fmea-facilitator

FMEA Facilitator

Overview

The FMEA Facilitator skill provides comprehensive capabilities for facilitating Failure Mode and Effects Analysis. It supports both Design FMEA (DFMEA) and Process FMEA (PFMEA), risk prioritization using RPN or AP methodology, and control plan integration.

Capabilities

• DFMEA (Design) facilitation
• PFMEA (Process) facilitation
• Severity/Occurrence/Detection scoring
• RPN (Risk Priority Number) calculation
• Action priority determination
• Control plan integration
• Recommended action tracking
• FMEA revision management

Used By Processes

• QMS-005: FMEA Facilitation
• SIX-005: Root Cause Analysis
• QMS-001: ISO 9001 Implementation

Tools and Libraries

• FMEA software
• AIAG templates
• Risk management tools
• Document management

Usage

skill: fmea-facilitator
inputs:
  fmea_type: "process"  # design | process
  scope: "Assembly process for Widget X"
  team:
    - "Process Engineer"
    - "Quality Engineer"
    - "Production Supervisor"
    - "Maintenance"
  process_steps:
    - step: "Install component A"
      function: "Secure component to housing"
    - step: "Torque fasteners"
      function: "Apply specified torque"
  methodology: "aiag_vda"  # traditional_rpn | aiag_vda
outputs:
  - fmea_worksheet
  - risk_assessment
  - action_plan
  - control_plan_inputs
  - revision_history

FMEA Process

Step 1: Planning and Preparation

• Define scope
• Assemble team
• Gather process flow
• Review similar FMEAs

Step 2: Structure Analysis

• Identify process steps
• Define functions
• Establish requirements

Step 3: Function Analysis

• Identify failure modes
• Determine effects
• Identify causes

Step 4: Failure Analysis

• Rate Severity
• Rate Occurrence
• Rate Detection
• Calculate risk

Step 5: Risk Analysis

• Prioritize risks
• Identify high-priority items
• Develop recommended actions

Step 6: Optimization

• Implement actions
• Reassess risk
• Update FMEA

Severity, Occurrence, Detection Scales

Severity (S) - Effect on customer

| Rating | Criteria |

|--------|----------|

| 10 | Safety hazard without warning |

| 9-10 | Safety or regulatory compliance |

| 7-8 | High customer impact |

| 4-6 | Moderate impact |

| 2-3 | Minor impact |

| 1 | No effect |

Occurrence (O) - Frequency of cause

| Rating | Frequency |

|--------|-----------|

| 10 | Very high (>100/1000) |

| 7-8 | High (20-50/1000) |

| 4-6 | Moderate (2-10/1000) |

| 2-3 | Low (<1/1000) |

| 1 | Remote (<0.01/1000) |

Detection (D) - Ability to detect

| Rating | Detection Method |

|--------|-----------------|

| 10 | No detection method |

| 7-8 | Low probability of detection |

| 4-6 | Moderate detection |

| 2-3 | High detection probability |

| 1 | Certain detection |

AIAG-VDA Action Priority (AP)

| AP Level | Action Required |

|----------|-----------------|

| High | Must take action |

| Medium | Should take action |

| Low | Could take action |

Integration Points

• Control plan systems
• Design systems
• Quality Management Systems
• Risk management platforms