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Effective FMEAs

Resource Page

Hello. My name is Carl Carlson, and I am a consultant and instructor in the areas of FMEA, reliability program planning and other reliability engineering disciplines. My bio is here, and I can be reached at Carl.Carlson@EffectiveFMEAs.com

This page is dedicated to FMEA practitioners from all industries and applications. It contains general information about FMEA, including articles, checklists, webinars, and other resources to performing effective FMEAs.

Here is an outline of the different sections of the Resource Page for Effective FMEAs.

Purpose and Objectives of FMEA

Index of Articles for the Series Inside FMEA

The Book Effective FMEAs

FMEA Articles

FMEA Checklists

FMEA Examples and Presentations

Purpose and Objectives of FMEA

Failure Mode and Effects Analysis (FMEA) is a method designed to:

  • Identify and fully understand potential failure modes and their causes, and the effects of failure on the system or end users, for a given product or process.
  • Assess the risk associated with the identified failure modes, effects and causes, and prioritize issues for corrective action.
  • Identify and carry out corrective actions to address the most serious concerns.

An FMEA is an engineering analysis done by a cross-functional team of subject matter experts that thoroughly analyzes product designs or manufacturing processes, early in the product development process. Its objective is finding and correcting weaknesses before the product gets into the hands of the customer.

Index of Articles for the Series Inside FMEA

“Inside FMEA” is a series of articles that covers the subject of FMEA. They are organized under the following headings:

FMEA Introduction Series (7 articles)

FMEA Fundamentals Series (32 articles)

FMEA Preparation Series (10 articles)

FMEA Special Topics Series (20 articles)

FMEA Facilitation Series (currently being written)

I hope you enjoy reading the articles, as much as I enjoyed writing them.

Click on this link to gain access to the full listing of articles in the Inside FMEA series.

The Book Effective FMEAs

Failure Mode and Effects Analysis (FMEA) is a key tool that supports high reliability, ensures safety and achieves customer satisfaction, in a cost-conscious environment. In this book . . .

Readers will learn the correct application of FMEA, including case studies and lessons learned, with a balanced emphasis on FMEA fundamentals and their application in different industries.

The correct preparation, procedure and execution of FMEA projects are covered, with examples from a variety of industry applications.
Industry professionals new to FMEA will understand how to perform FMEAs effectively.

Experienced FMEA users will learn practical advice on how to improve results with their FMEAs.
FMEA facilitators will learn the most important techniques to lead FMEA teams to outstanding results in minimum time.

Managers will learn how to implement an effective FMEA process in their company.
Academic faculty will have an excellent resource to teach the principles of FMEAs as part of engineering curricula, including end-of-chapter problems and solutions.

All types of FMEAs are covered: System FMEAs, Design FMEAs, Process FMEAs, FMECA, DRBFM, Fault Tree Analysis, Reliability-Centered Maintenance, Hazard Analysis, Concept FMEA, Software FMEA, and more.

Author Bio

Excerpts from the book “Effective FMEAs”

Introduction

Back Cover

Chapter Descriptions

Table of Content

About the Book Effective FMEAs

What readers are saying

Solutions Manual

Book Review

Link to Amazon

FMEA Articles

The following are articles on the subject of FMEA that have been published in various emagazines and websites.

FMEA Quality Audit Procedure

Effective FMEA Process

Implementing an Effective FMEA Process

Key Factors for Effective FMEAs

Practice Auditing an Actual FMEA

Preventing Problems

The Quality of FMEAs

Which FMEA Mistakes are You Making?

Good FMEAs, Bad FMEAs, What’s the Difference?

FMEA Checklists

These checklists are referred to in the book Effective FMEAs, and can be downloaded at no charge.

Glossary of FMEA Terms

FMEA Facilitator Thought-Starter Questions

Gather Information – for System and Design FMEAs

Gather Information – for Process FMEAs

Ground Rules and Assumptions

Ready-for-First-Meeting Checklist

FMEA Preparation

Effective Meetings

FMEA Function Types

List of Failure Mechanisms

FMEA Examples and Presentations

This is an excerpt of a partial Design FMEA on a pencil that has been used for training purposes.

Partial Design FMEA on pencil system for training purposes

The following are presentation charts that may be useful.

FMEA Quality Objectives

The logical relationship between FMEA elements

The following are webinars presented to ASQ Reliability Division members:

Webinar Slides – The 10 Most Common FMEA Mistakes

Webinar Slides – How to Audit FMEAs

Webinar Slides – Effective FMEA Process

This presentation was given to an engineering class at the University of Arizona.

Failure Mode and Effects Analysis

A few other presentations

FMEA – How to do it Right and the Litigation Consequences of Doing it Wrong

Reviewing SAE’s New FMEA J1739 Standard

Using FMEA to advance evolutionary biology research and application

Resource Listed by Carl Carlson
supporting the Effective FMEAs book

Information about FMEA Icon

Effective FMEAs can be visually represented by a large tree, with roots, a solid trunk, branches, and leaves.

– The roots of the tree represent the philosophy and guiding principles for effective FMEAs.
– The solid trunk of the tree represents the fundamentals for all FMEAs.
– The branches represent the various FMEA applications.
– The leaves represent the valuable outcomes of FMEAs.
– This is intended to convey that each of the various FMEA applications have the same fundamentals and philosophical roots.

 

For example, the roots of the tree can represent following philosophy and guiding principles for effective FMEAs, such as:

1. Correct procedure         2. Lessons learned
3. Trained team                 4. Focus on prevention
5. Integrated with DFR    6. Skilled facilitation
7. Management support

The tree trunk represents the fundamentals of FMEA. All types of FMEA share common fundamentals, and these are essential to successful FMEA applications.

The tree branches can include the different types of FMEAs, including:

1. System FMEA         2. Design FMEA
3. Process FMEA        4. DRBFM
5. Hazard Analysis     6. RCM or Maintenance FMEA
7. Software FMEA      8. Other types of FMEA

The leaves of the tree branches represent individual FMEA projects, with a wide variety of FMEA scopes and results.

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