The FMEA (Failure Modes and Effects Analysis) or Failure Modes and Effects Analysis is a systematic methodology used to identify, prioritize, and mitigate risks of failure in products, processes, or systems.
The goal is to anticipate what can go wrong, understand the effects of these failures, and take actions to prevent them or reduce their impact — promoting reliability, safety, and quality from development to production.
FMEA transforms technical knowledge and experience into preventive actions.
🧩 Types of FMEA
| Type | Main Application |
|---|---|
| Design FMEA (DFMEA) | Evaluates failure modes in the design of a product or system |
| Process FMEA (PFMEA) | Evaluates potential failures in the manufacturing or assembly process |
| Test FMEA (TFMEA) | Evaluates the coverage and reliability of tests applied to the product |
⚙️ Elements of FMEA Analysis
| Element | Purpose |
|---|---|
| Failure Mode | How the component or process can fail |
| Cause | What can cause this failure |
| Effect | Impact on the system or customer |
| Severity (S) | Level of severity of the effect |
| Occurrence (O) | Probability of the failure occurring |
| Detection (D) | Ability to detect before delivery |
| RPN (S x O x D) | Risk Priority Number — to rank actions |
🔧 How AJOLLY Testing Applies FMEA
AJOLLY Testing uses FMEA as a basis for the development of test benches, test interfaces, inspection procedures, and process control.
🛠️ FMEA Applied to Test Engineering
- Identification of common DUT failures not detected by current tests
- Evaluation of reliability of connections, sensors, and simulations in jigs
- Actions to mitigate failure risks during rework, recording, or calibration
📊 Integration with Real Data
- Feeding FMEA with real failure data, test history, and logs
- Connection with dashboards (Power BI) of Pareto, FPY, PPK, MTBF
- Prioritization of updates in test sequences and validation criteria
📁 Traceability and Standardization
- FMEA spreadsheets with controlled review and integration into the development flow
- Support for ISO 9001, IATF 16949, FDA, ANVISA audits
- Interface with process PFMEA and product DFMEA
With AJOLLY Testing, FMEA ceases to be a bureaucratic document and becomes a living tool for prevention, continuous improvement, and robustness of the test system.