Capture all critical failure modes into FMEA in half the time with a simple decomposition table (Actual case study savings = $4,206,000)

Abstract

Preparing a good Failure Mode Effects Analysis (FMEA) has always been time consuming and problematic, because even small and simple systems often have a few to several hundred potential failure modes. This becomes a struggle between Effectiveness vs. Efficiency. Until now it has been hard to achieve Effectiveness with limited time, money and resources, and the push for Efficiency. Speed, deadlines and human frailty, often cause potentially critical Failure Modes (FMs) to be missed all together - not so effective. FMEA preparation can consume 50-80 hours, or more, for the FMEA Facilitator alone. This time is then matched or exceeded by each of the FMEA team members. This paper presents a solution to the problem, the “Decomposition Table” (Decomp Table), a simple structured and rapid method for systematically capturing all potential failure modes and prioritizing by criticality, before populating the FMEA. The Decomp Table establishes confidence that fai lure modes are not being missed (overlooked) in the FMEA and provides an audit path to check the FMEA for content and completeness. FMEAs can thus be completed in less than half the time. Time saved can then be focused on mitigation, to optimize system reliability. The 2013 case study applying this Decomp method revealed $4,205,817 in FMEA team labor hours.