Common FMEA Confusions
Abstract
Carl and Fred discuss common FMEA confusions that come up from time to time. These are condensed from questions that Carl gets from “Inside FMEA” readers.
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SOR 903 Common FMEA Confusions
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Common FMEA Confusion
[Last month I mentioned that the next article would be on the subject of the application of models in the FMEA process. I am postponing that important topic, in order to do more research. Stay tuned . . .]
This month, I want to discuss one of the most common problems that FMEA teams face: getting confused about the difference between failure modes, effects and causes.
“Things are not always as they seem; the first appearance deceives many.” Phaedrus
What is a (good) Failure Modes and Effects Analysis (FMEA)?
FMEAs are like diets. There is the ‘5-bite diet’ (no need to explain this one too much) that is so simple to understand, easy to initially say ‘yes’ to, but demonstrably impossible to maintain (bordering on dangerous). Then there is the ‘werewolf diet,’ which appeals to our inner hunter-gatherer that we think we still are, but beyond that, it makes no nutritional sense. There are diets that work well for one person and not well for another. And finally, there is usually (barring medical conditions) a perfectly feasible, sensible, sustainable diet that can work for you if it is tailored to your needs, physiology, and goals.
The reality is that we cannot be truly healthy without a ‘perfect’ diet that works for us. There could be more than one ‘perfect’ diet. There are plenty of ‘mediocre’ diets. And lots of ‘terrible’ diets.
If you are with me so far … welcome to the world of FMEAs!
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Ask a question or send along a comment.
Please login to view and use the contact form.Are FMEA and RCM Separate Processes?
When you do RCM you also create an FMEA.
In this video, I explain the connection between Reliability Centered Maintenance (RCM) and Failure Modes and Effects Analysis (FMEA). Many people wonder if these are two different processes, but when you perform RCM, the first four steps—defining functions, identifying functional failures, analyzing failure modes, and assessing failure effects—essentially fulfill the requirements of an FMEA. By following the RCM process, you’re already doing the work needed for an FMEA. I break this down and show how they align.
I’m Nancy Regan, and I hope this clears up the confusion! Thank you for watching.
[Read more…]QDD 141 Exposing The Hidden Flaws of FMEA and Risk Matrices: Advancing Your Risk Assessment
Exposing The Hidden Flaws of FMEA and Risk Matrices: Advancing Your Risk Assessment
In the realm of risk assessment and management, traditional tools like Failure Mode and Effects Analysis (FMEA) and risk matrices have been widely accepted as the norm. However, beneath the surface of these established methods lie hidden flaws of FMEA and risk matrices that can significantly impact the effectiveness of risk analysis and decision-making processes. The latest podcast episode takes a deep dive into these issues, offering listeners an exploration of the challenges posed by conventional risk assessment techniques.
The episode emphasizes the importance of staying informed and adapting to new methods in the ever-evolving landscape of risk management. By doing so, professionals can ensure that they are not only equipped to handle current challenges but also prepared to meet the demands of the future.
What is the difference between Design and Process FMEAs?
An Accendo Reliability recorded webinar event
Ever heard of Failure Modes and Effects Analysis (FMEA)? It is a wonderful activity that can do amazing things for … what? It depends on what you might have heard or what you are used to. Why? Because there are several different FMEAs that do different things for … different things. A Design FMEA can help us prevent really basic, simple flaws in a new product. A Process FMEA can help us prevent really basic, simple flaws in a new process. What process? Any process … but typically manufacturing. Many people who have heard of FMEAs usually associate them with either design or processes. Then, there are System and Software FMEAs. Want to get an overview of which FMEAs do what and when you would use one instead of the other? Join us for this webinar.
[Read more…]10 Reasons to do FMEAs
10 Reasons to do FMEAs
podcast episode with speaker Chris Jackson
Everyone knows why we do reliability, and reliability things like FMEAs. Customer experience. Organization reputation. Reduced warranty claims 10 years from now. But these are boring reasons that really don’t motivate me to take FMEAs seriously now. Why should I invest so much time into an activity that benefits the ‘company’ or the ‘customer’ in the future but won’t make an immediate difference when my boss will give me a ‘gold star’ on my next performance appraisal? Right? Wrong! [Read more…]
PFMEAs can Identify Special Process Characteristics
[This is a companion article to “Using Design FMEAs to Identify Special Product Characteristics.” These two articles should be read in sequence.]
Identification and application of special product and process characteristics help to focus assembly and manufacturing processes on the most important areas, in order to achieve the right outcomes.
“Science is the process that takes us from confusion to understanding” – Brian Greene
Using Process FMEAs to Improve Process Control Plans
“Science is the process that takes us from confusion to understanding…” – B
Properly done, Process FMEAs should improve manufacturing and assembly processes and corresponding process controls. This article describes how PFMEAs can be used to improve process controls, which are embodied in the Process Control Plan (PCP).
Establishing FMEA Ground Rules and Assumptions
FMEA teams should agree to the ground rules that guide the analysis and the underlying assumptions that impact the entire FMEA. Failure to do so will add complexity and confusion to the resulting FMEA, and waste people’s time. Don’t miss this important step in FMEA preparation.
“Your assumptions are your windows on the world. Scrub them off every once in a while, or the light won’t come in.” Isaac Asimov
Inside FMEA – Index of Articles
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.
Making the most of FMEA
I have been working with clients recently who are keen users of FMEA. Getting engineers to contribute potential failures and their causes is not a problem with these clients, but ensuring that actions are correctly identified and followed up is not so easy. So, what goes wrong? What differentiates a good FMEA from a great FMEA? [Read more…]
FMEA Q and A – Managing System Changes
FMEA Q and A
In this Q and A article, a reader asks an interesting question about whether or not to update a System FMEA, when making subsequent changes to lower-level items. This is an excellent question, and shows the reader has good insight into the application of FMEA.
“Judge a man by his questions, not his answers.”
Voltaire
Understanding FMEA Functions – Part 1
The Essence of the Item
What is the essence of properly defined FMEA Functions? More than half of FMEA practitioners miss a key element when defining FMEA functions. This first article in the FMEA Definitions and Concepts Series will discuss functions and their application in FMEAs.
“A perfection of means, and confusion of aims, seems to be our main problem.”
Albert Einstein
Fundamentals of FMEA
An Accendo Reliability recorded webinar event
Failure mode and effects analysis (FMEA) starts with brainstorming and ends with prioritized actions. A great tool to get your team thinking about system failures. Let’s explore the fundamental steps and beset practices to get value from your analysis.
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