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Inside FMEA: New Insights on Achieving FMEA Excellence

With the Inside FMEA series of articles, my intention is to bring to life the subject of FMEA, and provide value to readers from all levels of experience.

Whether you are new to FMEA, or an FMEA expert, it is my sincere desire that each and every person who reads Inside FMEA articles will discover new insights about FMEA, and experience improved success in FMEA applications.

The first article, called “Welcome to Inside FMEA”, will introduce the series, and provide a glimpse of what is to come. Readers are encouraged to contact me with any questions about FMEA, or feedback on Inside FMEA articles. Questions, feedback, and ideas for future articles can be sent to carl.carlson@effectivefmeas.com. I will personally respond to all questions and feedback.

I’m excited to bring this new series to Accendo, and hope you enjoy reading the articles, as much as I enjoy writing them. As I say to readers of my book, “best wishes for effective FMEAs.”

Carl S. Carlson

Complete Listing of Inside FMEA Articles:

FMEA Introduction Series

Welcome to “Inside FMEA”

What is FMEA? A Brief Overview

Stand Like a Rock: The Philosophy of Effective FMEAs

Stand Like a Rock: The Philosophy of Effective FMEAs: Problems and Solutions

Six Essential Factors for FMEA Success

Six Essential Factors for FMEA Success: Problems and Solutions

FMEA Fundamentals Series

Understanding FMEA Functions: The Essence of the Item

Understanding FMEA Functions: Problems and Solutions

Understanding FMEA Failure Modes: Why Describing the Mode of Failure is Essential

Understanding FMEA Failure Modes: Problems and Solutions

Understanding FMEA Effects: If a Tree Falls in a Forest . . .

Understanding FMEA Effects: Problems and Solutions

Understanding FMEA Causes: Getting to the Root of the Matter

Understanding FMEA Causes: Problems and Solutions

Understanding FMEA Controls: Leveraging the Value of Today

Understanding FMEA Controls: Problems and Solutions

Understanding FMEA Recommended Actions: Actions Speak Louder than Words

Understanding FMEA Recommended Actions: Problems and Solutions

Understanding FMEA Severity Risk: The Seriousness of Consequences

Understanding FMEA Severity Risk: Problems and Solutions

Understanding FMEA Occurrence Risk: The Scale from Remote to Certain

Understanding FMEA Occurrence Risk: Problems and Solutions

Understanding FMEA Detection: Can You Find a Needle in a Haystack?

Understanding FMEA Detection Risk: Problems and Solutions

Prioritizing risk for corrective actions in an FMEA – Know before you go!

Understanding RPN Limitations: Problems and Solutions

Inside FMEA has Achieved its First Milestone!

FMEA Preparation Series

Determining the Scope of the FMEA: The first step in FMEA preparation

Making the FMEA Scope Visible – Adding Clarity to Your FMEA

Establishing FMEA Ground Rules and Assumptions

Gathering FMEA Information

Assembling the Correct FMEA Team

Parameter Diagram and FMEA

Identifying and Prioritizing FMEA Functions – a Key Step in FMEA Preparation

To Prepopulate or not to prepopulate, that is the question

Preliminary Risk Assessment

Application Tip – Begin with Concerns

FMEA Special Topics Series

Using the “Five Whys”

Use of Failure Mechanisms in FMEA

Action Strategies to Reduce Severity Risk

Action Strategies to Reduce Occurrence Risk

Action Strategies to Reduce Detection Risk

Using Design FMEAs to improve Design Verification Plans

Using Process FMEAs to Improve Process Control Plans

Can You Anticipate Everything

What is Unique About a System FMEA?

Using “Mode of Operation” in FMEA Applications

Common FMEA Mistakes and How to Avoid

Using FMEA Quality Objectives to Audit FMEAs

DFMEAs can Identify Special Product Characteristics

PFMEAs can Identify Special Process Characteristics

Legal Guidelines for FMEAs

Software FMEA

Hazard Analysis

FMEA and Robust Design

How to Get Better Results with FMEAs, in Less Time

Is there a better way than RPN?

Why FMEA needs to be team-based

Relationship between FMEA and risk management – part 1

Relationship between FMEA and risk management – part 2

FMEA Facilitation Series

Facilitating FMEAs

Facilitation Skill # 1: Encouraging Participation

Facilitation Skill #2: Controlling Discussion

Facilitation Skill #3: Asking Probing Questions

Facilitation Skill # 4: Asking Thought-starter Questions

Facilitation Skill # 5: Active Listening

Facilitation Skill # 6: Making Decisions

Facilitation Skill # 7: Managing Conflict

Facilitation Skill # 8: Brainstorming

Creativity and FMEA

Managing Time

To Scribe or Not to Scribe

Pugh Analysis (Decision Matrix Method)

Getting to Consensus

FMEA Q&A Series

FMEA Q and A – 3 Medical Device Questions

FMEA Q and A – Where do reliability requirements belong in an FMEA?

FMEA Q and A – System-Level Functions

FMEA Q and A – Managing System Changes

FMEA Q and A – Special Characteristics in Process FMEA

FMEA Q and A – FMEA Boundary Diagram

FMEA Q and A – Application of Generic FMEAs

FMEA Q and A – Auditing FMEAs

FMEA Q and A – Difference Between Controls and Actions

FMEA Q and A – addressing errant cleaning operation in Process FMEA

FMEA Q and A – Redundant FMEA Recommendations

Articles by Carl Carlson
in the Inside FMEA series

Information about FMEA Icon

Inside FMEA 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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