FMEA (Failure Mode and Effects Analysis)

Welcome to the FMEA section of the Elite Consulting website. We understand that many of you may be worried about performing a Failure Mode & Effects Analysis (FMEA for short). It seems a daunting task when you do it for the first time. However we are here to put your minds at rest and to take the mystery out of the process.

Originally used in the aerospace industry and then adopted and used extensively in the automotive industry, FMEA’s can be a powerful tool for predicting and avoiding product and process problems in any industry, and more and more companies are incorporating FMEA’s into their development process.

What Is An FMEA?

A Failure Mode and Effects Analysis is type of risk analysis to determine how something might fail (its Failure Mode) and to analyse the Effects that failure would have, hence Failure Mode and Effects Analysis. It is usually done as formalised type of brainstorm, using a particular format. It can be applied to almost any type of design or any type of of process, and we are continually developing new applications for it.

It seeks to quantify Severity (how bad the failure might be), Occurrence (how likely it is to occur) and Detection (whether it will be picked before being released), so as to be able to rank potential failure modes according to a Risk Priority Number (RPN). Then an action plan should be out in place to reduce the risk of the most important items.

For best results it should start in the design phase to ensure that potential failure modes and their associated causes have been considered and there is time to redesign the product or process if necessary to eliminate the potential faults or at least reduce their risk. However it is better to do it later, rather than not at all.

Types of FMEA

The two main types of FMEA are Design FMEA and Process FMEA.

Design FMEA

A Design FMEA is done at the design phase to try to find potential design faults before it is released for manufacture. A System FMEA is a high level Design FMEA looking at the system as a whiole and the major sub-systems and their interfaces.

Process FMEA

A Process FMEA is done on the manufacturing process to assess how this might go wrong and potentially release non-conforming product to the customer. In fact this type of FMEA can be done on any kind of process, not just a manufacturing process.

Other Types of FMEA

The FMEA procedure can be applied to other aspects, e.g. an Operations FMEA to assess potential problems in using or operating the product, a Maintenance FMEA to assess potential problemes in the maintenance of a product, a Service FMEA to find potential failures in a service environment.

FMEA Services from Elite Consulting

Whether you want FMEA training, so that you can then do it all yourselves, or FMEA consultancy to guide you along the way, or a mixture of the two, we are here to help. We understand the various forms of FMEA (System FMEADesign FMEA and Process FMEA); the different standards that can be applied and how it fits into the grand scheme of things.

We come from an engineering and project management background and have worked in a wide range of industries, but the principles apply to almost all designs and processes, including general business processes.

In an industrial setting we can show you how to link the various FMEAs together and into your other quality procedures such as Control Plans. Plus we can help choose which standard is most appropriate or tailor the process to your own requirements.

In a non-industrial setting, such as financial or healthcare, or any industry that uses any kind of process, we can help you to apply the principles of FMEA in a meaningful way, and develop a version that works for you. We have already developed a number of special versions, and we can do the same for you.

Please contact us for more information, or go to our download page to download brochures and white papers.

Elite Consulting will come to you to undertake FMEA trainingFMEA consultancy, or to be an FMEA facilitator.

Please contact us for more details, or to discuss your requirements.