The reduction of irregularities in the use of “process FMEA”

Abstract

Purpose Use of failure mode and effect analysis (FMEA) is a requirement of ISO/TS 16949. However, research has shown that there are inconsistencies in the way the technique is applied in automotive suppliers. The aim of this study is to identify these irregularities and to propose a strategy to minimize them. Design/methodology/approach Questionnaires were applied in seven of the main suppliers to a European automotive company, and ten FMEAs from each company were analyzed. Findings The study identifies irregularities in the development of process FMEAs and highlights seven factors that contribute to these inconsistencies. Based on these data, a strategy including a partially preconfigured FMEA form is suggested. When tested with three of the suppliers, the strategy was found to result in a significant improvement. Originality/value The study describes an application strategy for automotive companies to correct problems associated with the use of FMEAs. The strategy includes a partly parameterized spreadsheet for a cold stamping process that allows companies to implement their process FMEA in a collaborative supply chain environment.

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