Effective FMEAs - Reader's Website
About the book Effective FMEAs

Introduction       What readers are saying       Table of Contents      Solutions Manual

Chapter Descriptions      Back Cover     Author Bio     Purchase the Book  Special Acknowlegment

 Introduction

“Anything that can possibly go wrong, does.” Ancient mountaineering adage

Some call it the fourth law of thermodynamics. Some call it an ancient mountaineering adage. The most common ascription is Murphy’s Law: “If anything can go wrong, it will.” Whatever the source, it pays to anticipate problems and solve them before they entangle customers, or worse, become catastrophic.

Across the globe, development times are becoming shorter, cost concerns more acute, and customers are demanding and expecting absolute safety and high reliability. Companies need to rethink how they achieve these objectives. While it may have been sufficient in the past to focus on testing and analysis as the primary methods of ensuring high reliability, this is no longer sufficient because test-and-fix can take too long and is too costly. It is essential to ensure high design quality and reliability during the early development stages in order to shorten development times and stay within budgets. To do this, it is necessary to focus first on problem prevention, rather than merely problem solving, anticipating the factors that can lead to failure and ensuring designs are robust. Failure Mode and Effects Analysis (FMEA) can anticipate and prevent problems and help companies achieve high reliability in products and processes within considerably shorter development times, and within budget.

During my 30-year career in reliability engineering and management, I have had the pleasure to work with thousands of engineers and managers, and hundreds of companies. I have never met a single person who does not want to contribute to a successful team effort to develop trouble-free products or processes. Whether part of a design team, manufacturing, management, or a support activity, we all want to see our efforts make a difference in the quality and reliability of the products or services we support. There is a natural passion and energy of employees to achieve trouble-free products. Failure Mode and Effects Analysis is a key tool for accomplishing this objective.

The plain truth is FMEA has the potential to be a very powerful tool to achieve high reliability in products and processes; and when done well, it is remarkably effective. Yet in practice, FMEA does not always achieve the expected results, and can lose effectiveness.

While working in the fields of aerospace, vehicle engineering and reliability consulting, I have supervised or performed over two thousand FMEAs. During this time, I have seen just about every possible way to do FMEAs incorrectly, and discovered simple strategies to learn from these mistakes and turn them quality objectives. The purpose of this book is to share these best practices for doing FMEAs effectively.

One of the objectives of the book is to teach by example. Many case studies are discussed and examined, including industry-specific applications, two well known catastrophes (the Space Shuttle Challenger and the DC-10 cargo door blowout), and an FMEA case study on an all-terrain bicycle. Other case studies and stories about FMEA application are interspersed throughout the book. At the end of each chapter is a set of problems that can be useful in learning the fundamentals of FMEA and how FMEA can be applied to many different activities and industries. 

To get good results from FMEAs, it is necessary to learn and apply the correct procedures. To get uniformly outstanding results with each and every FMEA, it is essential to learn and apply a set of simple strategies. This book teaches these strategies.

FMEA has been around for many decades and has a long history as a method to support product designs, manufacturing processes, service, and maintenance. There is a wide range of applications and types of FMEAs. This book is for anyone who wants to learn about FMEAs and how to do them effectively and efficiently regardless of job discipline or prior FMEA experience.

Whether you are involved in product designs, manufacturing, service, maintenance, management, quality, or any other discipline that supports product development and operations, FMEA can be a valuable tool to dramatically increase reliability; and ensure safety of equipment, personnel, processes or services. What is important is to learn from mistakes, follow the simple strategies covered in this book, and do the procedure correctly.

My personal philosophy regarding FMEAs

Through the synergy engendered by the right team of experts, and by implementing correct and proven methods and procedures, problems can be anticipated and prevented resulting in safe and trouble-free products and processes, with the inherent risk in any system or process reduced to a very low level.

My Pledge to readers

"Humilty, that low, sweet root, from which all heavenly virtues shoot", Thomas More

FMEA is a broad subject, with a wide variety of standards, procedures and applications. There is no shortage of opinions and ideas from practitioners, both new and experienced. It is impossible to fully satisfy everyone, from every level of experience and every industry and application. However, I encourage feedback, and I will carefully listen to all comments, concerns, criticisms and suggestions. I will stay engaged and find ways to share comments, suggestions, and knowledge about the subject of FMEA with students, readers and industry practitioners. In the words of a great teacher, “learning is not a spectator sport.” No one person has all of the answers, and by sharing our experience and knowledge, we can learn from each other.

 I sincerely wish you the best in your quest to support safe and trouble-free products and processes.

 Carl S. Carlson

 Solutions Manual

Each of the chapters in the book have end of chapter problems. The solutions to these problems are in the companion Solutions Manual, available to industry professionals and academic faculty at no charge. To obtain the Solutions Manual, click on the link directly below, then click on "Supplemetary Material" in the upper left corner of the page, and fill out the form. A representative from the publisher will contact you with the password to access the Solutions Manual.

Solutions Manual

 

 

 

 What readers are saying . . .

“Best FMEA book ever! Mr. Carlson has laid out in the clearest and most detailed fashion everything that is necessary for FMEA to be efficiently and effectively implemented and integrated into the design of any system, product, or process. I highly recommend this book to anyone wanting to assure a failure-free product or process for their customer.” Richard J. Rudy, Senior Manager, Reliability (retired), Chrysler Corporation  

“Carl Carlson's new book makes the important topic of FMEAs accessible to a much wider audience than has hitherto been the case. . . Overall, this book is clearly written and well structured, and I highly recommend it.” Dr Caroline Lubert, Professor of Mathematics, James Madison University

“This book is well written and would work well for introduction of the subject for a beginner as well as a reference for the seasoned practitioner. It would be quite useful in the hands of students in the classroom as well as practitioners working to better understand how they can improve the quality, efficiency, and effectiveness of their work effort. In addition, managers and leaders would appreciate an understanding what it takes to set up an effective FMEA process from a business perspective.” Joe Michalek, former Reliability Engineering Group Manager, General Motors Corporation 

“I found this book suitable at all levels in the organization . . . Every case study and example seems to be presented from the hands-on experience which makes it easy to grasp the principles and practices. Every engineer should own this book.” Dev Raheja, President, Raheja Consulting, Inc.

“Safety and reliability are paramount characteristics of any engineered product. Effective FMEAs by Carl Carlson provides a comprehensive and in-depth look at one the most powerful reliability tools available in industry today. It offers a practical, step-by-step approach for how to effectively and efficiently apply Failure Mode and Effects Analysis within an organization. A Must-Have for any Reliability or Quality Professional” Brandon Johnson, Manager, Quality Promotion Department, Toyota Motor Engineering and Manufacturing North America

“Carl has taken the time to study and in this book reveal the elements that make the difference between just another FMEA and an effective FMEA. If you want to conduct a study that assists in the prevention of field failures in a cost effective and common sense manner, read and use this book.” Fred Schenkelberg, Reliability expert at FMS Reliability

“Carlson VERY effectively delivers on the promise in his books title! . . . Like having an experienced reliability professional by your side . . . I found this book easy to read and absorb.” Joseph M. Baum, Director - Engineering Quality, Reliability & Dependability, General Motors Corporation - Retired

Effective FMEAs is a very comprehensive analysis of the FMEA process. This book provides guidance and instruction throughout the entire FMEA process. The use of case studies reinforces the real world use of the FMEA process. Incorporating these proven fundamentals assure the benefits of the FMEA process are realized.” Charles Noel, Manager – Reliability Engineering and Field Test at John Deere


 
Special Acknowledgment

Many colleagues and friends have offered their support during this book's development. The Acknowledgments section of the book communicates my appreciation for the support received. There is someone who was inadvertently omitted from my acknowledgments as the first draft of the manuscript was submitted before his involvement. I regret that this was not realized and corrected before publication. Dr. Andre Kleyner is the Editor of the Wiley Series in Quality & Reliability. He wrote the Series Editor's Forward to the book. His contribution to this Forward, as well as his professional and candid advices to me during the critical production editing time period, proved to be invaluable and are sincerely appreciated. Thank you, Dr. Kleyner. My sincere apology for this omission.
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