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

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.