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What is a FMEA?

Failure Mode and Effects Analysis (FMEA) or FMECA is an analysis
technique which facilitates the identification of potential  problems in the
design or process by examining the effects of lower level failures.
Recommended actions or compensating provisions are made to reduce
the likelihood of the problem occurring, and mitigate the risk, if in fact, it
does occur.

The FMEA team determines, by failure mode analysis, the effect of each
failure and identifies single failure points that are critical. It may also rank
each failure according to the criticality of a failure effect and its probability
of occurring. The
FMECA is the result of two steps:

  • Failure Mode and Effect Analysis (FMEA)
  • Criticality Analysis (CA).

FMECA is just FMEA with Criticality Analysis. There are many different
flavors of FMEA. There are Conceptual or Functional FMEAs, Design
FMEAs, and Process FMEAs. Sometimes during a design FMEA the
analysis will look at a combination of functions and hardware. Sometimes it
will include just hardware, and sometimes the analyst will take a detailed
look at the system down to a piece-part level, especially when critical
functions or hardware are involved.

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Why is FMEA / FMECA Important?

There are a number of reasons why this analysis technique is so valuable.
Here are just a few:

  • FMEA provides a basis for identifying root failure causes and
    developing effective corrective actions

  • The FMEA identifies reliability/safety critical components

  • It facilitates investigation of design alternatives at all stages of the
    design

  • Provides a foundation for other maintainability, safety, testability, and
    logistics analyses
FMEA / FMECA Background and History

  • An offshoot of Military Procedure MIL-P-1629, titled Procedures for
    Performing a Failure Mode, Effects and Criticality Analysis, dated
    November 9, 1949.

  • Used as a reliability evaluation technique to determine the effect of
    system and equipment failures. Failures were classified according to
    their impact on mission success and personnel/equipment safety.

  • Formally developed and applied by NASA in the 1960’s to improve
    and verify reliability of space program hardware.

  • The procedures called out in MIL-STD-1629A are the most widely
    accepted methods throughout the military and commercial industry.

  • SAE J1739 is a prevalent FMEA standard in the automotive industry.
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