FMEA: Failure Mode and Effects Analysis

An FMEA follows the principle of identifying potential failures as early as during the product development process by analyzing and assessing possible risks. Then, by planning appropriate actions early, causes of failure can be effectively avoided. In addition to this risk analysis, you bundle valuable knowledge about products and processes. Once this knowledge has been included, you can refer to it again in each new FMEA.

Icon: Effective FMEA
Effective FMEA based on the proven 7 steps
Icon: FMEA - Risk Assesment
Risk Assessment Using standard-compliant or individual criteria
Icon: FMEA - Integration
Integration of FMEA, control plans, inspection plans and further modules
Preview of the "FMEA" module in the QM software BabtecQ

Detect and Avoid Potential Failures Early

Effective Planning, Execution and Documentation of FMEAs

The integrated solution of BabtecQ supports you in executing and documenting standards-compliant design and process FMEAs. The goal of the design FMEA is to detect possible weak points in the product design and to reduce their risks even before the new product is released for production. For a new product, the process FMEA particularly considers all value-added process steps of the planned production, assembly and logistics processes.

These analyses provide a risk assessment of the identified possible faults. Primarily, however, they provide appropriate actions that, when implemented, can effectively minimize the identified risks in the development and manufacture of the product. For example, when creating an FMEA in the Babtec software, you apply the systematic and structured 7-step procedure recommended by the two major automobile associations AIAG and VDA, which has also become established in other industries.

Features & Functions

FMEAs
FMEA in the QM software BabtecQ: Form sheet

Design and Process FMEAs

Access clearly-arranged tree structures to perform complex structure, function and failure analyses in the FMEA software. During the structure analysis, you describe the system to be covered for your product and/or the corresponding process. All required functions and product or process characteristics can be documented – for every system element and every process step. Define dependencies between the required functions in the function tree – simply and intuitively via drag & drop. You can also identify and document possible failure modes and identify failure cause, failure and failure effect in the same way based on cause-effect relationships in the failure tree.

Base FMEA

Base FMEA for Higher Efficiency

Improve your efficiency and create base FMEAs to reference recurring partial systems and processes. For example, if you want to assess processes that are relevant to the manufacturing of various products, but are not defined by product-specific properties, you can manage and assess them in a single base FMEA. In this case, you merely reference the applicable base FMEA in any respective product-specific FMEA. All specific elements as well as those referenced are supplied within the FMEA. Your benefit: You document assessments and process optimizations only in the base FMEA.

Risk Analysis

Risk Analysis with Integrated Warning System

The structure, function and failure analysis is followed by the analysis and assessment of identified risks. Define separate warning thresholds for severity (S), occurence (O) and detection probability (D). If these warning thresholds are exceeded, the integrated warning system in the FMEA form takes action and the determined risk focal points are identified. If all possible risks are identified, the automatically dertermined risk priority number (RPN) or action priority (AP) will help you to find out where there is a need for actions to reduce risk more urgent.

Reports

Communicate FMEA Results Internally and Externally

You can use the Babtec FMEA software during your team sessions as the perfect communication tool: The simple and established form view, which is always available context-based for each failure and at all times by clicking on a button, allows you an improved coordination in the team, e.g., during the creation of prevention and detection controls for identified failure causes. On top of that, convince your customers with sound reports for the presentation of your FMEA results. With the dynamic report designer, supplied reports and forms can be flexibly adapted to company-specific requirements.

Actions

Action Management for the Prevention of Failure Causes

With the risk analysis, you assess the risks initially based on the current prevention and detection controls. During the optimization phase, you can reduce existing risks through additional actions and continually perform reassessments. For every developed action, you decide in a team whether it can actually be implemented or has to be discarded. All actions to be implemented are finally adopted in the central action management for processing and tracking.

Integration

Integration of Further Modules with Change and Information Management

Specifications can be automatically derived from CAD drawings and can be used as characteristics in the FMEA. Moreover, as an active QM software, BabtecQ automatically and regularly informs you about events that are relevant to FMEAs. For example, you will be informed about all incoming complaints or initiated actions that are essential for the risk analysis or the planning of relevant inspection steps. Use the information potential of customer complaints and adopt the experiences and actions directly into your FMEA. With the linking of FMEAs, control plans and even inspection plans, the integrated change management provides you with convenient support for required changes to these documents – without elaborate and failure-prone data comparison.

FMEAs
Base FMEA
Risk Analysis
Reports
Actions
Integration

Design and Process FMEAs

Access clearly-arranged tree structures to perform complex structure, function and failure analyses in the FMEA software. During the structure analysis, you describe the system to be covered for your product and/or the corresponding process. All required functions and product or process characteristics can be documented – for every system element and every process step. Define dependencies between the required functions in the function tree – simply and intuitively via drag & drop. You can also identify and document possible failure modes and identify failure cause, failure and failure effect in the same way based on cause-effect relationships in the failure tree.

Base FMEA for Higher Efficiency

Improve your efficiency and create base FMEAs to reference recurring partial systems and processes. For example, if you want to assess processes that are relevant to the manufacturing of various products, but are not defined by product-specific properties, you can manage and assess them in a single base FMEA. In this case, you merely reference the applicable base FMEA in any respective product-specific FMEA. All specific elements as well as those referenced are supplied within the FMEA. Your benefit: You document assessments and process optimizations only in the base FMEA.

Risk Analysis with Integrated Warning System

The structure, function and failure analysis is followed by the analysis and assessment of identified risks. Define separate warning thresholds for severity (S), occurence (O) and detection probability (D). If these warning thresholds are exceeded, the integrated warning system in the FMEA form takes action and the determined risk focal points are identified. If all possible risks are identified, the automatically dertermined risk priority number (RPN) or action priority (AP) will help you to find out where there is a need for actions to reduce risk more urgent.

Communicate FMEA Results Internally and Externally

You can use the Babtec FMEA software during your team sessions as the perfect communication tool: The simple and established form view, which is always available context-based for each failure and at all times by clicking on a button, allows you an improved coordination in the team, e.g., during the creation of prevention and detection controls for identified failure causes. On top of that, convince your customers with sound reports for the presentation of your FMEA results. With the dynamic report designer, supplied reports and forms can be flexibly adapted to company-specific requirements.

Action Management for the Prevention of Failure Causes

With the risk analysis, you assess the risks initially based on the current prevention and detection controls. During the optimization phase, you can reduce existing risks through additional actions and continually perform reassessments. For every developed action, you decide in a team whether it can actually be implemented or has to be discarded. All actions to be implemented are finally adopted in the central action management for processing and tracking.

Integration of Further Modules with Change and Information Management

Specifications can be automatically derived from CAD drawings and can be used as characteristics in the FMEA. Moreover, as an active QM software, BabtecQ automatically and regularly informs you about events that are relevant to FMEAs. For example, you will be informed about all incoming complaints or initiated actions that are essential for the risk analysis or the planning of relevant inspection steps. Use the information potential of customer complaints and adopt the experiences and actions directly into your FMEA. With the linking of FMEAs, control plans and even inspection plans, the integrated change management provides you with convenient support for required changes to these documents – without elaborate and failure-prone data comparison.

Looks Good So Far?

Then take the opportunity and secure a non-binding presentation appointment! We would be happy to present the "FMEA" module and its functions to you in more detail!

Companies That Already Rely on Babtec

Companies from a wide range of industries rely on software solutions from Babtec – from medium-sized family businesses to international corporations. Read the success stories of selected customers in our case studies.

 

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Logo of Gebr. Eickhoff Maschinenfabrik u. Eisengießerei GmbH
Logo of Melitta Europa GmbH & Co. KG
Logo of MENNEKES Elektrotechnik GmbH & Co. KG
Logo of HAILO-Werk Rudolf Loh GmbH & Co. KG
Logo of HES-Präzisionsteile Hermann Erkert GmbH
Logo of KEUCO GmbH & Co. KG
Logo of KTM Sportmotorcycle Deutschland GmbH
Logo of Woodward L'Orange
Logo of Niterra EMEA GmbH
Logo of Rosenberg Ventilatoren GmbH
Logo of Stadler Rail AG
Logo of Thomas Magnete GmbH
Logo of ulrich GmbH & Co. KG
Logo of Weißer + Grießhaber GmbH
Logo of WMF GmbH
Logo of Woco Industrietechnik GmbH

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