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.
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
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.
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.