Failure Mode and Effect Analysis
Failure Mode and Effect Analysis (FMEA) is a widely-used technique used to identify potential risks, analyze their causes and effects, and devise appropriate corrective actions and preventive measures. FMEA is a tool used in the design and development phases of product or process development, or when implementing a process improvement program. It is one of the most important risk management techniques for a company.
The purpose of Failure Mode and Effect Analysis is to identify potential risks and their causes, analyze the severity of their effects and devise corrective actions for improving product/process performance and reliability. The FMEA process can help organizations improve process quality, reduce product defects and minimize costs. FMEA is one of the most important tools in the proactive prevention and control of product or process errors and malfunctions.
The FMEA process begins with a thorough analysis of the system, product or process and identification of potential failure modes. The failure mode is defined as a malfunction, an unexpected result, or an undesirable output. It is important to identify all potential failure modes, as well as the possible consequences. This can be done by brainstorming and asking the people involved in the process.
The next step is to determine the severity of the effect of the potential failure. Often, this is done by using a scoring system such as a five-point scale. 1 is the lowest effect and 5 is the highest. The severity of the effect is judged based on how important the result is to the customer, as well as the costs associated with the failure, such as the costs of repair, replacement, or other corrective actions.
Once the list of potential failure modes and their effects have been identified, it is then time to analyze the possible cause(s) of the failure. This can be done through brainstorming, research and evaluation of the existing process and/or product design. It is important to identify not only the cause of the failure, but also the responsible stakeholder and the parties affected by the failure.
The next step is to identify corrective actions that can prevent the failure from occurring. In some cases, the corrective action is simple, such as changing a process or making a design change. In other cases, the corrective action might be more complex, such as implementing a quality control system or restructuring the organization’s management hierarchy. Again, it is important to identify the responsible stakeholder and the parties affected by the corrective action.
Finally, a review of the FMEA process should be conducted periodically, such as once or twice a year, to ensure that the process is functioning as intended and that the corrective actions are effective. Reviewing the FMEA process also helps to ensure that new risks are identified and that corrective actions are put in place.
Failure Mode and Effect Analysis is an important tool for managing risk and improving process quality, reliability and safety. By identifying potential risks and their causes, analyzing their effects and implementing appropriate corrective actions, organizations can reduce product defects and minimize costs. FMEA is one of the most important tools in the proactive prevention and control of product or process errors and malfunctions.
