Failure Modes and Effects Analysis (FMEA) is one of the essential tools in any Six Sigma practitioner’s toolkit. This article does not explain how and why you should use the FMEA template rather it talks about the 4 common mistakes people make while updating this tool.
The first mistake is not involving the process expert. Good Six Sigma practitioners often take out the Process Failure Modes and Effects Analysis template as early as the Measure phase of a DMAIC cycle and start adding variables that they have identified by brainstorming and using a Cause and Effect Diagram. But it is important to consult your process experts before updating the Process Failure Modes and Effects Analysis.
The second mistake is not creating a way of prioritizing risk that’s meaningful to your organization. Most Process FMEA templates come with a standard guideline – Risk Priority umber (RPN), which is for rating three aspects: Occurrence, Severity, and Detection.
The third mistake is using the Process FMEA only once. A process FMEA needs to be updated every time there is a process change.
And the fourth mistake is to spend too much time preparing a control plan. Good practitioners will actually spend very little time connecting their Process FMEA to control plans.