Failure Mode and Effects Analysis
Failure Mode and Effects Analysis (FMEA) is a highly structured and systematic preventative process utilized to identify potential problems or failures before they occur. The process is used to analyze, anticipate and address potential problems with parts, assemblies, subassemblies, sub- processes, processes, and the overall system. FMEA was first developed by the military in the 1940s, and helps to identify potential risk before product failure, allowing for proactive countermeasures for reliable operations that reduce the risk at the design phase.
In essence, FMEA helps to prevent problems before they happen through analyses of individual parts, assemblies, subassemblies, processes and systems, as well as possible hazardous consequences resulting from these parts, assemblies, sub- processes, processes and systems. FMEA is an effective tool for identifying and addressing potential risk before it becomes an issue, ultimately leading to increased product quality, reliability and safety.
The FMEA process generally consists of six steps:
1) Identify the Process or System – the first step of FMEA is to define the process or system that is to be analyzed.
2) Outline Potential Failure Modes – the second step is to identify potential failure modes for each process or system. This step is critical for helping to identify and define each potential failure mode that may occur.
3) Assign Severity Values – the third step is to assign Severity values to each potential failure mode. This helps to create an evaluation of the potential consequences that could result from a potential failure mode.
4) Identify the Causes of the Potential Failure Modes – the fourth step is to identify the root causes for each potential failure mode. This helps to further assess the importance of each potential failure mode and identify any appropriate preventative or corrective measures that need to be taken.
5) Assign Prevention/Correctional Measures – the fifth step is to assign prevention/correctional measures for each potential failure mode. This step helps ensure that all potential failure modes are addressed through appropriate preventative or corrective actions.
6) Assign Corrective Action Verification – the sixth and final step of the FMEA process is to verify that the corrective action(s) has been taken. This helps to ensure that all appropriate preventative and corrective actions have been implemented and any potential risk has been reduced.
FMEA can thus be used to improve overall product quality and safety, while minimizing potential risks that can lead to failures. All organizations involved in the design, production and sale of products should consider using FMEA to help prevent failures and optimize performance.
The use of FMEA can have multiple benefits within an organization. First, it can be used to identify potential risk and causes of failure before it happens, thereby helping to prevent potential damage and loss. Additionally, since FMEA is a highly structured and systematic process, it can be easily used to identify and address potential risk through preventative or corrective countermeasures, thereby helping to improve overall product quality and safety. Furthermore, using FMEA can also foster collaboration within an organization and enable more efficient problem solving by breaking down complex processes into simpler and more manageable parts.
Overall, FMEA is a powerful preventative and corrective process that helps identify potential hazards and mechanism of failure at design, production, and/or operating phases of a product or system. Using FMEA can be immensely beneficial for organizations, ultimately leading to improved quality and safety, as well as financial gains associated with avoided losses resulting from failure at the design, production, and/or operating phases of a product or system.
