FMEA as applied to electronic manufacturing: A revised approach to develop a more robust and optimized solution

Failure Mode and Effect Analysis (FMEA) is a proactive tool used to identify, evaluate and prioritize potential weakness or failure modes in a given system. As with any methodology, familiarity leads to scrutiny. The more a particular method is utilized, the more questions are asked and inevitably the more weaknesses are found. The FMEA is no different. From its early stages of development with NASA, the FMEA has evolved into an industry accepted methodology used across varied fields from pharmaceutical, to militarily to automotive. It is this widespread use which has exposed the FMEA to various questions and critics. This paper will discuss a body of research which aims to dissect the FMEA process with particular focus on the perceived weaknesses documented in the available literature. Following a full and detailed literature review, the next phase of this research work will be to identify an optimum FMEA solution for use in the Electronics Manufacturing industry. All findings, recommendations and modifications will be trialed and proven in a high volume automotive electronic manufacturing environment across a number of global manufacturing sites.