The FMEA (Failure Mode and Effect Analysis) is a methodical approach to evaluate and prioritize risks about possible points of failure, this world known methodology is applied in several areas of knowledge as process, product…
The FMEA application depends on the user’s rigor and discipline and one the most common problem faced by the team is to perform regular review of the FMEA study.
However this activity is fundamental, if not regularly reviewed the results of the FMEA application are not maximized and are restricted to the reduction of the problems identified during the initial study.
Automakers are concerned with this matter, especially for the Process FMEA, and some OEM such as General Motors, PSA, Renault introduced as a specific requirement the use of a tool called Reverse FMEA to address the problem of FMEA revisions.
The Reverse FMEA is a structured process of Continuous Improvement that aims to ensure the permanent updating and progress of an FMEA study. It is a tool to support the application of FMEA.
The reverse FMEA is a review – done at the shop floor (reality) – of all failure modes included in the Process FMEA, conducted by a multifunctional team, focused to verify that all failure modes have proper controls (prevention / detection).
The main activities to be perform for a Reverse FMEA are:
- Review of the current process in the workstations
- Diagnosis of the actual situation of the previous plan of action
- Test of actual process efficiency
- Collect and analyze the actual performance results
- Update and integrate objectives and requirements to the process
- P-FMEA revision and new action plan definition
The Reverse FMEA can be carried out as soon as the final process is operational.
The systematic application of the FMEA Reverse tool brings many benefits to the company, such as:
- Get experience and knowledge of the production teams.
- Maintain, review and systematically improve the FMEAs
- Reduce risks and costs of non-quality
- Build a structured knowledge base
- Improve production processes.