Failures Modes, Effects, and Criticality Analysis (FMECA) is an integral part of the RCM Blitz™ process that is conducted alongside Process Verification Techniques, Consequence Reduction Tasks, Spare Parts Strategy, and Implementation Strategy.

Failure Modes, Effects, and Criticality Analysis (FMECA) is a methodology designed to identify potential failure modes in a product or process, to assess the risk associated with those failure modes, to rank the issues in terms of importance, and to identify and carry out corrective actions to address the most serious concerns.

FMECA Overview

In general, FMEA/FMECA requires the identification of the following basic information:

  • Item(s)
  • Function(s)
  • Failure(s)
  • Effect(s) of Failure
  • Cause(s) of Failure
  • Current Control(s)
  • Recommended Action(s)
  • Additional relevant details

Most analyses of this type also include some method to assess the risk associated with the issues identified during the analysis and to prioritize corrective actions. Two common methods include:

  • Risk Priority Numbers (RPNs)
  • Criticality Analysis (FMEA with Criticality Analysis = FMECA)

Basic Analysis Procedure for FMECA

The basic steps for performing an FMECA analysis include:

  • Assemble the team.
  • Establish the ground rules.
  • Gather and review relevant information.
  • Identify the item(s) or process(es) to be analyzed.
  • Identify the function(s), failure(s), effect(s), cause(s), and control(s) for each item or process to be analyzed.
  • Evaluate the risk associated with the issues identified by the analysis.
  • Prioritize and assign corrective actions.
  • Perform corrective actions and re-evaluate risk.
  • Distribute, review, and update the analysis, as appropriate.

Applications and Benefits of FMECA

The FMECA analysis procedure is a tool that has been adapted in many different ways. It can contribute to improved designs for processes, resulting in higher reliability, better quality, increased safety, enhanced customer satisfaction, and reduced costs. The tool can also be used to establish and optimize maintenance plans for repairable systems and/or contribute to control plans and other quality assurance procedures. It provides a knowledge base of failure mode and corrective action information that can be used as a resource in future troubleshooting efforts and as a training tool for new engineers.

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