The Origin of FMEA
The FMEA method has its origins in applications of the US military. Here, in the 1940s, a defect detection and avoidance system was developed to detect the errors that occurred during the production of the ammunition needed for weapons.
In the 1970s, defect detection supported by FMEA was first applied in the automotive manufacturing industry. Here, the method used by the car manufacturer detected the fault that led to a fire of the vehicle after the rear-end collision. Due to the success of the FMEA analysis, other car manufacturers subsequently introduced the analysis that detected and eliminated the defects.
Today, it is impossible to imagine the automotive industry without FMEA analysis. The errors arising during the design or manufacturing process are identified and neutralized by means of the analysis procedure.
By means of a knowledge repository used during the analysis process, the manufacturing company can also prevent an error that has already been identified from occurring again. In this way, FMEA ensures that production processes are constantly improved. Companies operating in other sectors of the economy can also benefit from this.
The Necessity of a Failure Detection and Prevention Analysis
The necessity of FMEA analysis becomes evident when a production process can no longer be completed as planned as a result of one or more errors. In this case, the company is penalized twice. For on the one hand, the stalled production process can lead to a client withdrawing his order and on the other hand, the company has to spend additional financial resources to eliminate the error. Depending on the consequences of the error, the production costs can then assume a considerable - and in particular not calculated - amount.
If a company wants to manufacture its products in a planned manner, comprehensive analysis of defects should also be an integral part of the entire process. This can be supported with the use of an analysis for fault detection and elimination (FMEA). For comprehensive defect detection and defect elimination, it is necessary that the correct procedure is followed when applying the FMEA method.
Ideally, the company appoints an FMEA moderator who is responsible for the organization and execution of the analysis procedure. This FMEA moderator knows, for example, how to integrate the FMEA software into the company's daily routine in such a way that, if possible, all defects can be identified and eliminated. The knowledge required for this is acquired by the FMEA moderator in a comprehensive FMEA training course.
Areas of Application for Comprehensive Failure Analysis
FMEA analysis was actually designed to perform comprehensive troubleshooting in the technical area of a company. In addition to the automotive industry, companies in other industries are also eligible to do so.
In addition, the analysis for FMEA also brings a benefit to the user in the non-technical area, because errors often creep in during the advance planning and product conceptions, which negatively influence the subsequent production process.
The Basic Principle of FMEA
The FMEA follows the basic principle of detecting faults that may occur in a production process at the earliest possible stage. The sooner the people in charge of the production process know why a machine is not working or a product is not of the desired quality, the sooner countermeasures can be initiated. This saves the company money and time. In addition to the start-up costs - if the FMEA method is applied successfully - the costs that would be incurred by unnecessary product recalls can also be avoided. Another advantage of FMEA is that it shortens development time.
The FMEA follows the basic principle of detecting faults that may occur in a production process at the earliest possible stage. The sooner the people in charge of the production process know why a machine is not working or a product is not of the desired quality, the sooner countermeasures can be initiated. This saves the company money and time. In addition to the start-up costs - if the FMEA method is applied successfully - the costs that would be incurred by unnecessary product recalls can also be avoided. Another advantage of FMEA is that it shortens development time.
Types of FMEA
In a fault analysis using FMEA, a distinction can be made between three types. These are the system FMEA, the design FMEA and the process FMEA.
The system FMEA considers the interaction of the system existing in a company with the individual components that are necessary for the analysis procedure. This is the basis for a successful FMEA application.
In the design FMEA, the scope of consideration focuses on the design phase, which precedes the pure manufacturing process. Systematic troubleshooting helps to ensure that defects are eliminated before the product development process begins.
The process FMEA summarizes and analyzes the results of system FMEA and design FMEA. Possible weak points are subjected to further consideration.
Professional Support in Conducting the FMEA
A successful analysis for FMEA is based on the support of the following factors:
FMEA Software
The software for FMEA supports failure analysis with appropriate tools and applications. It is just as successful with simple processes as with more complex tasks. In particular, the FMEA software can be used to initiate a risk analysis that examines how a detected defect could affect the further course of the production process.
FMEA Training
FMEA training provides the persons who will later assume the position of FMEA moderator with the basic knowledge and the knowledge based on it to perform a successful FMEA in the company. A special area of the training includes the use of the FMEA software.
The FMEA Moderator
After successful completion of the FMEA training, the FMEA moderator is able to coordinate and perform all necessary steps of the FMEA method. He has also been specially trained to use the FMEA software optimally in a company.
Conclusion
One of the main areas of application of FMEA is the automotive industry. In addition, the FMEA method can also be used successfully in other industrial sectors.
It is important that a company creates the conditions necessary for the analysis procedure to find and eliminate as many defects as possible. These prerequisites include the use of suitable FMEA software and the appointment of an FMEA moderator.
This FMEA moderator has acquired the compact knowledge for the correct procedure during a comprehensive FMEA seminar. He knows the basic principle, knows how to use the FMEA sensibly in a company and the use of the FMEA software supports him in this.