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Failure Mode and Effect Analysis (FMEA)

Failure modes and effects analysis (FMEA) is a systematic method for identifying every potential failure in a design, a production or assembly procedure, a product or service.
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Risk Assessment
Assess identified failure modes by considering various factors, such as potential consequences, probability of failures occurrence, and degree of detectability. The evaluation calculates the risk priority score, which aids in the systematic prioritization of failure modes that need to be addressed first.
Failure Mode and Effect Analysis
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Severity Analysis
Assessing the severity of each failure mode is a thorough process. It considers safety, environmental impact, operational performance, and regulatory compliance. This comprehensive assessment provides a holistic view of potential outcomes from these failure modes.
Mitigation Strategies
Develop mitigation strategies for high-risk failure modes that get identified with the help of FMEA. Few examples of these strategies may include preventive maintenance, equipment upgrades, redundancies, and process improvements.
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Severity Assessment
Assign a severity rating to each failure mode based on the potential impact or consequence. This rating helps prioritize the most critical failure modes that require immediate attention.
Cause Analysis
Determine the root causes or factors contributing to each failure mode. This involves analyzing the underlying mechanisms, design flaws, material defects, process variations, or other factors that can lead to the failure.
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Failure Mode and Effect Analysis
Probability Assessment
Estimate the likelihood or probability of each failure mode occurring. This can be based on historical data, expert judgment, failure rate calculations, or other quantitative or qualitative methods.
Detection Analysis
Evaluate the detectability or ability to detect each failure mode before it causes an adverse effect. This involves analyzing the existing controls, monitoring systems, inspections, maintenance practices, or other measures that can identify or prevent the failure.
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Risk Priority Number (RPN) Calculation
Calculate a Risk Priority Number (RPN) for each failure mode by multiplying the severity, probability, and detectability ratings. The RPN helps prioritize the failure modes based on their overall risk level.
Risk Mitigation and Improvement Actions
Based on the prioritized RPNs, develop and implement risk mitigation strategies and improvement actions. These can include design changes, process modifications, enhanced monitoring or inspection procedures, training programs, or other measures to reduce the likelihood or impact of failure modes.
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