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AutoDCP Failure Mode Effect Analysis (FMEA) Tips

How Much Detail Should Be On A FMEA?

One guideline we offer customers is the "What will change" threshold. Ask yourself, what will change as a result of the additional detail? Will the facility change its process? Inspection method? Work instruction? Anything? If the answer is that the additional level of detail won't result in any change, it has no value and you may have already gone too far.

How Do I Make A FMEA A Living Document?

The aggregate total of all your FMEAs represents the risk assessment of your facility. When you calculate overall average and total risk numbers by part, operation and failure mode, you start to get to meaningful information. But for the FMEA to be "alive", you must incorporate the improvements made and the new numbers represented by Recommended Actions on your FMEAs. What is needed is an overall average and total risk number by part, operation and failure mode that uses the new (usually lower) Occurrence and Detection numbers on Recommended Actions in place of the originals.  Then you are able to assess risk on an on-going basis rather than a useless one time snapshot. (AutoDCP software does this for you automatically)

How Do You Validate FMEAs?

Think of the failure modes and risk numbers from your FMEAs as your prediction of what will happen in the future absent any intervention or unexpected problem. Your corrective actions are actual events. When you link the actual events to your forecast, you can then see how well the forecast fared.  When your high risk numbers accurately predict the occurrence and severity of actual corrective actions, you have validated your forecast.


How Can FMEAs Be Used To Improve Quality? How can a FMEA be useful?

Think of the failure modes and risk numbers from your FMEAs as your prediction of what will happen in the future absent any intervention or unexpected problem. Your corrective actions are actual events. When you link the actual events to your forecast, you can then see how well the forecast fared.  When your high risk numbers accurately predict the occurrence and severity of actual corrective actions, you have validated your forecast.


How Do I Get Management Support?Quality Dashboard

This ones easy. You get management support by giving it. When you provide your management meaningful summary risk information that helps them prevent problems before they occur and improve profit, they will give you more support for performing the analysis. Give your management nothing and you will receive nothing.

Plant managers are not going to wander into your area, select a binder off a shelf , sit down and start reading FMEAs that you have completed. They will look at a one page summary or dashboard that highlights the largest risk items and is reliable in its predictive accuracy.


AutoDCP includes the  tools you need to give plant managers support. The Plant Manager Dashboard  shown at the right will help you earn  the management support you need to improve quality.




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