E6S-122 FMEA 10*10*10 Explodes Repeatedly Without Warning - Part 1

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Intro:  Welcome to the E6S-Methods podcast with Jacob and Aaron, your weekly dose of tips and tricks to achieve excellent performance in your business and career.  Join us as we explore deeper into the practical worlds of Lean, Six Sigma, Project Management and Design Thinking.  In this episode number 122,  Jacob and I introduce several takes on the Failure Modes and Effects Analysis.  We're gonna talk about the FMEA. If you like this episode, be sure to click the "like" link in the show notes.  It's easy.  Just tap our logo in the artwork, click and you're done. Tap-click-done!  Here we go. http://bit.ly/E6S-122 Leave a Review! http://bit.ly/E6S-iTunes


***FMEA 10-10-10 - Explodes Repeatedly Without Warning***                                          

Objection 1:  FMEA is too bureaucratic and too detailed; too nit-picky; takes too long, can't spare the time

Counter 1: It does take a long time. There are tactics to make it shorter and more manageable.  The belt should balance the needs of digging deeper with expedience.  The FMEA is extremely powerful. With great power comes great responsibility.

Objection 2:  FMEA is only good for existing processes or designs

Counter 2: Not true.  FMEA can be even more powerful for a new design, (allows to design it right), existing processes or designs make it easier to "imagine" what could go wrong, because it actually is going wrong. 

Objection 3:  FMEA is only good for processes/ or only good for designs.                                                                         

Counter 3: FMEA is good for both processes and products. Anything that varies in features and could have multiple failure points is conducive for the FMEA use.                                                                                                                                            



I            Failure Modes and Effects Analysis(FMEA) – Risk assessment technique to breakdown products, processes, services, etc. to detailed functional level to analyze potential points of failure.  Prioritizes where to focus.

II         Origins of the FMEA : Wikipedia; Risk Analysis https://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis

a.       Origins date back to US Armed Forces Military Procedures MIL-P-1629[5] (1949);

b.      Early 1960s, contractors for the NASA used similar variants for  Apollo, Viking, Voyager, Magellan, Galileo, and Skylab

c.       The civil aviation industry was an early adopter of FMEA, with the Society for Automotive Engineers (SAE) publishing ARP926 in 1967.[12] After two revisions, ARP926 has been replaced by ARP4761, which is now broadly used in civil aviation.

d.      During the 1970s, NASA recommended FMEA for offshore petroleum exploration. U.S. EPA application to wastewater treatment plants

e.       Ford Motor Company introduced FMEA to the automotive industry for safety and regulatory consideration after the Pinto affair. Ford applied the same approach to processes (PFMEA) to consider potential process induced failures prior to launching production.

f.       In 1993 the Automotive Industry Action Group (AIAG) published their 1st FMEA standard

III      FMEA Variants

a.       DFMEA – Design Failure Modes Effects Analysis

b.      PFMEA – Process Failure Modes Effects Analysis

c.       EMEA – Error Modes Effects Analysis

d.      FMECA – Failure Modes Effects Criticality Analysis

e.       FMMEA – Failure Modes Mechanisms Effects Analysis

IV      Commonalities

a.       Deep level, systematic approach

b.      Rubric Scoring, typical (Severity, Occurrence, Detection) 1-10 scale (more in future episode)

Outro: Thanks for listening to episode 122 of the E6S-Methods podcast. Don't forget to click "like" or "dislike" for this episode in the show notes. Tap-click-done!  Stay tuned for episode number 123 where we continue our discussion on the FMEA in design and processes.  We love hearing from our listeners and learning about how you use Lean and Six Sigma.  Feel free to email us, aaron@e6s-methods.com, or contact us through our website, we reply to all messages.  Reviews on iTunes are always appreciated and keeps us higher in the ranks and allows us to reach more superstars like you.  Don't forget to you can find notes and graphics for all shows and more at www.E6S-Methods.com. "Journey Through Success. If you're not climbing up, you're falling down?    Leave a Review! http://bit.ly/E6S-iTunes

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