How can you conduct a FMEA for manufacturing?

1 Define the scope

The first step of FMEA is to define the scope of your analysis. This means clarifying the objectives, boundaries, assumptions, and criteria of your FMEA. You should also identify the key stakeholders, team members, and resources involved in the process. You can use a process flow diagram, a work breakdown structure, or a functional block diagram to map out the main steps, inputs, outputs, and functions of your manufacturing process.

2 Analyze the failure modes

The next step of FMEA is to analyze the possible failure modes of each step or function of your manufacturing process. A failure mode is a way that something can go wrong or fail to meet the specifications or expectations. For each failure mode, you should describe the causes, effects, and current controls of the failure. You can use a FMEA worksheet, a spreadsheet, or a software tool to document your analysis. You can also use tools like brainstorming, fishbone diagrams, or 5 whys to generate ideas and root causes.

3 Prioritize the risks

The third step of FMEA is to prioritize the risks of each failure mode. This means assessing the severity, occurrence, and detection of the failure and assigning a numerical rating to each factor. The severity is the impact of the failure on the customer or the product. The occurrence is the frequency or probability of the failure. The detection is the ability to identify or prevent the failure before it reaches the customer or the product. You can use a scale of 1 to 10, where 10 is the highest or worst rating, to score each factor. Then, you can multiply the ratings to get the risk priority number (RPN) for each failure mode. The RPN is a measure of the relative risk of the failure and helps you to prioritize the actions to reduce the risk.

4 Implement the actions

The final step of FMEA is to implement the actions to reduce the risk of each failure mode. This means identifying and executing the corrective or preventive measures to eliminate or minimize the causes, effects, or occurrence of the failure or to improve the detection or control of the failure. You should also assign responsibilities, deadlines, and resources for each action and monitor the progress and results of the action. You should update the FMEA worksheet, spreadsheet, or software tool with the new ratings and RPNs after the action and verify the effectiveness of the action.

5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?