FMEA (Failure Mode and Effect Analysis) was developed in the 1940s by the U.S. Military and is widely used today in aerospace and electronics. FMEA’s purpose is to identify possible problems during manufacturing, assembly, or design and determine the consequences of failure. RPN is calculated to determine the probability of failure, the severity of any failure, and the impact of corrective actions. RPNs can be calculated by adding three variables: the severity of the failure, the occurrence of failure (O), and the likelihood that the failure will be detected (D). Multiplication results in the failure mode criticality.
This data is used in design and control, especially when launching a new product, adding new features, or adapting an established product. FMEA is a tool that can be used to determine the root cause of a problem in a product or process.
Failure modes and effects analysis is a step-by-step approach that separates the cause (or potential failures) from the consequences of the failure. FMEA permits the necessary actions to take to resolve any issue, starting with the most important.
There are three types of FMEA: design FME), concept FMEA and process FMEA. Each type has its advantages and applications. The table below is an example of an FMEA table.
|FAILURE MODE & EFFECTS ANALYSIS(FMEA) date: 10/09/2021
Process name: left front seat belt install process number: SY 683
FMECA, an enhanced version of FMEA, adds a criticality analysis section. This is used to compare the likelihood of failure modes with the impact of the consequences. FMECA is a method for identifying system failures, their causes, and the consequences. The FMECA process can also be used to identify and focus on very important areas of design.
FMECA is also helpful for improving product and process designs. This would lead to higher reliability, safety, quality, cost reduction, and customer satisfaction. This tool can be used to optimize maintenance plans and quality assurance procedures. The table below shows an FMECA analysis example of criticality ranking definitions.
Minor process upset, the small hazard to
facilities and personnel, process
shutdown not required
|Major process upset, significant
hazard to facilities and personnel,
orderly process shutdown required.
|Immediate hazard to facilities and
personnel, emergency shutdown
FMEA applications, just like FMEA, cover a broad range of industries and manufacturing processes.
FMECA can also be used when higher quality products are required with greater reliability and safety. FMECA can be used to reduce costs or even avoid lawsuits. FMEA can, like FMEA, help you meet safety and quality standards such as Six Sigma and PSM.
These methods can be used to design, manufacture, develop, and other business-critical applications in industries such as aerospace, construction, healthcare, software, or elsewhere.
FMEA can help customers by providing high-quality products and services. FMEA can be applied to many industries and applications, including aerospace, healthcare, baking, and software. Banks can use FMEA to identify flaws in ATMs, and hospitals can do FMEA on devices.
FMEA is a tool that can help improve product designs to produce safer, more reliable products and reduce costs associated with product development. FMEA also gives information to prove products meet safety and quality standards such as Six Sigma.
FMEA’s benefits have allowed it to be used in various industries, such as oil and gas, defences, automotive, and many other manufacturing sectors.
What Are the Main Differences Between Them?
FMEA and FMECA are often viewed as similar. However, there is a significant difference between the two methods. FMEA lacked the severity, occurrence, and detection ranking and the criticality matrix that FMECA provided. FMEA risks could not be prioritized without FMECA. FMECA became less important as FMEA templates were developed. FMECA’s criticality analysis is done after FMEA.
FMEA provides only qualitative information. FMECA can provide both qualitative and quantitative data. This allows users to determine the criticality of failure modes and to order them according to their importance.
FMECA can be done either top-down or bottom-up. The top-down approach is used during the initial design phase as a function-orientated process to determine how systems may fail. When the system design is complete, the bottom-up approach is usually used. This requires the analysis of every component starting at the bottom. Both cases result in creating a criticality matrix that can be used to determine critical items and make recommendations based on this analysis.
A quantitative approach should only be used when the actual component data are available. A qualitative approach should only be used when no or limited generic data is available.