How to do an FMEA (Failure Effects Mode Analysis)

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1. Gather/assemble a cross functional team of people with varied specializations about the process / service / customer needs

2. Put down the scope of FMEA. While scoping, arrive at the possible questions i.e.,Is it for meant for process / service e.t.c , its boundaries, extent of detail, e.t.c

3. Identify the functions of the scope

4. For each function, identify the possible ways it can fail / likely to go wrong. What we are doing here is identifying potential failure modes.

5. For each failure mode, identify the consequences of failure / going wrong. These are known as potential effects of failure. e.g., how does it affect the customer as a result of this failure ? 

6. Determine the seriousness / severity of of each effect and assign a rating [severity rating]

7. For each failure mode determine all possible / potential root causes.

8. For each cause determine Occurrence rating – O . The rating is on a scale from 1 to 101 being extremely unlikely, and, 10is inevitable.

9. For each cause identify the current process controls. These can be tests, audits, procedure, or a mechanism to keep failure at bay.

10. For each control determine the detection rating – D.  The rating for detection is usually on scale from 1 to 10. 1 denotes that the control is sure of detecting problem, and, 10 denotes that the control cannot / will not detect the problem.

11. Calculate the risk priority number as RPN (Risk Priority Number) = Severity x Ocurrence x Detection, and, caculate Criticality = Severity x Ocurrence. The numbers will address the priority accorded to the ranked potential failures.

12. State your recommended actions .

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