How can FMEA teams integrate with lean manufacturing systems?

So true. Too many times I’ve seen them done as an afterthought or just to comply with a gateway deliverable. Done properly, at the right time, you can deliver great robust products manufactured by a robust manufacturing process by a team who understand the important characteristics that need to be controlled

A car manufacturer implementing Lean principles might use FMEA to assess each stage of their assembly line. By identifying potential failure modes, such as a flaw in the welding process or a recurrent defect in a component from a supplier, the FMEA team can work to implement corrective measures. These measures could include improving quality control protocols or redesigning a process for greater reliability. This proactive approach not only minimizes waste (a key Lean principle) but also enhances product quality and reduces downtime, aligning with the goals of Lean manufacturing.

In its simplest form avoiding poor quality by truly collaborative failure mode analysis prevents waste in the e2e manufacturing process due poor quality and subsequent rework and storage with delays in the system.

I’ve always been a big proponent of FMEA’s almost unequivocally any issues can be traced back to the FMEA if done properly , correctly facilitated and worked , it’s a great source of experience and learning especially for new entrants and if done well and incrementally updated as concerns are raised a great source of reference. Sadly though it’s a very very very boring exercise and the bigger companies tend to see it as an annoyance rather than a help . The trouble is the very best risks are generated just as the yawns start . I defy anyone to evidence otherwise even our Teutonic friends struggle. Amazes me how many mistakes are repeated from vehicle to vehicle still , squeaks and rattle in particular and now weight ….. sorry mass

FMEA is a tool that is driven by a mindset of minimizing risks prior execution. It’s the simplest implementation of scenario based evaluation of all possible factors and the likely consequences. The fist key criteria for a successful use is to have as many scenarios as possible. The second is to approach each scenario with a scientific ranking system. FMEA is one of the most common tools in an automotive manufacturer’s tool kit.

Time and resources are the key limiting factors of FMEA and lean integration in manufacturing environments that are often under pressure to get production systems online quickly. Applying a high level FMEA approach to the manufacturing and assembly processes can help direct focus on the most urgent or impactful areas to perform initial lean work. This can provide an opportunity to kick off the effort into a continuous improvement program that will build on the initial FMEA framework and lean efforts over time, especially as manufacturing workforce and suppliers gain additional experience and can provide additional feedback.

Sharing knowledge gained across the implementation teams with your manufacturing workforce can build a better understanding of "why" procedures are the way they are, provide background on prior lessons learned across the team, and even build a greater sense of how impactful certain key manufacturing steps are on product performance and quality.