Failure Modes & Effects Analysis
Proactive risk assessment methodology to identify potential failure modes and their impact on system performance, safety, and reliability
Types of FMEA Analysis
Comprehensive failure analysis methodologies tailored to different phases of product and process development
System FMEA
High-level analysis focusing on system-level failures and their effects on overall system performance.
Design FMEA (DFMEA)
Product design analysis to identify potential failure modes during the design phase and their impact on product performance.
Process FMEA (PFMEA)
Manufacturing process analysis to identify potential failure modes in production processes and their impact on product quality.
FMEA Methodology
A systematic 6-step process for comprehensive failure mode and effects analysis
System Definition
Define system boundaries, functions, and interfaces to establish the scope of analysis.
Failure Mode Identification
Identify all potential failure modes for each component, subsystem, or process step.
Effects Analysis
Analyze the effects of each failure mode on system performance, safety, and reliability.
Cause Analysis
Identify root causes and mechanisms that could lead to each failure mode.
Risk Assessment
Calculate Risk Priority Numbers (RPN) based on severity, occurrence, and detection ratings.
Action Planning
Develop and implement corrective actions to reduce risk and improve system reliability.
Risk Priority Number (RPN) Components
Three key factors that determine the risk level of each identified failure mode
Severity (S)
Measures the impact of the failure effect on the system, customer, or end user.
Occurrence (O)
Measures the likelihood that the failure mode will occur during the design life.
Detection (D)
Measures the likelihood that the failure mode will be detected before it reaches the customer.
RPN Calculation
Risk Priority Number = Severity × Occurrence × Detection
Higher RPN values indicate higher risk and require immediate attention
FMEA Benefits
Measurable improvements achieved through systematic failure mode analysis
Risk Reduction
Proactive identification and mitigation of potential failure modes before they occur.
Cost Savings
Reduction in warranty claims, recalls, and field failures through early problem identification.
Quality Improvement
Enhanced product and process quality through systematic failure mode analysis.
Customer Satisfaction
Improved reliability and performance leading to higher customer satisfaction.
Industry Applications
FMEA methodology applied across diverse industries for risk management and quality improvement
Automotive Industry
Vehicle systems, powertrain components, safety systems, and electronic controls.
Examples:
Manufacturing
Production processes, equipment, and quality control systems.
Examples:
Aerospace & Defense
Aircraft systems, avionics, propulsion systems, and safety-critical components.
Examples:
Medical Devices
Medical equipment, diagnostic devices, and life-support systems.
Examples:
Energy & Power
Power generation, transmission, and distribution systems.
Examples:
Oil & Gas
Drilling equipment, processing facilities, and pipeline systems.
Examples:
Industry Standards & Certifications
Our FMEA practices are aligned with international standards and best practices, ensuring compliance and excellence in every analysis.
AIAG-VDA FMEA
Automotive Industry Action Group and Verband der Automobilindustrie FMEA standard
SAE J1739
Society of Automotive Engineers FMEA standard for automotive applications
IEC 60812
International Electrotechnical Commission standard for failure modes and effects analysis
MIL-STD-1629A
Military standard for procedures for performing a failure mode, effects, and criticality analysis
ISO 14971
Medical devices - Application of risk management to medical devices
IEC 61508
Functional safety of electrical/electronic/programmable electronic safety-related systems
Why Choose Our FMEA Expertise
Certified FMEA Practitioners
AIAG-VDA and SAE certified FMEA specialists
Industry Experience
Extensive experience across automotive, aerospace, and manufacturing
Proven Methodology
Systematic approach with measurable results and continuous improvement
Software Tools
Advanced FMEA software and digital tools for comprehensive analysis
Enhance Your Risk Management Today
Let our FMEA experts help you identify and mitigate potential failures before they impact your operations