Failure Modes and Effects Analysis (FMEA) is a method to analyze potential reliability problems in the development cycle of the project, making it easier to take actions to overcome such issues, enhancing the reliability through design. However, FMEA is one of the most poorly used tools for risk assessment, prevention and continual improvement, making it imperative for its users to gain a valuable insight in the FMEA training.
For FMEA training, the process of the analysis can be summarized as follows:
- Describe the product or process and its function.
- Create a Block Diagram of the product or process, showing the major components or processes as blocks connected together by lines that indicate their interrelationships.
- Make an FMEA Form worksheet.
- Use the diagram prepared to begin listing items or functions on the sheet.
- Identify Failure Modes.
- Each failure should now be listed in technical terms.
- Describe the effects of those failure modes on the function of the product/process as perceived by the customer. A numerical ranking can be established to help gauge the severity.
- Identify and enter the causes for the failure.
- Enter the probability factor for the cause.
- List current Control (for design and process), analyzing the prevention mechanism of the failure mode.
- Determine the likelihood that the current control will detect the failure.
- Assign Risk Priority Numbers (RPN) to prioritize the items requiring intense care. RPN = severity * probability * detection
- Determine the Recommended Actions.
- Assign Responsibility and a Target Completion Date for these actions.
- Specify and evaluate the actions taken and repeat the above steps if needed.
- Update the FMEA regularly.