FAILURE MODE AND EFFECTS ANALYSIS (F.M.E.A.

Failure Mode and Effects Analysis was first developed over 60 years
ago.

The Aerospace industry adopted FMEA during the 1960s. It is now in

widespread use in the Automotive industry.

Many manufacturers of automotive vehicles are now insisting that

suppliers use FMEA on new products and during product changes.

Its use in other industries is a comparatively recent phenomenon.

What is F.M.E.A ?

FMEA is a design and pre-product planning technique which structures

the engineers thought processes to consider every conceivable way in
which a component or product may fail. It is an analytical technique
which
Identifies potential failure modes
Assesses potential effects to a customer
Identifies potential causes of failure
Identifies needs for changes
Minimises potential cause of failure
Facilitates Inter-departmental dialogue
Facilitates identification of critical characteristics in a process

An FMEA enables engineers to look at all aspects of design and

process in formalised and structured way.

The potential problems are recorded, numerically assessed and

ranked in order, for action to be taken.

When to use FMEA

An FMEA study can be carried out at any stage during the

development of a product. However the ideal times to use this
technique are

At the original concept stage when specifications are being

established
As soon as the design is finalised but before any manufacturing of
tooling etc., is commenced
when the processing decisions are being made
 when major changes are to be carried out, either to the design or
process alterations
After an FMEA study has been conducted and corrective actions
taken; i.e., re-assessment

Benefits of FMEA

FMEA is an upstream, off-line activity and represents a quality

prevention cost. It is concerned with building quality into the product
prior to manufacture. Properly conducted, it should therefore lead to

A reduction of scrap, and rework activities

Reduction in inspection and process control activities
Reduction of failure conditions
Reduction in warranty costs
Overall reduction in manufacturing costs
Improved customer satisfaction