FMEA (failure mode and effect analysis) template

Before beginning, collect process flowcharts or product diagrams, historical failure data, customer complaints, and warranty information. You’ll also need input from cross-functional team members with experience in design, manufacturing, quality, and service. Having this information ready ensures your FMEA captures comprehensive failure scenarios and realistic risk assessments.

Update your FMEA whenever you implement design or process changes, discover new failure modes, receive customer feedback indicating unknown issues, or implement corrective actions. At minimum, review your FMEA annually as part of your continuous improvement process. Treat it as a living document that evolves with your knowledge of potential risks.

Multiply the severity (1-10), occurrence (1-10), and detection (1-10) ratings for each failure mode. However, don’t rely solely on the numerical value—pay special attention to any failure with high severity regardless of its overall RPN. Establish thresholds for action (e.g., RPN>100 requires immediate attention) and ensure your ratings are consistent across similar types of failures.

Provide training on FMEA methodology before starting, and schedule dedicated working sessions with clear objectives. Assign a facilitator to guide discussions and prevent analysis paralysis. Focus on one process step or component at a time, and encourage diverse perspectives. Document assumptions and follow up on action items with specific owners and deadlines.