FMEA

Excel template for Failure Mode Effects Analysis (FMEA)
Also known as Error Mode Effects Analysis (EMEA)
and Design DFMEA and Process PFMEA

The FMEA template comes with the DMAIC Lean Six Sigma bundle of templates,
an entire suite of DFSS tools to anticipate problems, and design processes and products to reduce risks.

---

Have you ever tried to use Excel's Filter or PivotTable features on a worksheet that contains merged cells?

Filtering and PivotTables don't work on most home-grown FMEA Excel templates.

Filtering and PivotTables do work on the Systems2win FMEA template.

How did Systems2win accomplish such an amazing (and useful) thing?

Download your own free trial, and see for yourself.

That's just one (huge) difference between Systems2win and home made FMEA templates. Here are some more...

• Optionally supports data in multiple languages
• Integrates with Root Cause Fishbone Diagram
• User-defined Class Code table
  (to call attention to alert conditions in ways far more useful than the outdated RPN system)
• Comes with full suite of templates needed for creating and continuously improving DFMEA's and PFMEA's
• Has all the features common to all Systems2win templates:
  (easily personalized using all you know about Excel, lots of free online training, consistent standardized tools for consistent standardized results...)

Sample FMEA example: Failure Mode and Effects Analysis Excel template

Features of the Systems2win FMEA Template

Like every Systems2win Excel template, the FMEA xls is fully editable and customizable, and comes with a sample FMEA sheet containing extensive online help and online training - so that your team members can devote their valuable time to actually performing analysis and problem solving - rather than "inventing an FMEA form".

• User-defined dropdown data lists

  dramatically reduce data entry errors -
  thereby making Filter so much more reliable when you want to filter and analyze your list

• Links to related documents

  Link Icons make it easy to link to FMEAs, Work Instructions, videos, and any other related documents

• User-defined document headers

  Header fields at the top of the page are easily personalized for the information YOU need -
  in a way that your personalizations are automatically found and transferred to your new template every time you upgrade. Learn more.

• All of the familiarity of Microsoft Excel

  and the consistent features for power and ease of use
  common to all 150+ Systems2win templates for Continuous Process Improvement

  "When you've learned how to use one, you've learned how to use them all"

• Sample data

  View this PowerPoint to learn more about the sample data that you can study and play with on the Sample worksheet of your FMEA template (download free trial)

 

Easily export data from your Excel FMEA spreadsheet to the Systems2win Fishbone Diagram template to perform Root Cause Analysis

---

New Features

A major upgrade was released in May 2012 - with many new FMEA software features, including...

AIAG Compliant Forms F or G

Form G has 2 extra columns for ID and Process Requirements

Data in Multiple Languages

Like all other Systems2win Excel templates...

click a button, and now the row & column headers and the help for your template
are in Chinese, Spanish, Portuguese, or any language that you choose.

Unlike most other Systems2win templates...

The FMEA template now includes special features to easily maintain your DATA in multiple languages.

Click the 'Select Language for Data' button,
and now the DATA in your FMEA form displays your chosen language.

Automatic formatting of repeat data

Merging cells create a lot of problems in Excel:

1. Filter doesn't work right
2. Pivot tables don't work right
3. You have to unmerge cells in order to insert, delete, or move rows
4. Then you forget to re-merge them - or your formatting gets messed up
5. Frequent merging and unmerging can cause the entire workbook to become corrupted

So the new FMEA template now has special features that eliminate all of the problems of merged cells.

In some (well-marked) columns, you can now copy & paste identical data in multiple cells,
and it will automatically:

1. White out the repeat data, and format the borders so that it LOOKS to the human eye like merged cells
2. Be smart enough to know when repeat data really should be visible
   (because the data happens to be the same for the next bordered line item)
3. Allow you to easily use Filter and Pivot Tables - with NO merged cells !!!
   (see 'Advanced Training' on Help sheet for how to create new FMEAs from a Master)

And if your data is in multiple languages,
then when you enter your repeat data for your Primary Language,
the borders are correctly formatted for the main FMEA form and all other language translations.

Vastly improved training

• Better pop-up help when you click any column header
• Sample page includes 'Additional Training' for each column
• Sample page includes clear explanation of how each column is related to its neighboring columns
  (which is one of the most common sources of confusion when using an FMEA template)
• Better online training - to guide you through the 'how to' process
• Better clarity of the relationships between the many documents and mehtods that can optionally be used
• Expert consulting now available - either on-site or by web conference.
  Contact us for a referral to a qualified consultant
  that has experience developing FMEAs for several industry-leading Fortune 500 companies.

Bookmark = DFSS

Full suite of DFSS tools for all steps of the FMEA process

Even if your company already owns and uses some other FMEA software...
you still might benefit greatly from all of the other Design for Six Sigma templates
that are used in the processes of creating DFMEAs, QFDs, and PFMEAs.

Note: These same tools are used for Design for Six Sigma, Design for Manufacturability, Design for Lean Manufacturing,
DMADV, and any other similar buzzwords that some author coins in the future.

Design for Six Sigma tools the Systems2win Six Sigma bundle comes with the entire suite of DFSS templates needed to do FMEA and QFD
FMEA Failure Modes and Effects Analysis Also known as EMEA Error Modes and Effects Analysis Design DFMEA and Process PFMEA Six Sigma tool to anticipate problems, and design processes and products to reduce risks Download free trial FMEA template
Control Plan To more diligently control the most severe or likely risks   Learn more about the Control Plan template
Root Cause Analysis also known as Cause and Effect Diagram, or Ishikawa Root Cause Analysis Fishbone Diagram To identify the root causes of a problem, and brainstorm creative ideas for solving them Download free trial Fishbone Diagram	Fishbone Diagram more info
Brainstorming & Affinity Group Tool Six sigma template to brainstorm ideas, then quickly organize them into affinity groups to stimulate even more ideas
Thought Map also known as Thought Map Relations Diagram To identify root causes of a complex, nonlinear problem. (Use a Cause and Effect Fishbone Diagram to identify root causes of less complex, linear problems.)
8D Problem Solving also known as Corrective Action Report To provide a systematic way for a team to resolve a problem that has uncertain root causes - in a way that systematically ensures that root causes have been identified and verified - and that permanent corrective actions are validated for effectiveness and instituted in a way that prevents the problem from ever recurring or escaping again.	8D Report
Corrective Action Request also known as Supplier Corrective Action The Supplier Corrective Action Report template does not pre-suppose that all of the rigid formality of the 8D process will be required.This simple Word template is structured as a one-page letter that simply requests the supplier to deal with a non-conformance issue.	Corrective Action
SIPOC Diagram Use the SIPOC template to identify and eliminate wastes of any kind: hazardous wastes and emissions, scrap, energy, packaging... Download free trial SIPOC template
Process Flow Diagram Prior to creating a PFMEA - use the Process Flow Diagram to identify Sources of Variation, and desired Deliverables (ideal Functions) for each Process Step.	Process Flow Diagram
P-Diagram aka Parameter Diagram Prior to creating an FMEA - use the p diagram to analyze Inputs and Outputs and Noise Factors and Control Factors that can affect performance of desired Ideal Functions, and mimimize Error States.	P-Diagram template
Interface Matrix Prior to creating a DFMEA - use the Interface Matrix to indentify and clarify interfaces between environment, systems, sub-systems, and components that are beneficial or detrimental to functionality. Also provides P-Diagram input/outputs and noise factors
Function/Requirements worksheet aka Item/Function worksheet To identify and clarify Functions and corresponding Requirements prior to completing the Function and Requirements columns of the FMEA form
Characteristic Matrix aka Product Characteristics Matrix When creating a PFMEA - identify process steps that can compromise characteristics of the product or service that are noticeable and important to the customer.
Design Verification Plan and Report aka DVP&R, DVPnR, DVPR Formalized testing of product or service to ensure compliance with all requirements.
House of Quality Quality Functional Deployment Matrix One of the most sophisticated quality improvement tools - to provide a guiding structure for a cross-functional product development team to rapidly design and deploy new products and services Download free trial QFD template	House of Quality Excel template
Cause and Effect Matrix A simpler quality improvement tool than the QFD - with a similar objective: To identify the few process input variables that provide the greatest opportunity to improve the key process outputs Video: Intro to QFD and Cause & Effect Matrix
Customer Segmentation Worksheet Quality improvement template to identify and focus attention upon the sub-segments of customers that generate the most value from each product or service
Voice of the Customer Data Collection Worksheet To plan and manage the collection of Six Sigma customer data - from existing company data, listening posts, surveys, interviews, point-of-use observation, and more
Voice of the Customer Requirements Translation and Kano Analysis Quality control template to translate potentially vague customer comments into measurable functional requirements - thereby strengthening your team's ability to design and deliver products and services that truly delight your customers

---

Bookmark = Training

FMEA Training & Demo Videos FMEA Videos & Training FMEA video (13 mins) Tips for using a VC worksheet 8D Problem Solving Additional training relevant to this template The Sample and Help worksheets of every template always contain training relevant to THAT template Quick Start Initial Training What every user should know to use any Systems2win template Language Translations Every Systems2win Excel template is available in ANY language How to Personalize your Systems2win templates Additional Tips to personalize your FMEA template Support & Training home page   Also see the rest of the Six Sigma tools that come bundled with your FMEA template

Make sure your sound is on Video Help   FMEA video

---

Primary objectives of any Lean Six Sigma initiative
are to reduce variability and reduce risk

and your Systems2win templates reduce the risk and variability in your systems for reducing risk and variability

Failure Mode and Effects Analysis is one of the most popular Lean Six Sigma methodologies
to reduce variability and reduce risk in both the end product or service that is delivered to the customer,
and the processes that make or deliver it.

FMEA analysis is used to:

1. Reduce development time and cost to Initially design any system, product, or process
2. Continuously improve the quality, reliability, and safety of any system, product, or process
3. Anticipate quality problems, and take actions to minimize risks
4. Prevent recurrence of problems surfaced though 8D problem solving and Corrective Action Reports
5. Prioritize risk reduction efforts
6. Assess the effectiveness of attempts to control variability
7. Improve customer satisfaction

---

What's the difference between FMEA & EMEA? Some systems and processes are more focused on "errors" rather than "failures". The concepts are identical, even when the title changes to Error Mode and Effects Analysis (EMEA). Your Systems2win Excel template can be easily personalized with the label of your choice. What's the difference between DFMEA & PFMEA? Although the same Systems2win template can be used for either a Design FMEA or a Process FMEA, there are substantial differences in when and how they are used. (as explained below) Are there more? Yes. The same FMEA template can be used for Concept, Software, Tools, and Environmental FMEA.

 

DFMEA (Design)	PFMEA (Process)
Initiated early in the design process, and completed before production design is released	Initiated early for feasibility study, and completed before tooling for production
Serve as a living document, being updated as changes happen, perhaps long after intial completion	Serve as a living document, being updated as changes happen, perhaps long after intial completion
Reduces risks of failure in the design process	Reduces risks of failure in production processes
Helps to objectively evaluate functional requirements and design alternatives	Helps to thoroughly identify and evaluate process functions, requirements, and alternatives
Identify and minimize potential failure modes and their effects early in the design process	Identify and evaluate potential product and process failure modes, and their effects on customers and the process itself
Any process failure modes that can't be eliminated in the DFMEA get passed to the PFMEA	If possible design changes are identified that might reduce process risk - then DFMEA gets involved again
Produce a prioritized list of potential failure modes - ranked by their effect on the customer	Prioritize the process variables to focus upon - to reduce occurrence and increase detection
Provide a format for identifying issues, and recommending and tracking actions	Establish priorities for preventive and corrective actions and controls
Accumulate lessons learned - for future design changes, and design of similar products	Accumulate lessons learned - for future process changes, and production of similar products
Multiple inter-related DFMEAs - to consider every aspect of design (from component to system)	Multiple inter-related PFMEAs - to consider every aspect of production, (from receiving to shipping), at every level (from component to system)

Bookmark = related

Inter-related FMEAs

The V Model illustration below helps to visually depict the inter-related engineering cycle.

DFMEAs (and related documents) are used in the left side of the V.
PFMEAs (and related documents) are used in the right side of the V.

Illustration courtesy of Strategic Quality

Are Failure Modes, Effects, and Causes getting confusing?

"The potential failure mode may also be the cause of a potential failure mode in a higher level, or be (or lead to) the effect of one in a lower level component." AIAG FMEA Manual, Rev 4

Effects of lower level Component & Sub-system FMEA's
are often Modes of higher level System and Sub-system FMEA's.

And DFMEA (design) Causes often relate to PFMEA (process) Failure Modes.

If your team starts wanting to use redundant items in your dropdown lists
for Failure Modes, Effects, and Causes...
then you probably need to better define the scope of your inter-related FMEAs.

Illustrations courtesy of Stategic Quality

The Sentencing Technique

For any level of FMEA, the cause is of the failure mode and never of the effect.

To guarantee proper classification of Cause, Failure Mode, and Effect...
use the Sentencing Technique to relate cause back to failure mode, not back to effect.

1. State the failure mode.
2. Ask "what could be the result of that failure mode?" - the answer will be the effect.
3. Ask "what could that failure mode be due to?" - the answer will be the cause.

---

How to do it - the FMEA Development Process

DFMEA	PFMEA
Assemble cross-functional team	Assemble cross-functional team
Gather and review information to understand the characteristics and functional requirements of the systems, sub-systems, and components being designed	Gather and review information to understand the functional requirements to produce the deliverable product or service
Source documents might include: Similar DFMEAs Boundary Diagrams - to clarify scope boundary, and the physical and logical relationships between components Parameter P-Diagram - to analyze inputs and outputs, and factors that can affect performance Drawings & schematics Bills of Materials Interface Matrix and/or Design Matrix - to identify and clarify system interfaces Function/Requirements worksheet Function Tree QFD 8Ds, complaints, warranty claims, and other sources of quality and reliability history Tip: You can use the 8D for Failure Prevention Analysis (FPA)	Source documents might include: The DFMEA Similar PFMEAs Process Flow Diagram - showing the flow of the product or service through the process, including inputs, outputs, and sources of variation Parameter P-Diagrams - to analyze inputs and outputs, and factors that can affect performance Drawings and other design documents Bill of Process and/or routings (perhaps from similar processes) Function/Requirements worksheet Characteristic Matrix - to identify which process operations affect which product characteristics 8Ds, complaints, warranty claims, and other sources of quality and reliability history
Your leaders should have already personalized your master template for: Your company's default Dropdown lists (on the DV worksheet) Your company's default Team structure (on the Team worksheet) Your company's default Rating scales (on the Rating worksheet) Your company's default Header fields (on the VC worksheet)
Complete the header information at the top of the DFMEA	Complete the header information at the top of the PFMEA
Complete the form - mostly left to right Click the gold column headers for pop-up help - and scroll down to see Additional Help in the lower section of the Sample worksheet
DFMEA: First column = Item Enter Item number and description The first row of a new Item or Process is a visual section break. There should be no data in that row for any other column.	PFMEA: First column = Process Step Enter Process Step number and description
Function: DFMEA: What is this item supposed to do? Start with an action verb.	Function: PFMEA: What is this step in the process supposed to do? Start with an action verb.
Requirement: DFMEA Measurable parameters, specifications, or characteristics that the Function must deliver.	PFMEA Form F - has a single 'Requirements' column. PFMEA Form G - has a separate column for Process Requirements, so use the 'Requirements' column for Product Requirements.
Potential Failure Modes: Brainstorm using 4 Thought Starters: 1) No function 2) Partial, excessive, or degraded function over time 3) Intermittent function 4) Unintended function
Potential Failure Effects When it fails in this way, what are the potential effects experienced by... the end customer? production, safety, regulations, other systems, subsystems, components?
Severity - You enter 1 Severity code per Effect, and when you click the Recalculate button, it will auto-calculate the Max Severity code per Failure Mode.	Before you print, publish, or analyze - always remember to click the Recalculate button - to update the values for 'Max' Severity per Failure Mode and 'Low' Detection per Potential Cause.
Classification Code Is auto-populated based on the table that you define on the Rating sheet Use Class Codes (not RPN), to determine when Action is required. There is no threshold RPN value that requires or excuses Action.
Prevention and Detection Control Methods - that are currently being used to prevent or detect: 1) the Failure Mode 2) the Cause of the Failure Mode
Actions Recommended - to improve Prevention or Detection Top row per Cause can never be blank. Can be "None" Action is required unless Class = 1
Who is Responsible? The dropdown list is defined on the Team worksheet - which also serves as your Team Attendance Log (as required by ISO)
The second Risk Priority Number (RPN) is calculated only for those rows that contain a Completed Action
Links Use the cell above the gold headers to link to documents that are related to the entire FMEA (not just specific line items) Documents such as Control Plans, 8D's, Design Verification Plan & Review (DVP&R), other FMEA's, etc
User Fields See the Sample sheet for examples of User Fields that can make your FMEA far more valuable for analyzing your data using Excel's familiar features for Filter and Pivot Tables.
Any time that the design changes - update all related documents - including all FMEAs, Design Verification Plan, QFD, checklists, etc.	Any time that the design or process changes - update all documents related to the process - including all FMEAs, the Control Plan, work instructions, audit checklists, etc.

 

---

Bookmark = ControlPlan

FMEA Control Plan Excel template

After taking initial Corrective Actions prescribed in the PFMEA,
the next step is to use a Control Plan to more diligently control product and process characteristics that have high Severity, Occurrence, and/or Risk Priority Number (RPN).

More FMEA examples

Learn more about the Systems2win Control Plan template

---

Bookmark = personalize

How to personalize your FMEA template

This training is for templates released May 2012 or later.
If you have older templates, these features will become available when you upgrade.

Before distributing your master FMEA template, your leaders should have already personalized it.
(as well as the Control Plan, P-Diagram, Process Flow Diagram, and all of the other templates used in the various stages of DFMEA and PFMEA development)

In addition to the standard instructions for how to personalize your Systems2win templates,
here are some additional personalization features unique to your FMEA template...

Personalize your dropdown lists

User-defined dropdown lists dramatically reduce data entry errors -
thereby making Filter so much more reliable when you want to filter and analyze your list

The FMEA template has more dropdown lists than any other Excel template, with lists for Item/Process, Function, Requirement, Process Requirement, Failure Mode, Cause, Effect, Prevention Method, Detection Method, Action, and more.

Your leaders should have already personalized the DV sheet in your master template with YOUR company's typical data - and then you as the document Author can easily add additional items to each list for things that are unique to YOUR working document.

Personalize your user-defined header fields

Use the VC worksheet to personalize the fields at the top of the document -
so that YOUR template requires users to enter the data needed by YOUR company.

(In a way that your personalized user-defined header fields are automatically found and transferred to your new template every time that you upgrade)

Personalize your rating scales

On the Rating sheet, you can personalize your rating criteria using User Substitutions -
in the same way that you can personalize text in ANY Systems2win template.

And you can also enter your own Class Code numbers in the Class Code table - knowing that your Class Codes will be automatically found and transferred every time you upgrade.

And you can even overwrite the 3 blue Detection columns - which will also be automatically transferred each time you upgrade.

Use your Customization Log

All of the above personalizations will be automatically found and transferred every time your upgrade your master templates.

If you make any other changes
(that won't be automatically found and transferred every time that you upgrade),
then be sure to use your Customization Log - to jot down a quick reminder to make those same changes to your new template each time you upgrade.

(But it should be a short list, because the Systems2win Personalization Upgrade Utility will automatically find and transfer most common personalizations)

 

Your leaders should have already personalized your master template with all of the above -
and then you (as the Author of YOUR working document),
can make further personalizations unique to your working document -
including changes to any of the above, and...

Personalize your team roles

On the Team worksheet, define your team - including Roles, Responsibilities, contact information, and the Team Codes (which will appear in the dropdown lists on the main FMEA form).

You shouldn't need to personalize anything about the Attendance Log - which is already pre-formatted to track the total number of meetings and total number of hours in meetings for each Team Member (in compliance with ISO requirements).

Personalize your Failure Modes, Effects, and Causes

Failure Modes for one level of FMEA might be Effects or Causes at another level.

Therefore, it is impossible for your master FMEA to come with pre-defined Failure Modes, Effects, and Causes that will be correct for every level. So it is up to your team to use the Sentencing Technique to get them right for YOUR FMEA. (See training for Inter-Related FMEAs)

---

Bookmark = Reading

Suggested Reading and Resources

         

You can also search the internet to download the free AIAG FMEA manual.

Personalized training and consulting is available from Joe Adams of Strategic Quality,
who helped to design and develop the Systems2win FMEA template.

---

These FMEA templates come bundled with all the other Six Sigma tools     and you can empower every team member with steep quantity discounts