each of the 31 prior engineering axes (battery thermal runaway = LOPA with multiple IPLs; brake failure = FTA top event; tire blowout = Bowtie threats+barriers+consequences; ...); 8-step DIY owner risk-management 'tells' checklist (recall registry tracking + safety-related characteristic markings + manufacturer field-issue subscription + warranty RCA depth + accident statistics transparency).

15 min read

User guide

Display and HMI engineering for electric scooters: sunlight-readability photometry (CR, cd/m², transflective LCD), glanceability ergonomics (ISO 15008, NHTSA 2-glance ≤ 2 s / 12 s, Fitts' law, Frutiger/DIN 1450), adaptive brightness (Weber-Fechner, PWM flicker per IEEE 1789-2015), environmental robustness (IP66, ISO 16750-3 vibration, IEC 60068 thermal −20…+70 °C), EMC (CISPR 14-1, ECE R10) and functional safety (IEC 62368-1, ISO 13849-1)

An engineering deep-dive into the one bidirectional channel between e-scooter and rider — paired with the introductory survey «Display, throttle, and error codes» (parts/display-throttle-error-codes): matrix physics (TN LCD with 90° twisted nematic vs IPS LCD with in-plane molecular switching vs OLED with organic electroluminescence via electron-hole recombination vs E-paper with electrophoretic ink); sunlight readability as a photometric problem (contrast ratio CR=(L_max+L_amb·R)/(L_min+L_amb·R) with ambient reflection, why a 250 cd/m² LCD against 100 000 lx direct sun drops to CR=1.05:1 without an anti-reflective coating, and transflective LCD as a hybrid with ambient backlight); glanceability as safety-critical ergonomics (ISO 15008:2017 in-vehicle visual presentation with minimum character-height-to-distance ratio 1:200, ISO 9241-303:2011 visual ergonomics, NHTSA Driver Distraction Guidelines 2013 + SAE J2364 2-glance principle ≤2 s single + ≤12 s total, Fitts' law T=a+b·log₂(D/W+1) for button-reach time, sans-serif Frutiger 1976 + DIN 1450:2013 Schriften — Leserlichkeit, kerning, x-height ≥60 % cap-height); adaptive brightness (Weber-Fechner logarithmic perception ΔI/I=const, ambient light sensor 0.01-100 000 lx, PWM dimming for LCD backlight with flicker frequency ≥1 kHz per IEEE 1789-2015 No-Observable-Effect threshold); environmental robustness (IEC 60529:2013 IP66 ingress dust-tight+powerful jets, ISO 16750-3:2012 road vehicle mechanical loads 10-2000 Hz random vibration, IEC 60068-2-1/-2 temperature −20…+70 °C cycling, IEC 60068-2-27 mechanical shock 1500g 0.5 ms half-sine, IEC 60068-2-30 damp heat 25/40 °C 95 % RH, ASTM B117-19 salt spray 5 % NaCl 35 °C 96 h); EMC (CISPR 14-1:2020 household-appliance emission, UNECE Regulation 10 Rev 6:2017 vehicle EMC 30 MHz-1 GHz radiated, ferrite chokes for PWM-backlight harmonic suppression); functional safety (IEC 62368-1:2018 hazard-based safety engineering with ES1/ES2 energy-source classes + PS1/PS2 power source + MS1/MS2 mechanical source, ISO 13849-1:2015 PL_d performance level so that display failure does NOT cause throttle/brake loss); and the full comparison matrix of 12 standards (ISO 15008 + ISO 9241-303 + ISO 9241-11 + NHTSA/SAE J2364 + IEEE 1789-2015 + IEC 62368-1 + IEC 60529 + IEC 60068-2 + ISO 16750-3 + CISPR 14-1 + UNECE R10 + ISO 13849-1).

18 min read