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FMEA is a widely used approach to understanding and managing risk; it can be applied to just about anything / situation, be it a process, product, design, supply chain, service operations, running an organization, and more.
***Interested in a quiz to evaluate your FMEA knowledge? Click here to start: FMEA Quiz ***
Here are just four examples from the many kinds of FMEAs I have been personally involved with over several decades:
DFMEA – Design FMEA. It is applied to a product or its design. The benefit is you can “prevent” potential product failures from happening.
PFMEA – Process FMEA. It is applied to a process. This is focused on the process steps, and helps by “preventing” process related failures.
UFMEA – Usability or User FMEA. Is applied to how a product may be handled or used. Although it is not frequently applied in practice I highly recommend it. There are multiple benefits such as: (a) increasing safe use of a product, and (b) insuring the product performs with a high level of reliability and is robust (which has a direct impact on customer confidence in the company and its products).
SFMEA – focuses on the entire supply chain, or it might be centered around the work being done at a supplier. In either case, the benefit is “reduction or prevention” of escapes of defective products or services which ultimately impact the customer.
FMEAs can be confusing and messy. Let’s fix that…start with understanding the the top 3 mistakes in conducting FMEA (Design, Process, Service, Usability, or other…). Here they are:
1: Jumping to a spreadsheet before mapping out relationships between Causes, Failure Mode(s) (FM), and Effects
2: Confusing between what is a FM, what is a Cause, and what is an Effect
3: Unclear / inappropriate rating scales for Severity, Occurrence, and Detection
Sound familiar? You don’t have to suffer through this…
Put our knowledge, to work – it will “eliminate” these and other headaches in conducting FMEAs – and turn them into Fun Methods for Error Analysis!
FMEA when conducted and used properly – is a great tool to help scout risks that can impact your product or service. In reality, you can apply it to just about anything.
Much of the work involved in doing an FMEA needs critical thinking and input, else – a significant amount of variability can creep in. When compounded with lack of proper training, it results in confusion and grossly sub-optimal outcomes.
For example: the Risk Priority Number (RPN) is an indicator of the “urgency” of the risk posed by a given FM. It is key to prioritizing Failure Modes and Causes to address. However, if the rating scales are lacking or inadequate, RPN becomes meaningless.
Then there is the possibility of un-controlled scope creep, and expansion of boundaries that leads to overwhelming the FMEA team / leader. This creates the potential of abandoning the FMEA, or turning it into a “just finish it – right or wrong.” Who benefits?
So take the right step to move forward – and put our services to work for you. Here is how we can assist:
- Coach / train – in-person, or by webinars
- Take on assignments to conduct FMEAs
- Train the trainer (we can provide materials and exercises that you can use)
- Guide in conducting FMEAs and also documentation to go with it (SOPs, work instructions, etc.)
- Ensure compliance with applicable standards such as ISO 9001, 13485, AS 9100, IATF 16949, and more…
- Coach managers and leaders on the best ways to engage with, and keep FMEA teams on track – and moving forward
We are easy to reach, call us at (512) 560 8326, or, just send us your info, and we will be happy to contact you:
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Last update: March 1st. 2025
