What is a Failure Mode and Effects Analysis?
A Failure Mode and Effects Analysis, or FMEA, is a tool to determine what failure modes are and how they happen. Additionally, it can be used for root cause analysis. Unlike merely listing failure modes, FMEA evaluates the effect and impact of each failure. Further, it can (and likely should) be included in a preventive maintenance plan.
Pros and Cons of FMEA
Advantages of an FMEA
Some of the benefits of an FMEA are:
- Changing and adjusting product design (for instance, testing if the probability of failure has decreased)
- Defining criteria for try-outs and inspections
- Identifying failure points and verifying system integrity
- Assessing failure modes and their impact
- Developing a safe, reliable work method
Disadvantages of an FMEA
Honestly, FMEA isn’t flawless. To say nothing of where it falls short would be a disservice:
- Different from vulnerability audits, FMEAs need constant updating, because as your knowledge increases, you’ll likely discover new failure modes you hadn’t noticed at the project start
- If you fail to consider a failure mode, you’ll likely underestimate the risk
- FMEAs rely on your team’s expertise to identify and list failure modes and they’re quite time consuming. In spite of best efforts, a failure mode is bound to be missed
- Another key point to realize is that if your system can have several failures at once, an FMEA is not suitable, since it doesn’t consider the correlation between them
Step-by-Step: Your First FMEA
Below, you’ll find 10 steps to do a process FMEA. Steps adapted from FMEA Training.
During this review, identify each process component. If you find yourself thinking your scope is becoming too large, it likely is. However, this is a great time to break it into more manageable chunks.
First, review existing documentation for potential clues about ways each component can fail. Contrary to our pros and cons above, this list should be exhaustive. Furthermore, there will likely be several potential failures for each component.
The effect is the impact the failure has on the end product or on steps in the process. There will likely be more than one effect for each failure.Â
Based on the severity of the consequences of failure, assign Severity rankings for each component.
Rate the severity of each effect using customized ranking scales as a guide.
Assign Detection rankings based on the chances the failure will be detected prior to it occuring.Â
RPN = Severity x Occurrence x Detection
Determine which failures will be worked on based on the highest RPNs. Define who will do what, by when.
Implement the improvements identified by your team.
Conduct a re-evaluation of each potential failure once improvements have been implemented, then determine the impact of the improvements.
Downloadable Resources
Downloadable FMEA Template
Click on the icon or title above to download a free FMEA template that includes an example of filling up a carafe with water in a restaurant. Use this to start your own FMEA!
Downloadable FMEA Example - Managing Operational Risk in Financial Services
Click on the icon or title above to download a graphic that outlines a first-round FMEA.
In Conclusion
Lastly, performing an FMEA might not be for everyone’s website, but for those it may benefit, it does so greatly. With an effective FMEA, you’ll notice improved reliability, prevention of late design changes, increased customer satisfaction…and that’s only the beginning.
Have you performed an FMEA? How did it go? Let us know in the comments below!Â
Resources & Further Reading
Failure Modes & Effects Analysis (FMEA): Template & Example. (2021, January 22). Retrieved January 23, 2021, from https://goleansixsigma.com/failure-modes-effects-analysis-fmea/
Forrest, G. (2020, March 26). FMEA (Failure Mode and Effects Analysis) Quick Guide. Retrieved January 23, 2021, from https://www.isixsigma.com/tools-templates/fmea/fmea-quick-guide/
Mikulak, R. (2017, January 20). 10 Steps to Doing a Process FMEA. Retrieved January 23, 2021, from https://fmea-training.com/10-steps-process-failure-mode-and-effects-analysis/
What is FMEA and what is it used for? • Infraspeak Blog. (2020, November 16). Retrieved January 23, 2021, from https://blog.infraspeak.com/what-is-fmea/
Please update more often because I love your blog. Thank you!
Thank you for the comment. I’m currently posting three times a week, but I’m hoping to increase that to 4-5 a week in the coming months. Thank you for your support!
Keep this going please, great job!