FAILURE MODE AND EFFECT

ANALYSIS OF SPARK-PLUG
By:
KDM
 What Is FMEA?
A structured approach to:
1. Identifying the ways in which a product or
process can fail
2. Estimating risk associated with specific
causes
3. Prioritizing the actions that should be taken
to reduce risk
4. Evaluating design validation plan (design
FMEA) or current control plan (process
FMEA)
 FMEA Procedure
1. For each process input (start with high value inputs),
determine the ways in which the input can go wrong
(failure mode)
2. For each failure mode, determine effects
Select a severity level for each effect

3. Identify potential causes of each failure mode

Select an occurrence level for each cause

4. List current controls for each cause

Select a detection level for each cause

3
 FMEA Procedure (Cont.)
5. Calculate the Risk Priority Number (RPN)
Risk Priority Number = Severity Occurrence Detection

6. Develop recommended actions, assign responsible persons,

and take actions
Give priority to high RPNs
Must look at severities rated a 10

7. Assign the predicted severity, occurrence, and detection

levels and compare RPNs
8. Take suitable corrective measures for failure having high
RPN and try to eliminate them.

4
S Proble Effects S O D Causes Solutions RPN
r m =SxO
. (Failure xD
N mode)
o.
1 Fouling Misfiring 7 4 5 Faulty Check the condition 140
Carbon injector of
Fouling Injector
and
Oil
Fouling
Weak 7 4 6 Clogging Clean the air 168
ignition of Filter
system air Check the battery
Voltage cleaner for its voltage
Element
Low 7 7 5 Rich Maintain correct 245
mileage air/fuel air/fuel Ratio
mixture Ensure injectors
arent Leaking
Service the
carburetor, the
autochoke system
or the fuel
S Problem Effects S O D Causes Solutions RPN
r (Failure =SxO
. mode) xD
N
o.
2 Flash Wear of 8 2 3 High Maintain optimal 48
over terminal compressi compression
electrode on Pressure
s pressure
Deterior 8 7 3 Widened Adjust the gap 168
ation of spark gap Precisely
plug cap
3 Spark Abnorma 9 3 4 Ignition Adjustment of 108
Plug l timing too ignition timing is
overheati Combust far required
ng ion advanced
Melting 9 3 2 Air/fuel Adjustment of air 54
of mixture(A/ fuel ratio
spark F) (A/f) is required.
plug too lean
electrode
s
Possible 9 4 4 Insufficien Top up cooling water 144
Sr Problem Effects S O D Causes Solutions RPN
.N (Failure =SxOx
o. mode) D
4 Spark Thread 9 2 2 Spark Tightening the plug 36
plug Damage plug by hand
deformati inserted first instead of
o at an using a wrench
n/ improper from the start
damage angle
Metal 9 3 5 Excessive Tighten to the 135
shell Tightenin specified
Damage g Tightening Torque
Insulator 9 2 6 Gasket Make sure 108
Breakag too gasket is
e loose or tightened to the
too recommended
tight Tension
Sr Problem Effects S O D Causes Solutions RPN
.N (Failure =SxOx
o. mode) D
5 Electrode Engin 8 4 4 Plugs Replace the 128
wear e have spark plugs
starting been left
Problems in
Misfiri the
ng engine
during too
running Long
Maximu 8 1 6 Incorrect Replace with 48
m spark spark plugs of
power plug the required
cannot selection heat range
be
obtained
from the
Engine
8 4 5 Inadequat Follow the 120
e service chart
engine Periodically
servicing
(fuel and
 Results from FMEA
Damage in spark plug mainly occurs due to
fouling and the overheating of spark plugs which
needs to be tackled first.
The carbon deposition can be controlled by means
of checking spark plug and fuel filter periodically
and maintaining a constant A/F mixture.
The defects such as spark plug deformation and
the electrode wear have the least the least
probability of occurrence
The spark plug would have an increased running
time if the described precautionary measures are
to be adopted.
Conclusion
The potential effects of failures are evaluated
with their severity value and then the causes and
their prevention are calculated along with their
occurrence rating
Risk priority numbers are specified which
indicates the priority for particular failure mode.
Possible alternative solutions are given for
failures.
This process analysis will serve as a helpful tool
to detect the occurring of failure modes and also
assures in the effective functioning of the spark
plugs.
THANK YOU!