Failure Mode and Effects Analysis
Introduction
Failure Modes and Effects Analysis (FMEA) is one of the most widely used and effective tools for developing quality designs, processes and services.
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When criticality is considered, FMEA is often times referred to as FMECA (Failure Modes, Effects and Criticality Analysis). For additional information, refer to Criticality Analysis. In this document, the term FMEA is used in a general sense to include both FMEAs and FMECAs.
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Developed during the design stage, FMEAs are procedures by which:
• Potential failure modes of a system are analysed to determine their effects on the system.
• Potential failure modes are classified according to their severity (FMEAs) or to their severity and probability of occurrence (FMECAs).
• Actions are recommended to either eliminate or compensate for unacceptable effects.
When introduced in the late 1960s, FMEAs were used primarily to assess the safety and reliability of system components in the aerospace industry. During the late 1980s, FMEAs were applied to manufacturing and assembly processes by Ford Motor Company to improve production. Today, FMEAs are being used for the design of products and processes as well as for the design of software and services in virtually all industries. As markets continue to become more intense and competitive, FMEAs can help to ensure that new products, which consumers demand be brought to market quickly, are highly reliable, safe and affordable.
The principle objectives of FMEAs are to anticipate the most important design problems early in the development process and either to prevent these problems from occurring or to minimise their consequences as cost effectively as possible. In addition, FMEAs provide a formal and systematic approach for design development and actually aid in evaluating, tracking and updating both design and development efforts.
Because the FMEA is typically begun early in the design phase and is maintained throughout the life of the system, the FMEA becomes a diary of the design and all changes that affect system quality and reliability.