LANGUAGE OF LEAN
FMEA
The method of the FMEA - Failure Mode and Effect Analysis has been used for years in the automotive and manufacturing industry.
Failure Mode Effects Analysis - FMEA
The method of the FMEA - Failure Mode and Effect Analysis has been used for years in the automotive and manufacturing industry.
The risk analysis framework has been applied in a wide range of industrial sectors. The first areas of application were traditionally in product development. Based on this the integration of the production process planning and the production. In the automotive industry, the joint creation of FMEA for products and processes by Today customer, supplier and subcontractor are a natural part of a cooperation.
The user is guided through the "10 Steps to Creation of the FMEA".
Step 1 - Review the process
Use a process flow chart or an already existing value stream map to identify each part of a process
List all process steps in a FMEA table
If you think the list gets too long it might is. Use this chance to split up the process and cut the elephant. It makes more sense to work on smaller parts of the process instead of getting lost in the woods.
Step 2 - List potential failures
Review all existing data and documents that can give you a hint about each component that can lead to a failure
After having a complete list try to cut it down and to combine the parts of the initial list
The chances are high that you will identify several potential risks of failures for each component
Step 3 - List potential effects of failures
The effect is the outcome of a failure on the finished good or a process step
It is common that not only one effect will occur for a single failure, don’t be suprised
Step 4 - Assign the level of failure to risks
This is based on the consequences for each failure
Think about the ranking as the worst impact that it can have
Step 5 - Assign the possibility of occurrence
How high is the possibility of occurrence
What impact will it have if occur
Step 6 - How can it be detected
What are the chances that you will detect the failure before occurring
Step 7 - Calculate the RPN (Risk Priority Number)
Severity (S)
Severity x Occurence (S x O) = criticality
Severity x Occurence x Detection (S x O x D) = RPN
Step 8 - Define the action plan
With the decision making process followed by the prioritization from the RPN (Step 7) focus on the topics with the highest RPNs
Follow a classic action plan by defining who will be doing what till when
Step 9 - Take action
Get things done!
Implement the defined improvement actions
Follow the PDCA principle
Plan - done
Do - right now
Check - Step 10
Act - loop starts over
Step 10 - Re-evaluate the RPN
Time to check on the impact of your actions
Re-evaluate each potential failure identified and determine if the improvement measures have an effect or not
If not follow the PDCA and start over with step 8
The FMEA is linked to all CIP and Kaizen activities - there is always something to improve.
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