Why FMEA is Critical in Industrial Manufacturing

Brittany Beckmann No Comments

Customers who entrust a manufacturer with their industrial design and production have high expectations about quality and reliability. That’s understandable, and it’s also why manufacturers need to plan for failure in order to prevent it.

Industrial manufacturers rely on failure mode and effects analysis (FMEA) to identify and eliminate potential defects early in the process in order to avoid costly late-stage correction. The result? Quality products, pride in craftsmanship and satisfied customers.

What’s FMEA?

Failures Modes and Effects Analysis, or FMEA, presents an effective method for identifying any plausible issues or concerns that may arise in any given design or redesign project.

Dissecting the name further provides a better understanding of the process. “Failure modes” refers to how and the number of ways something might fail, and the actual or plausible negative effects. “Effects analysis” refers to the analysis of the failure modes and their impact.

What is PFMEA?

There are other types of FMEA that are tailored toward specific points of focus such as Process Failure Modes and Effects Analysis (PFMEA).

Process Failure Modes and Effects Analysis (PFMEA) takes place prior to the product being made and emphasizes manufacturing process outcomes, including:<

  • The number of errors that occur
  • The effect of the errors
  • Ways to eliminate errors
  • Determination of if the product will get to the customer on time, without defects
While PFMEA has a distinct focus, it’s based on a points system that indicates when the team needs to take action on potential failure modes.
FMEA plays a critical role in:
  • Brainstorming potential failures
  • Examining the effects of those failures
  • Determining the severity of a failure and its detection rating
  • Assigning the Risk Priority Number (RPN)

If the RPN reaches a certain level, the team develops and executes a plan of action. Afterwards, team members repeat the process to evaluate their actions’ success.

What’s MFMEA?

Materials Failure Modes and Effects Analysis (MFMEA) is a process specific to HUI. While similar to other FMEA processes, MFMEA emphasizes materials, specifically the risk of material outages caused by suppliers or other circumstances, and material delivery lead-times. Supplier quality is researched and discussed thoroughly for optimal results. In some cases, this leads to developing a contingency plan. However, MFMEA in industrial manufacturing is generally applied with high volume components and new material.

MFMEA accounts for the volume requirements, the need for any unique and raw materials, their availability and tooling requirements.

Taking this “extra step” approach to industrial manufacturing ensures HUI produces superior, defect-free products that consistently exceed customer expectations.

To learn more about FMEA, like the mechanics of the scoring system, check out the details online, or contact  Ryan Arnold at rarnold@huimfg.com. We’re happy to help!

Share this:


Manufacturing Blog Manufacturing Blog Industry Insights Industrial Manufacturers Manufacturing Wisconsin Manufacturers Quality Sheet Metal Fabrication custom industrial products design engineering custom enclosures Project Management LEAN standard enclosures electrical enclosures LEAN Management Powder Coating made to order IP Enclosures Midwest Manufacturers NEMA Enclosures lean principles Continuous Improvement Engineering build to order custom enclosure make to order CI Manufacturing Production Capacity Supply Chain Management Warehouse Waste bend radius cash flow dimensioning Continuous Improvement Teams Engineering for Manufacturing IEC 60529 IP Ratings IP Ratings Guide ISO ISO 13485 ISO 9001 ISO 9001 Certified Suppliers Laser and Punch Machine Lead Times Production Speed Safety Stock Sheet Metal Machine TRUMPF TruMatic 6000 TruMatic 6000 TRUMPF Trumpf Machine bend allowance custom electrical enclosures enclosures 5s B2B Case Study Customer Experience Customer Service Customer Service for B2B Damaged Freight Drive Enclosures Encourage Continuous Improvement FIRST Robotics Competition FMEA Flat Pattern Freight Claim Industry Ingress Protection Lean Communication Lean Teams NEMA 250 NEMA Ratings Paint Specification Standards Sheet Metal Layout Shipping Damages Tooling UL Ratings assembly process bend deduction branding chassis enclosure custom chassis fabrication custom chassis fabricator custom fab custom fabrication enclosure improving safety medical equipment chassis press brake robotics surface finish surface finishing standards theoretical sharp virtual sharp


    Recent Posts