FMEA Template

Introduction

In order to prevent failures from happening, it is essential to make a list of possible failures and address them before they manifest. This activity is known as Failure Mode and Effects Analysis. However, for the analysis to be completed properly, a FMEA template should be used. A FMEA template is basically a paper or table, an FMEA Excel template for example, which helps one to fully cover all the details of the analysis and conduct a failure mode and effects analysis properly.

What is a FMEA Template?

A Failure Mode and Effects Analysis (FMEA) is an analytical tool, which helps to determine the potential failure modes in a system, a product, or a service. It also focuses on the effects that these failures may have, their causes, and the existing controls to prevent these failures.

To make the description of such analysis clear, a FMEA form or a FMEA worksheet (both are other names for a FMEA template) should be used. These documents help to remember all the important points and calculate the risk priority number.

Understanding FMEA Briefly

One should also remember that there are different FMEA types, such as Design FMEA, Process FMEA, and System FMEA. Therefore, when using a FMEA template, one should choose a certain type of FMEA in accordance with the task.

Moreover, when using such documents, it is vital to follow the established order of filling in its cells. For instance, a number of FMEA templates have the following structure:

• Process step/function;

• Potential failure mode of the process step/function;

• Potential failure effects;

• Severity;

• Potential causes/mechanisms of failure;

• Occurrence;

• Current process controls;

• Detection;

• Risk priority number (RPN);

• Recommended actions;

• Responsibility and target date;

• Additional actions taken and RPN after action.

This structure can be seen in most FMEA documents. Now, let’s take a closer look and define the purpose of each cell in a FMEA Excel template.

Key Components of an FMEA Template

Each of these cells has a certain goal, and it is important to understand the purpose of each of them. When filling out a FMEA template, it is recommended to provide precise information in all the cells.

1. Process step/function

In this particular cell, the analyzed process step, function, or product should be described. This entry will be the point from which the description will start.

2. Potential failure mode

Next, a failure mode should be defined. It should provide an idea of how the process step or function can go wrong.

3. Potential failure effects

Here, the results of the failure that has been defined should be described. In other words, what can happen if a failure mode occurs?

4. Severity (S)

In this column, the severity score should be defined. It is usually defined on a scale from 1 to 10.

5. Potential causes/mechanism of failure

What causes can lead to a failure? For this reason, this cell is devoted to the causes and mechanisms of failure.

6. Occurrence (O)

The frequency of the occurrence of failure should be defined here. Again, it is defined on a scale from 1 to 10.

7. Current process controls

What controls exist to prevent failure occurrence and failure detection? This information should be provided in this cell.

8. Detection (D)

This cell is similar to the previous one. To define the likelihood of detecting the failure, use a scale from 1 to 10.

9. Risk priority number (RPN)

This part is rather simple as it is enough to calculate the RPN score using this formula (RPN= S x O x D).

10. Recommended actions

Here, the recommended actions to eliminate the problems that have been determined should be defined. These actions should be aimed at reducing the S, O, and D scores.

11. Responsibility and target date

Who will be responsible for taking the recommended actions and when? This information should also be provided.

12. Additional actions taken

In this part, the actions that have actually been taken should be described.

13. RPN after action

Based on the actions that have been taken, the new RPN score will be defined.

By completing all the cells, it will be possible to take proper actions to prevent the failures from happening.

How to Use a FMEA Template?

There are several things that should be remembered when using a FMEA template. First, a proper scope should be identified and a team assembled. This team will have enough expertise to fill out each cell correctly. The members of the team should be able to define the potential failure modes.

Having identified the failure modes, the effects of these failures should be characterized. The severity, occurrence, and detection scores should be defined as well. It is recommended to provide some comments to each of these sections. Having filled out all the cells, the RPNs should be calculated to prioritize the list of problems. Then, it will be possible to develop a list of recommended actions, which will help address the problems.

When using a FMEA template, it is essential to follow the instructions. Only in this case, it will be possible to address all the problems that may occur. This document provides a clear picture of the situation and helps to develop appropriate recommendations.

Choosing the Right FMEA Template

However, it is essential to choose a FMEA template, which will help address the particular question. This document can be found in various sources, for example, on the Internet. There are numerous FMEA forms available, which are free of charge.

The choice of the most appropriate FMEA form depends on several factors.

• Type of FMEA: First, it should be defined what type of FMEA analysis will be conducted: Design, Process, or System.

• Industry Standards: There are also industry-specific FMEA templates, which should be used in accordance with the industry standards.

• FMEA Software: Another factor is the type of FMEA software that will be used. Usually, such software has an appropriate FMEA template built-in.

• Excel Template: However, an Excel version of the FMEA template can also be used.

Conclusion

All in all, there are several variations of a FMEA plan available. Each of them should be selected in accordance with the task. By using an appropriate FMEA form, one will be able to address the problems that may occur successfully.