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Inside FMEA

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

by Carl S. Carlson Leave a Comment

Is There a Better Way Than RPN?

“Number rules the universe.” – Pythagoras

Risk Priority Number (RPN) . . . by definition, a single number that represents relative risk for prioritizing issues in an FMEA. Sounds simple. But, how well does it work in practice? And, is there a better way?

This article highlights shortcomings and concerns when using RPN in FMEA, and discusses an alternative. It is a companion article to “Prioritizing risk for corrective actions in an FMEA.”

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

How to Get Better Results with FMEAs, in Less Time

How to Get Better Results with FMEAs, in Less Time

“Time is money” – Benjamin Franklin

One of the most common complaints about FMEAs is that they can take a long time to do. This article presents solutions to this challenge.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

FMEA and Robust Design

FMEA and Robust Design

One of the most important concepts in designing for reliability is robust design. This article is a high-level overview of robust design and its relationship to FMEA.

“For the robust, an error is information.” Nassim Nicholas Taleb

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: Robust Design

by Carl S. Carlson Leave a Comment

Hazard Analysis and FMEA

“The danger which is least expected soonest comes to us.” Voltaire

This article discusses the application of Hazard Analysis, why it is used, and the similarities and differences with FMEA.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson 4 Comments

Understanding Software FMEA

“My software never has bugs. It just develops random features.” Anonymous

More and more mechanical and electrical systems include software integration. The FMEA methodology applies very well to software as well as hardware. It is possible to include software functionality in the System FMEA as part of the functional descriptions. However, for complex software functionality such as embedded control systems, it may be useful to perform a separate software FMEA.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

Legal Guidelines for FMEAs

Legal Guidelines for FMEAs

FMEAs are legal documents that support the demonstration of due care in product development. FMEA teams should ensure their worksheets are consistent with good legal practices for documents, and follow company legal guidelines.

“Common sense often makes good law.” William Orville Douglas, past Justice of the Supreme Court

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

PFMEAs can Identify Special Process Characteristics

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

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

DFMEAs can Identify Special Product Characteristics

DFMEAs can Identify Special Product Characteristics

One of the most important principles in reliability engineering and management is the differentiation between the vital few and the trivial many. The application of special product characteristics uses that principle.

“The whole of science is nothing more than the refinement of thinking.” – Albert Einstein

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

Using FMEA quality objectives to audit FMEAs

Using FMEA quality objectives to audit FMEAs

In last month’s article we discussed the most common FMEA mistakes and how to convert them into quality objectives. This month we will focus on how to audit FMEAs, using the FMEA quality objectives as a guideline.

“Twice and thrice over, as they say, good is it to repeat and review what is good.” Plato

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson 1 Comment

The Most Common FMEA Mistakes and How to Convert Them into Quality Objectives

The Most Common FMEA Mistakes and How to Convert Them into Quality Objectives

“Good judgment comes from experience and experience comes from poor judgment.” Will Rogers

Much is learned by observing the mistakes companies have made in doing FMEAs. Based on the experience of over 2,000 FMEAs and working with many companies in a wide variety of applications, certain common mistakes show up repeatedly. In this article, I’ll share ten common FMEA mistakes and how to convert them into quality objectives.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

Using “Mode of Operation” in FMEA

Using “Mode of Operation” in FMEA

More than one operational mode may need to be considered to ensure that all important failure modes are identified and analyzed in the FMEA. This article focuses on what you need to know about modes of operation when performing FMEAs.

“My favorite mode of transport is hot-air ballooning. It’s so graceful to be blown by the wind, to go where the wind takes you.” Richard Branson

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

What is Unique about System FMEA?

What is Unique about System FMEA?

Many companies miss out on the value of System FMEA and begin with lower level sub-assemblies or components. This article explains why it is usually best to begin with a properly done System FMEA.

“Big whirls have little whirls,
That feed on their velocity;
And little whirls have lesser whirls,
And so on to viscosity.”
Lewis Fry Richardson

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: FMEA, system

by Carl S. Carlson Leave a Comment

Can You Anticipate Everything?

Can You Anticipate Everything?

Is it possible to anticipate everything that could go wrong?

“Prediction is very difficult, especially if it’s about the future.” Niels Bohr

In an FMEA, is it possible to think of everything that might happen in the future? What strategies can be used by FMEA teams to maximize the opportunity to anticipate what can go wrong, so risk can be reduced to an acceptable level?

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: FMEA

by Carl S. Carlson Leave a Comment

Gathering Information

Gathering Information

[Author note: This article is being published mid-month, and is part of the FMEA Preparation series. It was earlier written, but inadvertently omitted from publication, as part of this series.]

Gathering Information for FMEA Preparation

One of the most important steps in FMEA preparation is gathering all of the relevant documents and information. If this step is missed or done inadequately the FMEA meetings will be burdened with extra tasks related to missing information, the time of the subject-matter experts will be wasted, and the FMEA results potentially compromised.

“True genius resides in the capacity for evaluation of uncertain, hazardous, and conflicting information.” – Winston Churchill

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

by Carl S. Carlson Leave a Comment

Using Process FMEAs to Improve Process Control Plans

Using Process FMEAs to Improve Process Control Plans

“Science is the process that takes us from confusion to understanding…” – Brian Greene

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).

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

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Articles by Carl Carlson
in the Inside FMEA series

[popup type="" link_text="Logo Info" ]

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. [/popup]

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