How to Test for FMEA
FMEA is an acronym for Failure Modes and Effects Analysis. As the name implies, it is a step-by-step analysis of how something fails and is used in the product design process. For example, if a company planned to manufacture a new type of flashlight, a group of people that includes design engineers and product support personnel would have a meeting and discuss the potential ways the new flashlight could malfunction or otherwise fail to work properly. There may be a history of corrosion for a particular flashlight part or of flashlight batteries going bad if the flashlight gets too cold.
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Instructions
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Review the failure modes that were determined to exist from the analysis of the product. The failure modes will vary according to the product. Some failure modes can be procedural failures. The failure mode must be understood before it can be tested.
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Identify the tests that would provide an indication that failures could occur. This can best be accomplished in a group setting by using a dry erase board and markers. Encourage group participation to identify tests. For example, light bulb filaments could be tested for continuity if there is a potential for filaments breaking during the manufacturing process.
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Conduct a review process in which the proposed test for the failure mode is checked to see if it produces the desired results.
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Tips & Warnings
There may be multiple tests that can be performed to check for a particular failure mode. Conduct several dry runs of the different tests to see which one is most efficient at catching failures before they occur in products after they've been manufactured and sold.
Perform a trial run of the product in the field before releasing the product and its design to the manufacturing personnel. This helps to identify more potential failure modes, which can be tested for in advance.
Although FMEA can provide many avenues of failure of a particular product, there can be a host of unexpected failures that can occur due to unforeseen circumstances.
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Resources
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