{"id":2302,"date":"2025-03-21T06:11:14","date_gmt":"2025-03-21T12:11:14","guid":{"rendered":"https:\/\/limblecmms.com\/blog\/?p=2302"},"modified":"2025-05-30T12:59:01","modified_gmt":"2025-05-30T18:59:01","slug":"fmea-fmeca","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/fmea-fmeca\/","title":{"rendered":"Performing FMEA and FMECA with Examples for Maintenance"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text css=&#8221;&#8221;]<span style=\"font-weight: 400;\">Remember when Samsung had to recall the Galaxy Note 7 phone because it <\/span><i><span style=\"font-weight: 400;\">kept exploding<\/span><\/i><span style=\"font-weight: 400;\">? They ended up dedicating 700 engineers and built an entire facility just to solve this one problem. In all, the fiasco is estimated to have cost $10\u2013$17 billion. <\/span><\/p>\n<p><span style=\"font-weight: 400;\">Can you imagine how much better off Samsung would be if they had tested for a defect like this before launching the product? <\/span><b>FMEA is just the analysis tool for this situation<\/b><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This article will give you a detailed introduction to FMEA and FMECA. It will show you how to use your <a href=\"\/cmms\/\">Computerized Maintenance Management System (CMMS) <\/a><\/span><span style=\"font-weight: 400;\">t<\/span><span style=\"font-weight: 400;\">o make your testing even more successful.\u00a0<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text css=&#8221;&#8221;]<\/p>\n<h2 id=\"what-is-FMEA\">What is FMEA?<\/h2>\n<p><span style=\"font-weight: 400;\">Failure modes and effects analysis (FMEA) is a method that reveals:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The failure modes <\/span><span style=\"font-weight: 400;\">\u2014 the ways something could go wrong.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The \u201cdomino effect\u201d those flaws would have on the rest of the system.<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">It searches for the weak points in materials, manufacturing processes, and subsystems, then steps back to look at the big picture.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The FMEA process was one of the first ways to systematically look at potential problems. It is at the core of <\/span><a href=\"https:\/\/limblecmms.com\/blog\/reliability-engineering\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">engineering for reliability<\/span><\/a><span style=\"font-weight: 400;\">, safety, and quality control.<\/span><br \/>\n<span style=\"font-weight: 400;\">To identify the failure modes (again, the way something could go wrong):<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Look at how similar products\/processes have failed in the past.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Take into account the physical characteristics of your materials. For example, you can assume a component will fail in a 200-degree-Fahrenheit environment if its thermal plastic is only rated to 140 degrees.<\/span><\/li>\n<\/ul>\n<p><a href=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA.webp\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-7802 size-full\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA.webp\" alt=\"\" width=\"624\" height=\"233\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA.webp 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-300x112.webp 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-768x287.webp 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-451x169.webp 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-554x207.webp 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-93x35.webp 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-540x202.webp 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-100x37.webp 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/a><\/p>\n<p><span style=\"font-weight: 400;\">Depending on how bad the fallout would be, you can either:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Make changes to decrease the chances of it happening.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Lessen the impact the failure will have on the rest of the system.<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The end goal of FMEA and FMECA is to <\/span><b>eliminate (or at least minimize) chances that the system will have severe breakdowns<\/b><span style=\"font-weight: 400;\">. Knowing the potential weaknesses and their potential effects on the whole system makes it easier to decide which parts can be adjusted to make it more reliable.<\/span><\/p>\n<h2 id=\"what-is-FMECA\"><b>What is FMECA?<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Failure mode effects and criticality analysis (FMECA) is easy to grasp. It is like FMEA, but it adds a criticality analysis or ranked list.<\/span><br \/>\n<img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-5527 size-full\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA.png\" alt=\"FMECA\" width=\"624\" height=\"255\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-300x123.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-451x184.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-554x226.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-93x38.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-540x221.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-100x41.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><br \/>\n<span style=\"font-weight: 400;\">Basic FMEA is qualitative and only explores \u201cwhat-if\u201d scenarios. When we add the <\/span><i><span style=\"font-weight: 400;\">criticality<\/span><\/i><span style=\"font-weight: 400;\"> analysis from FMECA, you get a number that will allow you to rank your failure modes. This makes it easier to prioritize your work and (hopefully) keep problems from happening in the first place.\u00a0<\/span><\/p>\n<h2 id=\"history-and-types-of-FMEA\"><b>History and types of FMEA<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">FMEA was developed around 1950 and was first used by the U.S. military to create better weapons. FMEA worked so well for the military, it was quickly adopted by NASA, then the aviation and automotive industries, and so on.<\/span><br \/>\n<span style=\"font-weight: 400;\">We can split FMEA into three categories based on what we are looking at:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Design<\/b><span style=\"font-weight: 400;\"> failure mode and effects analysis (DFMEA) aims to create long-lasting products.<\/span><span style=\"font-weight: 400;\"> It considers how the product might fail at each phase of its life cycle.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Process<\/b><span style=\"font-weight: 400;\"> failure mode and effects analysis (PFMEA) looks at each step of a process. <\/span><span style=\"font-weight: 400;\">Think of sourcing, assembly processes, transportation, data processing, etc. It determines where the process could break down.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Functional <\/b><span style=\"font-weight: 400;\">failure mode and effects analysis (<\/span><a href=\"https:\/\/www.burgehugheswalsh.co.uk\/Uploaded\/1\/Documents\/FFMEA-Tool-v1-2.pdf\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">FFMEA<\/span><\/a><span style=\"font-weight: 400;\">) looks at the system as a whole. Instead of correcting the failure, it tries to bypass it entirely. (Think back on our example of avoiding broken levers on paper towel dispensers by switching to motion sensors.)<\/span><\/li>\n<\/ul>\n<h2 id=\"the-role-of-CMMS-in-failure-analysis\"><b>The role of CMMS in failure analysis<\/b><\/h2>\n<p><span style=\"font-weight: 400;\"><a href=\"\/cmms\/cmms-software\/\">CMMS software<\/a> helps maintenance experts manage their work. Remember how reviewing past breakdowns is a key step in FMEA? Suppose you are studying a machine or process in your facility. In that case, <\/span><b>your maintenance crew may have been gathering that data for you all along.<\/b><span style=\"font-weight: 400;\">\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">A robust CMMS like Limble will have logged:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Everything that has broken<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When it broke<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Why it broke<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">What was done to fix it<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Whether it broke down again<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The more user-friendly the CMMS is, the more (accurate) data you will have.<\/span><\/p>\n<h2 id=\"how-to-perform-FMEA-analysis\"><b>How to perform FMEA analysis<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">FMEA and FMECA aim to provide a list of potential failure modes ranked by:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Importance:<\/b><span style=\"font-weight: 400;\"> Is it a key component?<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Effect:<\/b><span style=\"font-weight: 400;\"> What else happens if it fails?<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Probability:<\/b><span style=\"font-weight: 400;\"> How likely is it to happen?<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Use an FMEA table or worksheet to guide your decisions about changes that could prevent failure from spreading.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-1853 size-full\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet.png\" alt=\"PFMEA worksheet\" width=\"637\" height=\"190\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet.png 1540w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-300x89.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-1024x305.png 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-768x229.png 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-1536x458.png 1536w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-451x134.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-554x165.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-93x28.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-540x161.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/PFMEA-worksheet-100x30.png 100w\" sizes=\"auto, (max-width: 637px) 100vw, 637px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Example of process FMEA worksheet. Source:<\/span><\/i> <a href=\"https:\/\/quality-one.com\/fmea\/\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Quality One<\/span><\/i><\/a><\/p>\n<h3><b>Step 1: Decide which FMEA you will use and gather the necessary information<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">As outlined in the intro, there are three types of FMEA:<\/span><\/p>\n<p><b>Design FMEA<\/b><span style=\"font-weight: 400;\"> takes the entire life span of the component into consideration at the design stage. You will look at things like material properties, interface between components, geometry, and engineering requirements.\u00a0<\/span><\/p>\n<p><b>Process FMEA<\/b><span style=\"font-weight: 400;\"> considers all the steps (processes) that lead to the final product and is popular in manufacturing. You will look at processing methods, machinery, and maintenance strategies.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Lastly, <\/span><b>Functional FMEA<\/b><span style=\"font-weight: 400;\"> thinks about the big picture rather than focusing on individual parts.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Once you have decided which type of FMEA to perform, the next phase is to <\/span><b>gather as much information as possible<\/b><span style=\"font-weight: 400;\"> to describe the product\/process in detail. This can be done with the help of drawings, schematics, component lists, and interface information, to name a few resources.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Consider using a tree or block diagram to make it easy to see the relationships between the different parts.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5528\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example.png\" alt=\"tree diagram example\" width=\"480\" height=\"301\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example.png 480w, https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example-300x188.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example-380x238.png 380w, https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example-466x292.png 466w, https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example-93x58.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/tree-diagram-example-100x63.png 100w\" sizes=\"auto, (max-width: 480px) 100vw, 480px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Example of a tree diagram. Source: <a href=\"https:\/\/www.researchgate.net\/figure\/Product-hierarchical-tree-structure-diagram_fig2_301446979\">ResearchGate<\/a><\/span><\/i><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5529\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example.png\" alt=\"block diagram example\" width=\"480\" height=\"311\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example.png 480w, https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example-300x194.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example-367x238.png 367w, https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example-451x292.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example-93x60.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/block-diagram-example-100x65.png 100w\" sizes=\"auto, (max-width: 480px) 100vw, 480px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Example of a block diagram. Source: <\/span><\/i><a href=\"https:\/\/www.mathworks.com\/discovery\/block-diagram.html\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">MathWorks<\/span><\/i><\/a><\/p>\n<h3><b>Step 2: Identify potential failure modes<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Refer back to your tree and block diagram. For each item on the chart <\/span><span style=\"font-weight: 400;\">\u2060\u2014 <\/span><span style=\"font-weight: 400;\">and each of its connections <\/span><span style=\"font-weight: 400;\">\u2060\u2014 <\/span><span style=\"font-weight: 400;\">write down all the ways it could break down. Approach it from a variety of angles.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Get creative! There are many ways in which an asset can malfunction:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">part\/system performs an unintended function<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">poor performance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">reduced functionality\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">failure to complete the intended function<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Here are some \u201chidden\u201d failure modes that are not easy to spot:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">cracking<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">electrical short circuit\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">torque fatigue<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">excessive deformation<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">so many more possibilities\u2026<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The data from your CMMS will be rich fodder for this step. Let these past unexpected breakdowns open your eyes to failure points you had not considered before.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This step is time-consuming. Let it be. The goal is to be as thorough as humanly possible.<\/span><\/p>\n<h3><b>Step 3: Do a failure effect and cause analysis<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Failures propagate, so for each component\/step, ask yourself, \u201cIf this node stops performing, what happens downstream?\u201d<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Think about its impact on the environment and customers\/users&#8211;both internal and external. The more you invest early on in creating a robust, detailed diagram, the easier this step will be.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">As you fill out your FMEA worksheet, think about each failure in two directions: What it affects downstream, as well as what upstream could cause such an issue in the first place like:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Human error<\/b><span style=\"font-weight: 400;\"> (like using the wrong type of material for load-bearing walls)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Material defects<\/b><span style=\"font-weight: 400;\"> (like low-quality material due to the manufacturer\u2019s poor standards)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Incorrect engineering requirements<\/b><span style=\"font-weight: 400;\"> (like failing to follow engineering standards that stipulate minimum area requirements for a steel frame support)<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">This upstream thinking is called <\/span><a href=\"https:\/\/limblecmms.com\/blog\/root-cause-analysis-rca\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">root cause analysis (RCA)<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5530\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram.png\" alt=\"Root cause diagram\" width=\"279\" height=\"310\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram.png 279w, https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram-270x300.png 270w, https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram-214x238.png 214w, https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram-263x292.png 263w, https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram-54x60.png 54w, https:\/\/limblecmms.com\/wp-content\/uploads\/Root-cause-diagram-90x100.png 90w\" sizes=\"auto, (max-width: 279px) 100vw, 279px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Root cause diagram. Source: <\/span><\/i><a href=\"https:\/\/asq.org\/quality-resources\/root-cause-analysis\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">ASQ<\/span><\/i><\/a><\/p>\n<h3><b>Step 4: Assign severity rankings<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Rank each failure on a scale of 0 to 10 where:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">0: This failure has no measurable impact.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">10: This failure would be dangerous and requires immediate intervention.<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">You are looking at the impact on users, downstream operations, the environment, and anyone or anything else that could be affected. Think of it in terms of dollars and cents, physical safety, time loss, damage to equipment, etc.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5531\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA.png\" alt=\"severity ranking in FMEA\" width=\"624\" height=\"312\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA-300x150.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA-451x226.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA-554x277.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA-93x47.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA-540x270.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-in-FMEA-100x50.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Failure mode severity ranking for FMEA. Source: <\/span><\/i><a href=\"https:\/\/www.researchgate.net\/publication\/269985652_Failure_Mode_and_Effects_Analysis_Under_Uncertainty_A_Literature_Review_and_Tutorial\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Soyer<\/span><\/i><\/a><\/p>\n<h3><b>Step 5: Assign occurrence rankings<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">In this step, consider <\/span><b>how often<\/b><span style=\"font-weight: 400;\"> this failure is likely to happen.\u00a0<\/span><\/p>\n<p><b><i>Sidenote:<\/i><\/b><i><span style=\"font-weight: 400;\"> You are answering this question for the failure on that row of your worksheet <\/span><\/i><i><span style=\"font-weight: 400;\">\u2060\u2014 <\/span><\/i><i><span style=\"font-weight: 400;\">not for the residual failures that it triggers.\u00a0<\/span><\/i><\/p>\n<p><span style=\"font-weight: 400;\">For example, let\u2019s assume the failure is \u201csubstandard building material causes the wall to give way.\u201d You are answering how often the wall is likely to fall, not how often the equipment is destroyed because the wall fell on it.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Once again, you rank possible failures on a scale of 0 to 10 where:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">0: This failure is unlikely to ever happen.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">10: This failure is virtually guaranteed.<\/span><\/li>\n<\/ul>\n<p><i><span style=\"font-weight: 400;\">Probability of occurrence classification for FMEA. Source: <\/span><\/i><a href=\"https:\/\/www.researchgate.net\/publication\/269985652_Failure_Mode_and_Effects_Analysis_Under_Uncertainty_A_Literature_Review_and_Tutorial\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Soyer<\/span><\/i><\/a><\/p>\n<h3><b>Step 6: Evaluate and assign failure detection rating<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Consider <\/span><b>how easy or difficult it will be to detect this failure<\/b><span style=\"font-weight: 400;\"> with the control systems you currently have in place. The \u201ccontrol system\u201d could be a complex array of custom sensors, or it could be a quick <\/span><a href=\"https:\/\/limblecmms.com\/blog\/visual-inspection\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">visual inspection<\/span><\/a><span style=\"font-weight: 400;\"> to look for dripping oil.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Ideally, you will detect the problem <\/span><i><span style=\"font-weight: 400;\">before<\/span><\/i><span style=\"font-weight: 400;\"> it results in a complete failure <\/span><span style=\"font-weight: 400;\">\u2060\u2014 <\/span><span style=\"font-weight: 400;\">for either the component or the whole system. Think about all of the places you could put process control systems to catch the issue before it cascades.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Rank each failure on a scale of 0 to 10 where:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">0: You are almost guaranteed to detect the failure early.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">10: Neither the failure nor its possible causes can be detected.<\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5532\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA.png\" alt=\"Detection rankings for FMEA\" width=\"624\" height=\"425\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA-300x204.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA-349x238.png 349w, https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA-429x292.png 429w, https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA-88x60.png 88w, https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA-540x368.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/Detection-rankings-for-FMEA-100x68.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Detection rankings for FMEA. Source: <\/span><\/i><a href=\"https:\/\/www.researchgate.net\/publication\/269985652_Failure_Mode_and_Effects_Analysis_Under_Uncertainty_A_Literature_Review_and_Tutorial\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Soyer<\/span><\/i><\/a><\/p>\n<p><span style=\"font-weight: 400;\">If there is a low likelihood of detection, ask yourself:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Is there a different product component or process step I can use where this malfunction is detectable?<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">If I cannot detect the process or product failure, how quickly could I detect the damage? What systems would I need to put in place?<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">If automatic monitoring simply isn\u2019t possible, can I make periodic testing a part of our <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/routine-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">routine maintenance<\/span><\/a><span style=\"font-weight: 400;\"> protocol?<\/span><\/li>\n<\/ul>\n<h3><b>Step 7: Calculate RPN<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">RPN stands for <\/span><i><span style=\"font-weight: 400;\">risk priority number<\/span><\/i><span style=\"font-weight: 400;\">. Calculate your RPN by multiplying the three rankings you calculated above.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-1843 size-full\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation.jpg\" alt=\"(RPN) risk priority number formula\" width=\"638\" height=\"217\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation.jpg 1000w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-300x102.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-768x261.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-451x153.jpg 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-554x188.jpg 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-93x32.jpg 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-540x184.jpg 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-100x34.jpg 100w\" sizes=\"auto, (max-width: 638px) 100vw, 638px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">A moderately severe failure (5 out of 10) with a very low chance of occurrence (2 out of 10) but also high difficulty of detection (8 out of 10) has an <\/span><b>RPN of 80 (5 x 2 x 8)<\/b><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Do this calculation for every failure on your worksheet, and order the failures from high risk to low risk. Consult with your team to determine a \u201ccritical\u201d level. In some industries or settings, that might be 90. In others, it might be as low as 50.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Some failures that seem minor could be triggers for other malfunctions that are downright catastrophic, so hopefully, you were mindful in each step above. Mountains and molehills are not so easy to distinguish in complex systems.<\/span><\/p>\n<h3><b>Step 8: Take action<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Starting at the top of the list, look for ways that you could lower the RPN by adjusting at least one of the three factors that contribute to it:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Occurrence:<\/b><span style=\"font-weight: 400;\"> Make the potential failure causes more robust, so they fail less often. If possible, remove that component altogether.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Detection:<\/b><span style=\"font-weight: 400;\"> Add more control plans. There are innumerable sensors available, many of them with alarms or <\/span><a href=\"https:\/\/limblecmms.com\/blog\/iiot-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">IoT integrations<\/span><\/a><span style=\"font-weight: 400;\">. These condition monitoring systems are an integral part of <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/condition-based-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">condition-based monitoring<\/span><\/a><span style=\"font-weight: 400;\"> and <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/predictive-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">predictive maintenance<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Severity:<\/b><span style=\"font-weight: 400;\"> Put controls in place so that the consequences are not so significant. For example, wildfire fighters dig lines that make it difficult for a fire to spread from one area to another. That way, any one section catching fire is not as big of a deal as it would have been without any natural barriers.<\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5533\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline.png\" alt=\"firefighters digging a fireline\" width=\"624\" height=\"397\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline-300x191.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline-374x238.png 374w, https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline-459x292.png 459w, https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline-93x60.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline-540x344.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/firefighters-digging-a-fireline-100x64.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Firefighters digging a fireline. Source: <\/span><\/i><a href=\"https:\/\/media.defense.gov\/2009\/May\/13\/2000575460\/-1\/-1\/0\/090508-F-3755M-001.JPG\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Department of Defense<\/span><\/i><\/a><\/p>\n<blockquote><p><span style=\"font-weight: 400;\">As a rule, the severity rating is the most difficult to adjust. It should not be reduced unless you have made a <\/span><i><span style=\"font-weight: 400;\">significant<\/span><\/i><span style=\"font-weight: 400;\"> change to the design or process.<\/span><\/p><\/blockquote>\n<h3><b>Step 9: Recalculate RPN<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">When you have implemented your improvements, redo your occurrence, detection, and severity rankings, and recalculate your RPN. If you are still above the critical threshold, look for more ways to mitigate the failure.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">If you are below your critical threshold, congratulations! You are free to move on to the next failure.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row content_placement=&#8221;middle&#8221; kd_background_image_position=&#8221;vc_row-bg-position-center&#8221; kd_top_separator_style=&#8221;arrow-down&#8221; kd_top_separator_height=&#8221;separator-height-small&#8221; kd_bottom_separator_style=&#8221;arrow-down&#8221; kd_bottom_separator_height=&#8221;separator-height-small&#8221; kd_top_separator=&#8221;true&#8221; kd_bottom_separator=&#8221;true&#8221; css=&#8221;.vc_custom_1699569372066{margin-bottom: 40px !important;padding-top: 60px !important;padding-bottom: 40px !important;background: #dde4e8 url(https:\/\/limblecmms.com\/wp-content\/uploads\/cta-laired-hex-4.webp?id=9077) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;border-radius: 0px !important;}&#8221; css_tablet_landscape=&#8221;.vc_custom_1699569372066{padding-bottom: 80px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1699569372066{padding-bottom: 80px !important;}&#8221; css_mobile=&#8221;.vc_custom_1699569372067{padding-bottom: 80px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_row_inner content_placement=&#8221;middle&#8221; gap=&#8221;15&#8243; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner width=&#8221;1\/2&#8243;]<header class=\"kd-section-title col-lg-12 text-left  subtitle-below-title kd-animated fadeIn   vc_custom_1682969314293\" data-animation-delay=200><h2 class=\"separator_off\" style=\"font-size: 42px;font-weight: 500;margin-bottom:30px;\">Mean Time Metrics Calculator<\/h2><h6 class=\"subtitle\" style=\"color: #152232;\">Just getting started with maintenance metrics? Use this helpful calculator with formulas and calculations.<\/h6><\/header>[\/vc_column_inner][vc_column_inner width=&#8221;1\/2&#8243;][vc_raw_html]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[\/vc_raw_html][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"FMEA-example\"><b>FMEA example<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Let\u2019s have a look at the FMEA process when <\/span><b>designing a bicycle brake cable<\/b><span style=\"font-weight: 400;\">. First, you made sure you understood the bicycle as a whole. You listed the failure modes and the effects of failure. You assigned rankings and calculated the RPN.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Here is the worksheet you produced:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5534\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables.png\" alt=\"FMEA applied to bicycle cables\" width=\"624\" height=\"308\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables-300x148.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables-451x223.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables-554x273.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables-93x46.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables-540x267.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-applied-to-bicycle-cables-100x49.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">FMEA applied to bicycle cables. Source: <\/span><\/i><a href=\"https:\/\/www.weibull.com\/hotwire\/issue197\/fmeacorner197.htm\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Weibull<\/span><\/i><\/a><\/p>\n<p><span style=\"font-weight: 400;\">At an RPN of 300, <\/span><b>the worksheet makes it clear that the first issue to tackle is your cable material<\/b><span style=\"font-weight: 400;\">. Environment and loading will affect nylon\u2019s material properties, which will cause an accident if the rider cannot close the brake calipers. This is a design issue (material choice). You need to look for nylon substitutes that perform as well or better but do not have the same safety issues in low humidity.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">After selecting your new material, you recalculate your RPN.<\/span><\/p>\n<h2 id=\"how-to-perform-FMECA-analysis\"><b>How to perform FMECA analysis<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">As we mentioned at the beginning, FMECA is an FMEA <\/span><i><span style=\"font-weight: 400;\">plus criticality<\/span><\/i><span style=\"font-weight: 400;\">. Just like FMEA, it has a worksheet:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5535\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet.png\" alt=\"FMECA Worksheet\" width=\"624\" height=\"275\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet-300x132.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet-451x199.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet-554x244.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet-93x41.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet-540x238.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-Worksheet-100x44.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">FMECA Worksheet. Source: <\/span><\/i><a href=\"https:\/\/quality-one.com\/fmeca\/\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Quality One<\/span><\/i><\/a><\/p>\n<h3><b>Step 1: Perform FMEA<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Having read the sections above, you are practically a professional at this point.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5536\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow.png\" alt=\"FMECA flow\" width=\"593\" height=\"706\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow.png 593w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow-252x300.png 252w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow-200x238.png 200w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow-245x292.png 245w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow-50x60.png 50w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow-340x405.png 340w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-flow-84x100.png 84w\" sizes=\"auto, (max-width: 593px) 100vw, 593px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">FMECA flow. Source: <\/span><\/i><a href=\"https:\/\/www.wbdg.org\/FFC\/ARMYCOE\/COETM\/tm_5_698_4.pdf\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">WBDG.org<\/span><\/i><\/a><\/p>\n<p><span style=\"font-weight: 400;\">At this point, you have a big choice to make: Will you use the top-down approach or the bottom-up approach?<\/span><\/p>\n<p><b>The top-down approach (also known as the \u201cfunctional method\u201d) looks at the design requirements.<\/b><span style=\"font-weight: 400;\"> It is usually invoked when creating a new product or new process. If you need to design a bicycle that costs just $50, what kind of failures is that likely to introduce? Low-cost materials are usually low quality, so the frame is more likely to break. To avoid it, you can try making a thicker frame. That kind of thing.<\/span><\/p>\n<p><b>The bottom-up approach is used most often on products or processes that already exist.<\/b><span style=\"font-weight: 400;\"> It looks at each component individually &#8211; then as a part of bigger and bigger systems. Sound familiar? The first steps we outlined for the FMEA approach are inherently bottom-up. They say to list all your components and assess their potential failures one by one.<\/span><\/p>\n<h3><b>Step 2: Determine your parameters<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">You get to choose whether to make this a qualitative or quantitative analysis. If you have rich historical data, go quantitative.<\/span><\/p>\n<h4><b>Step 2a: Qualitative parameters<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">As in the FMEA, you will look at severity and occurrence.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The goal is to label the failure:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Catastrophic:<\/b><span style=\"font-weight: 400;\"> Considerable losses to the environment, human life, and business operations.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Harmful:<\/b><span style=\"font-weight: 400;\"> The system is compromised and cannot perform its intended function. Trying to use the system causes additional damage.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Marginal:<\/b><span style=\"font-weight: 400;\"> There is some level of degradation, but it can still perform its functions.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Minor:<\/b><span style=\"font-weight: 400;\"> Although there is degradation, the component\/step continues to function optimally.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>No impact:<\/b><span style=\"font-weight: 400;\"> You do not know whether a failure has occurred.\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The official military standard for criticality analysis uses a specific 1 to 10 ranking:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5537\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking.png\" alt=\"severity ranking example\" width=\"624\" height=\"324\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-300x156.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-451x234.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-554x288.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-93x48.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-540x280.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/severity-ranking-100x52.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Example of severity ranking according to MIL-STD-1629. Source: <\/span><\/i><a href=\"https:\/\/www.wbdg.org\/FFC\/ARMYCOE\/COETM\/tm_5_698_4.pdf\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">WBDG<\/span><\/i><\/a><\/p>\n<p><span style=\"font-weight: 400;\">In other cases, there are four severity levels for FMECA instead of our original five. Frankly, it\u2019s different in just about every industry.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">After that, <\/span><b>rank the chances of occurrence<\/b><span style=\"font-weight: 400;\"> according to your team\u2019s designated FMECA procedure, such as the table below:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5538\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA.png\" alt=\"Failure rates for FMECA\" width=\"624\" height=\"273\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA-300x131.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA-451x197.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA-554x242.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA-93x41.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA-540x236.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/Failure-rates-for-FMECA-100x44.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Failure rates for FMECA. Source: <\/span><\/i><a href=\"https:\/\/www.wbdg.org\/FFC\/ARMYCOE\/COETM\/tm_5_698_4.pdf\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">WBDG<\/span><\/i><\/a><\/p>\n<h4><b>Step 2b: Quantitative parameters<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Instead of a gut check (like all the rankings so far), this step lets you fall back on hard data. Looking at known failure rates, use specific mathematical formulas with specific variables to calculate the failure mode criticality number.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">You probably want us to go into more detail, but those advanced concepts are far beyond the scope of this article. For some juicy reading, start on page 4-7 of <\/span><a href=\"https:\/\/www.wbdg.org\/FFC\/ARMYCOE\/COETM\/tm_5_698_4.pdf\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">this technical manual<\/span><\/a><span style=\"font-weight: 400;\"> instead:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5539\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example.png\" alt=\"FMECA equations example\" width=\"383\" height=\"321\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example.png 383w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example-300x251.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example-284x238.png 284w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example-348x292.png 348w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example-72x60.png 72w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-equations-example-100x84.png 100w\" sizes=\"auto, (max-width: 383px) 100vw, 383px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Example FMECA equations from the US Army\u2019s technical manual MIL-STD-1629<\/span><\/i><\/p>\n<p><span style=\"font-weight: 400;\">Anyway, when you are done with all that, you will have a <\/span><b>failure mode criticality number representing how often a particular failure node occurs<\/b><span style=\"font-weight: 400;\">. It quantifies the consequences of that failure by summing up all the failure criticality numbers.<\/span><\/p>\n<h3><b>Step 3: Adjust failure rate for redundancy<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">During the FMEA process, you discovered potential failures and took corrective action. One of those recommended actions may have been introducing redundancy <\/span><span style=\"font-weight: 400;\">\u2060\u2014 <\/span><span style=\"font-weight: 400;\">backup systems that correct for the same failure but in different ways.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Again, accounting for those redundancies requires complex mathematics, but MIL-STD-1629 is an excellent reference.<\/span><\/p>\n<h3><b>Step 4: Calculate criticality number or RPN<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">If this is a quantitative CA case, you got your criticality number in step 2b. For quantitative, you calculate your risk priority number. Depending on your industry and detection methods, you may calculate RPN using occurrence X severity X detectability as outlined above. Otherwise, your particular case may only require occurrence X severity.<\/span><\/p>\n<h3><b>Step 5: Create a criticality matrix<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">A criticality matrix is a visual representation of failure modes ranked by their likelihood and severity.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5540\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix.png\" alt=\"Example of a criticality matrix\" width=\"624\" height=\"240\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix-300x115.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix-451x173.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix-554x213.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix-93x36.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix-540x208.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/Example-of-a-criticality-matrix-100x38.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Example of a criticality matrix. Source: <\/span><\/i><a href=\"https:\/\/www.semanticscholar.org\/paper\/Criticality-assessment-of-GIS-components-Al-Suhaily-Meijer\/0f4eede699b105280b990fba878ee5cc0fdf9734\/figure\/4\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Semantics Scholar<\/span><\/i><\/a><\/p>\n<p><span style=\"font-weight: 400;\">Severity is plotted on the x-axis and probability (frequency) on the y-axis. Components with a <\/span><i><span style=\"font-weight: 400;\">low<\/span><\/i><span style=\"font-weight: 400;\"> failure mode will end up in the bottom right (the green area), while <\/span><i><span style=\"font-weight: 400;\">high<\/span><\/i><span style=\"font-weight: 400;\"> failure mode components will be in the top left (the red area).<\/span><\/p>\n<h3><b>Step 6: Determine critical items and take appropriate action<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">I\u2019m sure you can guess which region of the criticality matrix deserves your full attention. Take steps to lower the chances of any of those malfunctions happening:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Modify your designs to control for potential risks posed by parts\/steps you cannot change.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Make changes that reduce the likelihood of failure.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Create redundancies that add an extra layer of security and make the systems more <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/fault-tolerance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">fault tolerant<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Replace specific pieces to optimize performance.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Build up your systems that detect failures early on.<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Of course, after changing anything, update your calculations and your matrix. Rinse and repeat until you no longer have critical issues.<\/span><\/p>\n<h2 id=\"FMECA-example\"><b>FMECA example<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Let\u2019s look at how this could be applied in the oil and gas industry.<\/span><br \/>\n<span style=\"font-weight: 400;\">In the example below, you broke the water supply (the primary system) into different subsystems. Each subsystem gets its own criticality number.<\/span><br \/>\n<img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-5541\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example.png\" alt=\"FMECA example\" width=\"624\" height=\"357\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example.png 624w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example-300x172.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example-416x238.png 416w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example-510x292.png 510w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example-93x53.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example-540x309.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMECA-example-100x57.png 100w\" sizes=\"auto, (max-width: 624px) 100vw, 624px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">FMECA applied in the oil and gas industry (open in new tab). Source: <\/span><\/i><a href=\"https:\/\/blogs.dnvgl.com\/software\/2016\/04\/fmeca-ram-studies\/\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">DNV<\/span><\/i><\/a><\/p>\n<p><span style=\"font-weight: 400;\">Immediately, we can see that these folks did <\/span><i><span style=\"font-weight: 400;\">both <\/span><\/i><span style=\"font-weight: 400;\">qualitative and quantitative criticality analyses. The redundancies are accounted for in all the subsystems. You can see that they included the failure rate both with and without redundancies.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Notice that the RPN values are all below 10. Does that mean the failure mode is not critical? Not necessarily. Remember, early in the process, your team set the thresholds for your particular industry or scenario.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Nonetheless, we can see that the severity for the storage system is higher than for the pumping system.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">What can be done to remedy that? Remove the pumping system\u2019s redundancies, of course. <\/span><i><span style=\"font-weight: 400;\">Just kidding!<\/span><\/i><span style=\"font-weight: 400;\">\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The goal is for the risk assessment to come in low across the board. You know that. For the heat exchanger failure mode, better controls to detect scaling due to untreated water and a more robust <\/span><a href=\"https:\/\/limblecmms.com\/blog\/the-ridiculously-simple-preventive-maintenance-plan\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">preventative maintenance plan<\/span><\/a><span style=\"font-weight: 400;\"> are some of the ways to adjust the criticality and RPN values.<\/span><\/p>\n<h2 id=\"if-it-is-worth-doing-it-is-worth-doing-right\"><b>If it is worth doing, it is worth doing right<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Performing FMECA and FMEA analysis is not something that should be done just for the sake of it. It is a fairly complex process that brings huge benefits, but only if it is executed correctly.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This article aims to provide a comprehensive overview so you have a better idea of what to expect. For those that are doing it for the first time, it is recommended to first go through <\/span><b>proper FMEA training. <\/b><a href=\"https:\/\/asq.org\/quality-resources\/six-sigma\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">Six Sigma<\/span><\/a><span style=\"font-weight: 400;\"> is a great place to start for engineers and non-engineers alike.<\/span><\/p>\n<h2 id=\"final-thoughts\"><b>Final thoughts<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Until now, we have mentioned a CMMS only as a data source to help you identify and quantify ways that your product or system could fail. But knowledge is only valuable when put into action.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">When all is said and done, <\/span><b>your CMMS is how you will ensure that your plans are carried out<\/b><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">You may determine that wear and tear on your manufacturing line\u2019s conveyor belts is the root cause behind your excessive downtime. In a robust <\/span><a href=\"https:\/\/limblecmms.com\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">CMMS like Limble<\/span><\/a><span style=\"font-weight: 400;\">, you can <\/span><b>create a preventive maintenance routine to check conveyor belts weekly<\/b><span style=\"font-weight: 400;\">. Limble will:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">generate the task<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">automatically assign it to the right team member<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">log when it is completed<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">tabulate the cost of the task in labor and parts<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">update inventory counts as spare parts get used<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">alert Purchasing when parts run low (long before they run out)<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Finally, Limble compiles reports showing the financial impact as your maintenance team transitions from run-to-failure (fixing things that broke) to a <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/preventive-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">preventive maintenance strategy<\/span><\/a><span style=\"font-weight: 400;\"> (keeping things from breaking in the first place).<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Whatever action you prescribe based on your FMEA or FMECA analysis, <\/span><b>you look good when you can translate it to dollars saved instead of (billions of) dollars lost<\/b><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p><a href=\"https:\/\/limblecmms.com\/demo-request\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">Request a demo<\/span><\/a><span style=\"font-weight: 400;\"> to start the journey.<\/span>[\/vc_column_text][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text css=&#8221;&#8221;]Remember when Samsung had to recall the Galaxy [&hellip;]<\/p>\n","protected":false},"author":24,"featured_media":29411,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[740],"tags":[],"class_list":["post-2302","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-metrics"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Performing FMEA and FMECA with Examples for Maintenance<\/title>\n<meta name=\"description\" content=\"We explain what FMEA and FMECA are, why they are used, and provide a detailed outline for how to perform both FMECA and FMEA analysis.\" \/>\n<meta name=\"robots\" content=\"index, follow, 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