How can you effectively verify the actions to mitigate failure modes in a product design with FMEA?

1 Define verification criteria

The first step to verify the actions to mitigate failure modes is to define clear and measurable criteria for each action. These criteria should specify the expected outcomes, the methods and tools to measure them, the acceptance thresholds, and the responsibilities and timelines for verification. For example, if an action is to add a sensor to monitor the temperature of a component, the verification criteria could be the accuracy, reliability, and durability of the sensor, the frequency and quality of the data transmission, and the impact on the overall performance and cost of the product.

2 Conduct verification tests

The next step is to conduct verification tests according to the defined criteria and document the results. Verification tests can include simulations, experiments, inspections, audits, surveys, or any other methods that can provide objective evidence of the effectiveness of the actions. The verification tests should cover all the relevant failure modes, effects, causes, and controls identified in the FMEA, and compare the actual results with the expected results. For example, if an action is to improve the user interface of a software product, the verification tests could include usability testing, user feedback, error analysis, and functionality testing.

3 Update FMEA and risk priority numbers

The final step is to update the FMEA and the risk priority numbers (RPNs) based on the verification results. RPNs are calculated by multiplying the occurrence, severity, and detection ratings of each failure mode, and they indicate the relative risk level of each failure mode. By updating the RPNs after verification, you can evaluate the impact of the actions on reducing the risk of failure, and identify any remaining gaps or issues that need further improvement. For example, if an action is to change the material of a part to increase its strength, the verification results could show a lower occurrence and severity rating of the failure mode, and thus a lower RPN.

FMEA is a powerful tool to improve the quality and reliability of a product design, but it requires verification to ensure that the actions taken are effective and sufficient. By defining verification criteria, conducting verification tests, and updating FMEA and RPNs, you can verify the actions to mitigate failure modes in a product design with FMEA and achieve better outcomes for your product and your customers.

4 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?