Tired of Process Failures? Use FMEA (Failure Mode and Effects Analysis) to Mitigate Risks in DMAIC!

In this video, we dive deep into FMEA (Failure Mode and Effects Analysis) and its critical role in the DMAIC process. Learn how to effectively use FMEA during both the Measure Phase and the Control Phase to identify, document, and address potential failure modes in your processes.

During the Measure Phase, FMEA helps us identify existing failure modes. We break down how to score each failure mode based on these three factors—occurrence, detection, and severity—using a scale from 1 to 9. By calculating the FMEA score, we can prioritize which failure modes need immediate attention.

In the Control Phase, we shift our focus to anticipating future failure modes. This is where FFMEA (Future Failure Mode Effects Analysis) comes into play. Documenting corrective actions for potential failures ensures that process owners are equipped with clear responses when issues arise. This proactive approach prevents processes from reverting to their original state after improvements are made.

Using real-world examples, like how commercial pilots handle in-flight failures with pre-documented procedures, we illustrate why having a robust FMEA process is essential for long-term success in continuous improvement projects.

🔑 Key Takeaways:

What is FMEA and how it fits into the DMAIC process
How to score failure modes based on occurrence, detection, and severity
The difference between using FMEA in the Measure vs. Control phases
How FFMEA helps anticipate future failures and ensures corrective actions are in place

Whether you're new to FMEA or looking to refine your understanding of its application in Lean Six Sigma projects, this video will provide you with practical insights and actionable steps.

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