Free Online FMEA (Failure Modes and Effects Analysis) for Problem Prevention

What is Failure Mode & Effects Analysis (FMEA)?

Failure Mode and Effects Analysis (FMEA) is a systematic, proactive method for evaluating a process or design to identify where and how it might fail and to assess the relative impact of different failures. The goal is to identify, prioritize, and eliminate or reduce potential failures, starting with the highest-priority ones. This tool supports the modern AIAG & VDA 7-Step FMEA process, focusing on the Structure, Function, and Failure Analysis steps.

Key components of an FMEA include:

• Failure Modes: The specific ways in which a component, system, or process could fail to meet the design intent.
• Effects of Failure: The consequences of a failure mode on the system, customer, or downstream processes.
• Causes of Failure: The design or process weaknesses, errors, or conditions that could trigger the failure mode.
• Risk Priority Number (RPN): A numerical ranking of the risk associated with each potential failure. It is calculated as: RPN = Severity (S) × Occurrence (O) × Detection (D)
  • Severity (S): The seriousness of the effect of the failure.
  • Occurrence (O): The likelihood that the cause of the failure will occur.
  • Detection (D): The ability of current controls to detect the cause or the failure mode before it reaches the customer.

Brief History of FMEA and Modern Standards

The FMEA methodology was first developed by the U.S. military in the late 1940s and documented in military procedure MIL-P-1629. It was designed to evaluate the reliability and safety of military equipment by identifying all possible failure modes and their effects on mission success.

Its value was quickly recognized by the aerospace industry. NASA extensively used FMEA during the Apollo program in the 1960s to mitigate risks and enhance the safety of space missions. In the 1970s, the automotive industry, led by Ford Motor Company, adopted FMEA to improve vehicle safety and quality, popularizing its use in the commercial sector. Today, the standard for FMEA is often governed by the AIAG & VDA FMEA Handbook, which promotes a 7-Step approach for systematic analysis and risk mitigation. This tool helps practitioners structure their analysis according to these modern principles.

How to Use This Tool: The 7-Step FMEA Approach

1. Define Structure (Step 1): In the "Components" panel, add all the parts or steps of your system/process. Mark items as "External" if they are outside your system boundary (e.g., user, power source). Use the "Contacts" panel to define the connections and interfaces.
2. Define Functions (Step 2): In the "Functions" panel, describe what the system is supposed to do (requirements). Assign each function to the specific contacts involved in carrying it out.
3. Visualize: The tool automatically generates a structure chart (network diagram) to help you visualize the system's components, interfaces, and functions, supporting the Structure and Function Analysis. You can drag nodes to rearrange the layout.
4. Generate FMEA Table (Step 3 - Failure Analysis): Click the "Generate FMEA" button. This will create a new FMEA analysis block below based on the functions you defined. Each time you click it, a new analysis is added, allowing you to compare versions.
5. Analyze Failures (Steps 4 & 5): For each function in the table, fill in the potential failure modes, their effects (Step 4: Effect Analysis), potential causes, and any current controls in place to prevent or detect them (Step 5: Risk Analysis).
6. Assess Risk (Step 5: Risk Analysis): Use the dropdowns to assign Severity (S), Occurrence (O), and Detection (D) scores. The tool automatically calculates the RPN to help you prioritize.
7. Define Actions & Export (Steps 6 & 7): For high-risk items, list recommended actions (Step 6: Optimization). When complete, you can export that specific FMEA table to an Excel file for your records (Step 7: Results Documentation).